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Hisun HS700UTV-4, Maintenance Handbook

The Hisun HS700UTV-4 Maintenance Handbook is an essential manual for owners looking to keep their UTV in top condition. Easily download your free copy from our website and gain access to detailed maintenance instructions to ensure your vehicle remains in peak performance.

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CHASSIS                              

 

- 266-

 

 

（

The service method of the rear bridge parts 

is as the same as the front bridge parts, 
please refer to the before-mentioned to 
operate

.

）

   

1

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.

 

                                                 

 
 

Summary of Contents for HS700UTV-4

Page 1: ...se 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...

Page 2: ...ely 5 Cleaning parts 5 Warning labels 6 SERIAL NUMBERS 6 FASTENERS 6 Torque specifications 6 Self locking fasteners 6 Washers 7 Cotter pins 7 Snap rings and E clips 7 SHOP SUPPLIES Lubricants and Flui...

Page 3: ...eler gauge 18 Calipers 18 Micrometers 19 Adjustment 20 Care 20 Metric micrometer 20 Standard inch micrometer 21 Telescoping and small bore gauges 22 Dial Indicator 22 Compression gauge 23 Multimeter 2...

Page 4: ...arm 35 Flooded engine 36 ENGINE WILL NOT START 36 Identifying the problem 36 Spark test 37 The starter cannot work repeatedly or can only work slowly 38 POOR ENGINE PERFORMANCE 38 The engine starts sl...

Page 5: ...LNE LUBRICATION 46 HIGH OIL CONSUMPTION OR EXCESSIVE 46 Exhaust smoke 46 Low oil pressure 46 High oil pressure 46 No oil pressure 47 Oil level too low 47 Oil contamination 47 CYLINDER LEAK DOWN TEST 4...

Page 6: ...brake caliper 58 Leaking master cylinder 59 CHAPTER 2 SPECIFICATIONS HOW TO USE CONVERSION TABLE OF UNIT 60 How to use conversion table 60 Definition of unit 60 GEBERAR SPECIFICATIONS 61 ENGINE SPECIF...

Page 7: ...belt 102 Cleaning the spark arrester 103 Adjusting the brake pedal 104 Adjusting the parking brake 105 Checking the brake fluid level 105 Checking the front brake pads 106 Checking the rear brake pads...

Page 8: ...ry 121 Checking the fuses 127 Adjusting the headlight beam 128 Changing the headlight bulb 129 Changing the tail brake light bulb 130 CHAPTER 4 ENGINE ENGINE NOTE 131 ENGINE REMOVAL 132 CYLINDER HEAD...

Page 9: ...PECTION 197 DIRECTION SYSTEM The steering wheel parts EPA type 200 The steering wheel parts E mark type 203 BRAKE SYSTEM 213 Disk brake components 214 Front and rear brake discs 216 Front and rear bra...

Page 10: ...283 Radiator 1 283 Radiator 2 285 Oil cooler 288 Water pump 289 SEAT 294 OIL SYSTEM 296 FUEL TANK 296 CHAPTER 6 ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION 301 ELECTRICAL 302 ELECT...

Page 11: ...2 Checking the signal system 323 COOLING SYSTEM 332 Circuit diagram 332 2WD 4WD SELECTING SYSTEM 335 Circuit diagram 335 CHAPTER 7 ENGINE MANAGEMENT SYSTEM INTRODUCTION Ems engine management system 34...

Page 12: ...performance 362 POOR MEDIUM AND HIGH SPEED PERFORMANCE 363 Poor medium and high speed performance 363 FAULTY GEAR SHIFTING 363 Shift lever does not move 363 Jumps out of gear 363 ENGINE OVERHEATING 36...

Page 13: ...EFI DIAGRAM 368 IGNITION SYSTEM CIRCUIT DIAGRAM 369 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 370 CHARGING SYSTEM CIRCUIT DIAGRAM 371 LIGHTING SYSTEM CIRCUIT DIAGRAM 372 SIGNALING SYSTEM CIRCUIT DIAGR...

Page 14: ...he 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 Mecha...

Page 15: ...3 Spark arrester 14 Passenger seat belt 15 Passenger seat 16 Oil filter cartridge 17 Engine oil dipstick 18 Battery 19 Fuses 20 Coolant reservoir 21 Radiator cap 22 Fuel tank cap 23 Light switch 24 St...

Page 16: ...GENERAL INFORMATION 3 IDENTIFICATION CODE Frame No Frame No is carved in the lower right side of Figure Engine No Engine No is carved on the right side of the Engine Figure...

Page 17: ...ers make sure the new fasteners are the same size and strength as the original ones 9 Keep the work area clean and organized 10 Wear eye protection anytime the safety of the eyes is in question This i...

Page 18: ...lass B BC or ABC fire extinguisher which are dedicated to extinguish the gasoline fire 8 Always turn off the engine before refueling Do not spill fuel onto the engine or exhaust system Do not overfill...

Page 19: ...ter and the thread pitch The measurement across two flats on a nut or bolt indicates the wrench size WARNING1 Do not install fasteners with a strength classification lower than what was originally ins...

Page 20: ...les do not align Tighten the fastener enough to achieve alignment Cotter pins are available in various diameters and lengths Measure the length from the bottom of the head to the tip of the shortest p...

Page 21: ...e American Petroleum Institute API service classification The Society of Automotive Engineers SAE viscosity rating Standard classification The API and SAE information is on all oil container labels Tw...

Page 22: ...not intermix different types of brake fluid as this may cause brake system failure DOT 5 brake fluid is silicone based DOT 5 is not compatible with other brake fluids may cause brake system failure Wh...

Page 23: ...capabilities Gasket Remover Aerosol gaskets remover can help remove stubborn gasket This product can speed up the removal process and prevent damage to the mating surface that may be caused by using...

Page 24: ...ool set from a quality tool combinations and offer substantial savings when complicated specialized tools can be added Screwdrivers Screwdrivers of various lengths and types are mandatory for the simp...

Page 25: ...the 12 point works well It allows the wrench to be removed and reinstalled without moving the handle over such a wide are An open end wrench is fast and works best in areas with limited overhead acces...

Page 26: ...pact sockets are made of thicker material for more durability Compare the size and wall thickness of a 19 mmhand socket A Figure 9 and the 19 mm impact socket B Use impact sockets when using an impact...

Page 27: ...es Figure 11 on fasteners with hexagonal recesses in the fastener head These wrenches are available in L shaped bar Socket and T handle types A metric set is required when working on most motorcycles...

Page 28: ...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...

Page 29: ...ers used for gripping and bending Diagonal cutting pliers 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 som...

Page 30: ...tance or the possibility of fuel vapor being ignited by an open spark remove the spark plug cap and ground it directly to a good engine ground with the tool shown in Figure 18 Make the tool shown from...

Page 31: ...spark plug gap Calipers Calipers Figure 20 are excellent tools for obtaining inside outside and depth measurements Although not as precise as a micrometer they allow reasonable precision typically to...

Page 32: ...he usual sizes Figure 23 are 0 25mm 0 1 in 25 50 mm 1 2 in 50 75 mm 2 3 in and 75 100 mm 3 4 in Micrometers that cover a wider range of measurements are available These use a large frame with intercha...

Page 33: ...f pressure is applied b If the adjustment is correct the 0 mark on the thimble will align exactly with the 0 mark on the sleeve line If the marks do not align the micrometer is out of adjustment c Fol...

Page 34: ...50mm to the reading in Step 1 3 Read the thimble mark that aligns with the sleeve line Each thimble mark equals 0 01mm NOTE If a thimble mark does not align exactly with the sleeve line Estimate the...

Page 35: ...nd Care fully insert the gauge into the bore Carefully move the gauge in the bore to make sure it is centered Tighten the knurled end of the gauge to hold the movable post in position Remove the gauge...

Page 36: ...t does not start and hold the throttle in the wide open position when performing a compression test An engine that does not have adequate compression cannot be properly tuned Refer to Chapter Three Mu...

Page 37: ...SYSTEM FUNDAMENTALS A thorough study of the many types of electrical systems used in today s motorcycles is beyond the scope of this manual However a basic understanding of electrical basics is neces...

Page 38: ...rent of circuit or components measured by amperage exceeds the standard level must check and repair electrical system at once BASIC SERVICE METHODS Most of the procedures in this manual are straightfo...

Page 39: ...ring bearings fuel hoses wheel bearings suspension and electrical components Water may force grease out of the bearings and possibly damage the seals 14 If special tools are required have them availab...

Page 40: ...ctor 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...

Page 41: ...on the hose or fitting Remove the hose do not exert excessive force on the hose or fitting Remove the hose clamp and carefully insert a small screwdriver or pick tool between the fitting and hose App...

Page 42: ...y against the shaft Instead use a brass or aluminum rod between the hammer and shaft Figure 43 and make sure to support both bearing races with wooden blocks as shown 3 The ideal method of bearing rem...

Page 43: ...procedure when installing a bearing over a shaft When a tight fit is required the bearing inside diameter is smaller than the shaft In this case Driving the bearing on the shaft using normal methods m...

Page 44: ...ON Do not heat the housing with a propane or acetylene torch Never bring a flame into contact with the bearing or housing The direct heat will destroy the case hardening of the bearing and will likely...

Page 45: ...in areas 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 Selec...

Page 46: ...to Service The amount of service required when returning 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 n...

Page 47: ...gine 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...

Page 48: ...ll revise the volume of air up automatically If change to new air filter or air throttle idle speed step motor inside ECU need to match the volume of oil when in idle speed automatically Countermeasur...

Page 49: ...arting procedures are correct 2 If the engine seems flooded refer to Starting The Engine in this chapter If the engine is not flooded continue with Step 3 3 Remove the cap from the fuel tank and make...

Page 50: ...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 s...

Page 51: ...e 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 en...

Page 52: ...use these conditions Perform the Peak Voltage Tests to isolate the damaged ignition system component Check the ignition timing as described NOTE The ignition timing is controlled by the ICM and cannot...

Page 53: ...After riding the UTV Come to a stop on a level surface Turn the engine off and shift the transmission into neutral Walk or push the UTV forward If the UTV is harder to push than normal Check for dragg...

Page 54: ...knocks when it is accelerated or when running at high speed Check for one or more of the following possible malfunctions a Incorrect type of fuel b Lean fuel mixture c Advanced ignition timing NOTE O...

Page 55: ...y be preventing the correct amount of fuel from being supplied to the spark plug Troubleshoot the fuel system as follows 1 Clogged fuel tank breather hose 2 Check that there is a sufficient amount of...

Page 56: ...ough the water cannot collect in the crankcase and should not become a problem Once the engine heats up to normal operating temperature the water evaporates and exits the engine through the crankcase...

Page 57: ...ling System WARNING Do not remove the radiator cap coolant drain plug or disconnect any coolant hose immediately after or during engine operation Scalding fluid and steam may be blown out under pressu...

Page 58: ...damage Power Loss Refer to Poor Engine Performance in this chapter Engine Noises Unusual noises are often the first indication of a developing problem Investigate any new noises as soon as possible So...

Page 59: ...r damaged valve train components e The valve hose hole is damaged f The valve sticks on the hose g Broken valve spring h Low oil pressure i Clogged cylinder oil hole or oil passage ENGLNE LUBRICATION...

Page 60: ...formed by applying compressed air to the cylinder through a special tester and then measuring the percent of leakage A cylinder leak down tester and an air compressor are needed to perform this test W...

Page 61: ...eak down tester when turning the engine As the piston moves toward TDC on its compression stroke compression building inside the combustion chamber may cause the gauge needle to move slightly If the c...

Page 62: ...he transmission play and know what direction the countershaft should be turned and locked NOTE If a large amount of air escapes from the exhaust pipe or through the throttle the air is leaking through...

Page 63: ...y terminals 3 Disconnect each electrical connector in the suspect circuit and make sure there are no bent terminals in the electrical connector 4 Make sure the terminals on the end of each wire are pu...

Page 64: ...ional differences when the engine is cold and hot d If the engine does not start isolate and remove the component First test it at room temperature and then after heating it with a hair dryer A change...

Page 65: ...powered test light can be constructed from a 12 volt light bulb a pair of test leads and a 12 volt battery When the test leads are touched together the light bulb should go on Use a self powered test...

Page 66: ...ood ground If the lamp does not come on with the jumper installed The lamp s connection to ground is good so the problem is between the lamp and the power source To isolate the problem Connect the jum...

Page 67: ...s in an electrical circuit are designed to carry current with low resistance This endures that current can flow through the circuit with a minimum loss of voltage Voltage drop indicates where there is...

Page 68: ...results If using an analog ohmmeter calibrate the meter by touching the leads together and turning the calibration knob until the meter reads zero 1 Disconnect the negative battery cable 2 Attach one...

Page 69: ...fluid from a closed container Always check the brake operation before riding the motorcycle Soft or Spongy Brake Lever or Pedal Operate the front brake lever or rear brake pedal and check to see if t...

Page 70: ...ster cylinder assembly 13 Contaminated brake caliper assembly 14 Brake caliper not sliding correctly on slide pins 15 Sticking master cylinder piston assembly 16 Sticking brake caliper pistons Brake D...

Page 71: ...ad pin bolt Look for steps or cracks along the pad pin bolt surface 2 Contaminated brake pads and disc 3 Incorrect wheel alignment 4 Warped brake disc 5 Loose brake disc mounting bolts 6 Brake caliper...

Page 72: ...aged 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 ma...

Page 73: ...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 Centig...

Page 74: ...stroke Water cool Forward inclined single cylinder 686cm3 100 84 0mm 3 94 3 31in 9 2 1 Electric starter Wet sump Oil type or grade Engine oil Final gear oil Differential gear oil API service SE SF SG...

Page 75: ...ission ratio Low High Reverse gear V belt Shaft drive 16 339 2 475 V belt automatic Right hand operation 0 75 2 45 5 3595 30 17 41 21 24 18 3 2230 26 21 41 21 24 18 3 8282 25 17 41 21 24 18 Chassis Fr...

Page 76: ...oil spring oil damper Coil spring oil damper 185 mm 7 3 in 185 mm 7 3 in Electrical Ignition system Generator system Battery type Battery capacity EFI A C magneto GSU1 9 or U1L 11 12 V 32 0Ah Headligh...

Page 77: ...3 9392 in 50 mm 1 97 in 100 10 mm 3 9410 in Camshaft Drive method Cam dimensions Chain drive Left Intake A B Exhaust A B 30 06 30 16 mm 1 1835 1 1874 in 35 69 35 79 mm 1 4051 1 4091 in 30 11 30 21 mm...

Page 78: ...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 29 9 30 1...

Page 79: ...0 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 32 6...

Page 80: ...5 mm 0 8663 0 8667 in 21 991 22 000 mm 0 8658 0 8661 in 0 15 mm 0 0059 in 22 045 mm 0 8679 in 21 971 mm 0 8650 in Piston rings Top ring Type Dimensions B T End gap installed Side clearance installed 2...

Page 81: ...ut limit C1 C2 Big end side clearance D Big end radial clearance E 74 95 75 00 mm 2 9508 2 9528 in 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...

Page 82: ...6 psi 65 Kpa 0 65 kg cm2 9 2 psi at 1 500 r min Cylinder head 0 23 mm 0 0091 in 0 17 mm 0 0067 in 0 24 mm 0 0094 in Water pump Type Reduction ratio Single suction centrifugal pump 15 15 1 0 Shaft driv...

Page 83: ...g rate Stroke 81 mm 3 19 in 328 mm 12 91 in 273 2 mm 10 76 in 44 1 N mm 4 41 kg mm 246 95 lb in 117 7N mm 11 77kg mm 659 08 lb in 0 60 mm 0 2 36 in 60 81 mm 2 36 3 15 in Front wheel Type Rim size Rim...

Page 84: ...mm 7 87 0 14 in 5 2 mm 0 20 in 5 2 mm 0 20 in 17 4 mm 0 69 in 27 0 mm 1 06 in DOT 4 1 5 mm 0 06 in 1 5 mm 0 06 in Rear disc brake Type Disc outside diameter thickness Pad thickness inner Pad thicknes...

Page 85: ...Resistance 4 5 5 0 k Oxygen sensor type 25325359 Charging system Nominal output Charging coil resistance color 14 V 23 A at 5 000 r min 0 32 0 43 at 20 68 F White White Rectifier regulator Regulator t...

Page 86: ...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 at 20 C 68 F 12 5 mm 0 49 in 7 65 10 01...

Page 87: ...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...

Page 88: ...over Bolt M6 12 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 Scre...

Page 89: ...7 0 7 5 1 Radiator 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 Muf...

Page 90: ...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 a...

Page 91: ...nd 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 B...

Page 92: ...hten 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...

Page 93: ...journal Oil pump assembly Oil filter cartridge O ring Starter idle gear shaft Starter wheel gear Clutch housing assembly shaft end Clutch carrier assembly One way clutch bearing Middle driven shaft sp...

Page 94: ...nt 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 Adjust...

Page 95: ...SPECIFICATIONS 82 HYDROGRAPHIC CHART Hydrographic chart Pressure splash...

Page 96: ...SPECIFICATIONS 83 LUBRICATION OIL WAY Hydrographic chart Pressure splashing oil...

Page 97: ...filter element clean Replace if necessary Every20 40hours More often in wet of dusty areas Front brake Check operation fluid leakage Correct if necessary Rear brake Check operation Adjust if necessar...

Page 98: ...Engine oil Replace Warm engine before draining Engine oil strainer Clean Engine oil filter cartridge Replace Final gear oil Differential gear oil Check oil level oil leakage Replace Lights and switch...

Page 99: ...ve clearance must be adjusted when the engine is cool to the touch Adjust the valve clearance when the piston is at the Top Dead Center TDC on the compression stroke 1 Remove following parts Valve cov...

Page 100: ...se rotation crankshaft According to the rotor turning counterclockwise rotor turn to mark the dead spots of crank box namely the dead point position is compressed 4 Check valve clearance Beyond the st...

Page 101: ...oper clearance is obtained In order to avoid the regulator adjust rotation together after fastening tool fixed lock nut Measuring clearance rules with the valve clearance If the gap beyond the standar...

Page 102: ...fied if the pole clearance is between 0 6 to 0 7mm 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 pl...

Page 103: ...keep it at the specified speed Engine speed 1 400 1 500 r min b Remove the timing plug c Visually check the stationary pointer to verify it is within the required firing range indicated on the flywhee...

Page 104: ...LVE CLEARANCE standard value standard compression pressure data 1200Kpa 12kg cm2 1000r min 5 read the highest data on the compression pressure meter Above the maximum pressure Check the cylinder head...

Page 105: ...n the gauge stabilizes NOTE When cranking the engine ground the spark plug lead to prevent sparking 4 Install spark plug 18 Nm 20Nm 1 8 m kg 13 ft lb 5 Lower the cargo bed CHECKING THE ENGINE OIL LEVE...

Page 106: ...ve the dipstick just after high speed operation because the heated oil could spurt out Wait until the oil cools down before removing the dipstick 5 Install console passenger seat driver seat Refer to...

Page 107: ...an oil filter wrench 6 Install engine oil drain bolt 7 conditions Change for new oil filter before impouring oil to crankcase and make sure it is in good working condition before assembling make sure...

Page 108: ...one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to THE ENGINE in chapter 4 d Start the e...

Page 109: ...ter 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 o...

Page 110: ...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...

Page 111: ...able 2 Drain coolant from the coolant reservoir 3 Connect coolant reservoir hose 4 Remove coolant drain bolt water pump along with the copper washer 5 Remove radiator cap WARNING A hot radiator is und...

Page 112: ...olt water pump T R 10 Nm 1 0 m kg 7 2 ft lb 11 Connect water pump inlet hose coolant outlet hose 12 Remove air bleed bolt 13 Fill cooling with the specified amount of the recommended coolant Recommend...

Page 113: ...g 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 NOTE Adding water instead of coolant...

Page 114: ...hapter 4 NOTE Before checking the coolant level wait a few minutes until the coolant has settled Close the hood Install console Install passenger seat Install driver seat Refer to SEATS in chapter 5 C...

Page 115: ...33 2 mm 1 31 in Limit 29 9 mm 1 18 in Coolant temperature warning light checking method Turn the main switch ON Coolant temperature warning light does not come on Coolant temperature warning light co...

Page 116: ...he direction shown in the illustration Remove the bolts 2 Install drive belt cover console passenger seat driver seat CLEANING THE SPARK ARRESTER 1 Clean Tap the tailpipe lightly with a soft face hamm...

Page 117: ...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 the brake rod should lightly contact the...

Page 118: ...Loosen the locknut c Turn the adjuster in or out until the corre ct free play is obtained Turning in Free play is increased Turning out Free play is decreased d Tighten the locknut e Slide the adjust...

Page 119: ...and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in a vapor lock 4 Clos...

Page 120: ...BRAKE PIPES 1 Remove driver seat passenger seat console Refer to SEATS in chapter 5 2 Lift the hood up 3 Lift the cargo bed 4 Check front brake hoses rear brake pipes rear brake hoses Cracks wear dama...

Page 121: ...dd the moderate brake liquid d Place the other end of the hose into a container e Slowly apply the brake pedal several times f Push down on the pedal and hold it g Loosen the bleed screw and allow the...

Page 122: ...may be damaged 1 Adjust Select lever shift rod a Make sure the select lever is in NEUTRAL b Loosen both locknuts WARNING The select lever shift rod locknut select lever side has left handed threads T...

Page 123: ...GEAR OIL LEVEL 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 oi...

Page 124: ...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 e...

Page 125: ...t NOTE If gear 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 c...

Page 126: ...tie rod ends Turn the steering wheel to the left and right until it stops completely and then move the steering wheel slightly in the opposite direction Tie rod end s have vertical play Replace the t...

Page 127: ...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 Be sure that both tie rods are turned the same amount If not the vehicle...

Page 128: ...tment can cause poor handling and loss of stability NOTE The spring preload of the shock absorbers can be adjusted to suit the operator s preference weight and the operating conditions 1 Adjust spring...

Page 129: ...th or attempt to open the cylinder assemblies Do not subject the shock absorber assemblies to an open flame or other high heat source This may cause the unit to explode due to excessive gas pressure D...

Page 130: ...tion The shorter is the lower the spring preload the longer distance A is the higher the spring preload With each complete turn of the adjusting nut Spring travel setting Front Minimum soft 332mm 13 0...

Page 131: ...or skin until suspension components have cooled Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stabil...

Page 132: ...hitch Pulling load total weight of trailer and cargo 100 kg Tongue weight vertical weight on trailer hitch point 50 kg Be extra careful of the vehicle balance and stability when towing a trailer 1 Mea...

Page 133: ...mmediately CHECKING THE WHEELS 1 Check Wheels Damage bends Replace NOTE Always balance the wheel when a tire or wheel has been changed or replaced WARNING Never attempt even small repairs to the wheel...

Page 134: ...eye gear when handling or working near batteries Charge batteries in a well ventilate2d area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes DO NOT SMOKE w...

Page 135: ...ll drop considerably Therefore take special care when charging the battery NOTE Since MF batteries are sealed it is not possible to check the charge state of the battery by measuring the specific grav...

Page 136: ...ery 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 chargin...

Page 137: ...ry 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 curren...

Page 138: ...in the standard charging amperage If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery Set the timer to the charging time determined by the open circuit v...

Page 139: ...harging Is the amperage higher 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 ba...

Page 140: ...te 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 li...

Page 141: ...0 A 1 Reserve 30 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...

Page 142: ...m the bulb while it is on since it will be hot Do not touch the bulb until it cools down 2 Install bulb new Secure the new bulb with the headlight bulb holder NOTE Avoid touching the glass part of the...

Page 143: ...the bulb while it is on since it will be hot Do not touch the bulb until it cools down 2 Install bulb new Secure the new bulb with the tail brake light bulb holder NOTE Avoid touching the glass part...

Page 144: ...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 Deter...

Page 145: ...he order listed 1 Water temperature sensor 1 2 O ring 1 3 Fuel injection 1 4 Washer 6 2 2 5 Seat fuel injection 1 6 Bolt M6 20 2 7 Ducting dampers 1 8 Inlet Temperature pressure sensor 1 9 Bolt M4 8 1...

Page 146: ...No Part Name Qty Remarks Removing Throttle and intake manifold Remove the parts in the order listed 13 Inlet pipe 1 14 Bush inlet pipe 4 15 Bolt stud 4 16 Nut M6 4 For installation reverse the removal...

Page 147: ...ove drain plug please prepare vessel for containing oil and cotton yarn 2 INSTALL Install intake manifold Install intake manifold bolt Install carburetor joint Install carburetor NOTE When installed d...

Page 148: ...ove the parts in the order listed 1 Union bolt 3 2 Copper washer 7 3 Oil delivery pipe 3 1 4 Oil delivery pipe 2 1 5 Spark plug 1 6 Tappet cover intake 1 7 Tappet cover exhaust 2 8 Timing chain tensio...

Page 149: ...ENGINE 136 No Part Name Qty Remarks 13 Thermo switch 1 1 For installation reverse the removal procedure...

Page 150: ...d as a set 3 Checking the tappet covers tappet cover exhaust tappet cover intake Cracks damage Replace O rings NOTE When installing new replacement washer and apply wheel bearing grease LS 4 Removing...

Page 151: ...ching spark plug threads valve seats 2 Check cylinder head Scratches damage Replace the cylinder head cover and cylinder head as a set cylinder head water jacket Mineral deposits rust Eliminate 2 INST...

Page 152: ...pressing the timing chain tensioner rod wind it clockwise with a thin screwdriver until it stops c With the screwdriver still inserted into the timing chain tensioner install the timing chain tensione...

Page 153: ...rts in the order listed camshaft Cylinder head cover 1 Plug O ring 1 1 2 Rocker arm shaft stopper 2 3 Rocker arm shaft 2 1 4 Rocker arm 3 1 5 Rocker arm shaft3 O ring 1 1 6 Rocker arm 4 1 7 Rocker arm...

Page 154: ...ENGINE 141 No Part Name Qty Remarks 13 Decompress or cam guide plate 4 14 Camshaft sprocket 5 15 Camshaft 5 16 Cylinder head 2 17 Cylinder head gasket 1 For installation reverse the removal procedure...

Page 155: ...iameter of the rocker arm holes Out of specification Replace Rocker arm inside diameter repairing limit value 12 038mm d Check the surface of the rocker arm shafts Worn pitting scratches Replace e Mea...

Page 156: ...d 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 a Check...

Page 157: ...ily install the camshaft sprocket on the camshaft Do not install the bolts Then install the timing chain on the camshaft sprocket 1NOTE Make sure the small holes on the camshaft face upward a Align th...

Page 158: ...ENGINE 145 1NOTE Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide intake side inward f Remove the retaining wire...

Page 159: ...lve springs Remove the parts in the order listed Cylinder head cover 1 Valve cotter 10 2 Valve spring retainer 5 3 Intake valve spring 3 4 Exhaust valve spring 2 5 Intake valve 3 6 Exhaust valve 2 7 V...

Page 160: ...rger 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 cle...

Page 161: ...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 sprin...

Page 162: ...to ensure impermeability 3 Lap valve face valve seat 1NOTE 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 repla...

Page 163: ...NSTALL 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 1NOTE Install the valve spring...

Page 164: ...and piston Remove the parts in the order listed Water pump outlet hose Cylinder head 1 Coolant inlet joint 1 2 Cylinder O ring 1 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 6 Piston pin 1...

Page 165: ...oove 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 strok...

Page 166: ...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 Repairing limit value 0 02mm b...

Page 167: ...ston 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 prev...

Page 168: ...Remove the parts in the order listed Drive belt cover Engine oil Coolant Water pump assembly 1 Engine cooling fan air duct assembly 1 2 Air shroud 1 1 3 Engine cooling fan 1 4 Air shroud 2 1 5 A C ma...

Page 169: ...arks 10 Pickup coil 1 11 Stator assembly 1 12 A C magneto rotor 1 13 Woodruff key 1 14 Starter wheel gear 1 15 Washer 1 16 Starter idle gear shaft 1 17 Bearing 1 18 Starter idle gear 1 For installatio...

Page 170: ...installing apply the locking agent a Install the starter wheel gear onto the starter clutch and hold the starter clutch 1NOTE Install the starter wheel gear with the groove a facing the A C magneto ro...

Page 171: ...ean 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 A C...

Page 172: ...ley do not forget to install the O ring engine cooling fan 7Nm 1NOTE Install the bolts in the holes in the collar of the engine cooling fan air shroud 10Nm engine cooling fan air duct assembly 1NOTE I...

Page 173: ...gears Remove the parts in the order listed 1 Nut lock washer 1 1 2 Balancer driven oil pump drive gear 1 3 Chain 1 4 Straight key 1 5 Oil pump driven gear 1 6 Plate 1 7 Balancer drive gear 1 8 Spring...

Page 174: ...cer drive gear and balancer driven gear as a set Excessive noise during operation Replace the balancer drive gear and balancer driven gear as a set 3 Checking the timing chain and guides timing chain...

Page 175: ...gear with the punch mark b on the balancer driven gear lock washer new replacement balancer driven gear nut 110Nm 1NOTE Place an aluminum plate between the teeth of the balancer drive gear and balanc...

Page 176: ...s Remove the parts in the order listed Engine assembly 1 Drive belt cover 1 2 Rubber gasket 1 3 Bearing housing 1 4 Dowel pin 2 5 Primary sheave assembly 1 6 V belt 1 7 Primary fixed sheave 1 8 Second...

Page 177: ...ary sheave Remove the parts in the order listed 1 Primary pulley sheave cap 1 2 Primary pulley slider 4 3 Spacer 4 4 Primary pulley cam 1 5 Primary pulley weight 8 6 Collar 1 7 Oil seal 2 8 Primary sl...

Page 178: ...secondary Sheave Remove the parts in the order listed 1 Nut 1 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1 9...

Page 179: ...nes Wear cracks damage Replace spacer primary pulley cam Cracks damage Replace primary sliding sheave primary fixed sheave Cracks damage Replace 2 Checking the secondary sheave secondary fixed sheave...

Page 180: ...ave face primary fixed sheave face collar weights primary sliding sheave cam face 1NOTE Remove any excess grease 2 Install weights 1NOTE Apply grease 90g to the whole outer surface of the weights and...

Page 181: ...eave fixed block locknut wrench and sheave spring compressor to the secondary sheave assembly b Place the sheave fixed block in a vise and secure it c Tighten the sheave spring compressor nut and comp...

Page 182: ...ndary fixed and sliding sheaves to widen Install the V belt so that its arrow faces the direction show in the illustration 2 Tighten primary sheave nut 120Nm secondary sheave nut 100Nm 1NOTE Use the s...

Page 183: ...moving the clutch Remove the parts in the order listed Primary and secondary sheaves 1 Clutch housing assembly 1 2 Gasket dowel pin 1 2 3 One way clutch bearing 1 4 Nut 1 5 Clutch carrier assembly 1 F...

Page 184: ...ty Remarks Disassembling the clutch housing Remove the parts in the order listed 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For ass...

Page 185: ...ing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly b When turning the clutch housing clockwise A the clutch housing should turn freely If not the one way clutch...

Page 186: ...ay clutch bearing 1NOTE The one way clutch bearing should be installed in the clutch carrier assembly with the arrow mark a facing toward the clutch housing dowel pins gasket clutch housing assembly 1...

Page 187: ...ter Remove the parts in the order listed A C magneto rotor Primary and secondary sheaves Clutch carrier assembly 1 Starter motor O ring 1 1 2 Oil filter cartridge O ring 1 3 Oil pipe assembly O ring 1...

Page 188: ...ENGINE 175 No Part Name Qty Remarks 9 Reverse switch 1 10 Oil filler cap 1 11 Oil delivery pipe 1 1 For installation reverse the removal procedure...

Page 189: ...nkcase Remove the parts in the order listed 1 Shift lever cover gasket 1 1 2 Dowel pin 1 3 Shift lever 1 1 4 Shift lever 2 assembly 1 5 Right crankcase 1 6 Dowel pin 1 7 Left crankcase 1 8 Spacer 1 9...

Page 190: ...arks Removing the crankcase bearings Remove the parts in the order listed Crankshaft and oil pump Transmission Middle drive driven shaft 1 O ring collar 1 1 2 Oil seal 1 3 Bearing retainer 1 4 Bearing...

Page 191: ...the defective part s 3 Checking the crankcase 1 Thoroughly wash the case halves in a mild solvent 2 Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly 3 heck crankcase Crac...

Page 192: ...sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions 4 Tighten crankcase bolts 10Nm follow the proper tightening sequence crankcase bol...

Page 193: ...E 180 2 Installing the shift levers shift lever 2 assembly 14Nm shift lever 1 1NOTE When installing the shift lever 1 align the punch mark a on the shift lever 1 with the punch marks b on the shift le...

Page 194: ...emoving the crankshaft and oil pump Remove the parts in the order listed Crankcase separation 1 Oil strainer O ring 1 1 2 Oil pump assembly gasket 1 1 3 Balancer 1 4 Plate 1 5 Relief valve assembly 1...

Page 195: ...rt Name Qty Remarks Disassembling the oil pump Remove the parts in the order listed 1 Rotor cover 1 2 Pin 2 3 Shaft 1 4 Pin 1 5 Inner rotor 1 6 Outer rotor 1 7 Oil pump housing 1 For assembly reverse...

Page 196: ...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 o...

Page 197: ...in CAUTION The buffer boss and woodruff key should be replaced when removed from the crankshaft 3 INSTALL 1 Assembling the oil pump inner rotor outer rotor oil pump shaft with the recommended lubrica...

Page 198: ...e order listed Crankcase separation Middle driven gear 1 Low wheel gear 1 2 Shift drum 1 3 Shift fork assembly 1 4 Short spring 1 5 Shift fork 1 1 6 Long spring 1 7 Shift fork 2 1 8 Guide bar 1 9 Seco...

Page 199: ...No Part Name Qty Remarks Disassembling the drive axle Remove the parts in the order listed 1 Clutch dog 1 2 High wheel gear 1 3 Middle drive gear 1 4 Driven sprocket 1 5 Drive axle 1 For assembly rev...

Page 200: ...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 th...

Page 201: ...damage Replace 4 Checking the secondary shaft and driven sprocket gear teeth Blue discoloration pitting wear Replace gear movement Unsmooth Repeat steps 1 or replace the defective parts circlip Bends...

Page 202: ...t fork 1 short spring 2 Installing the transmission chain drive axle assembly secondary shaft shift fork assembly shift drum low wheel gear 1NOTE Oil each gear and bearing thoroughly Before assembling...

Page 203: ...he middle drive shaft Remove the parts in the order listed Crankcase separation 1 Bearing housing 1 2 Middle drive gear 1 3 Nut 1 4 Middle drive pinion gear 1 5 Shim 1 6 Middle drive shaft 1 7 Bearing...

Page 204: ...ive shaft Remove the parts in the order listed Crankcase separation 1 Drive shaft coupling 1 2 Circlip 2 3 Bearing 2 4 Universal joint 1 5 Universal joint yoke 1 6 Bearing housing O ring 1 1 7 Shim 1...

Page 205: ...ENGINE 192 No Part Name Qty Remarks 9 Bearing retainer 1 10 Bearing retainer 1 11 Middle driven shaft 1 For installation reverse the removal procedure...

Page 206: ...gear shim middle driven gear shim 2 MEASURE gear lash Middle gear lash 0 1 0 3 mm a Temporary install the left crankcase b Wrap a rag around a screwdriver and then insert it into the installation hol...

Page 207: ...n it counterclockwise bearing retainer a Place a rag in the vise b Secure the bearing housing edge in the vise c Attach the bearing retainer wrench d Tighten the bearing retainer CAUTION The middle dr...

Page 208: ...the bearing onto the yoke 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 n...

Page 209: ...se the coupling gear middle shaft tool to hold the drive shaft coupling 2 Installing the middle drive shaft 1 Tighten middle drive pinion gear nut 145Nm 1NOTE Secure the middle drive shaft in the vise...

Page 210: ...rake 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 Brak...

Page 211: ...ck 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 Fr...

Page 212: ...ber 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 whet...

Page 213: ...emarks Removing the steering wheel parts 1 Steering mechanism comp 1 2 Driving gear 1 3 Steering wheel comp 1 4 Spring washer 8 6 5 Up cover for steering wheel 1 6 Middle cover for steering wheel 1 7...

Page 214: ...Hexagon flange bolt M10 1 25 35 4 13 Ball joint steering mechanism 2 14 Hexagonal nut M12 2 15 Steering drive axle 1 16 Hexagon flange bolt M8 30 2 17 Steering column 1 18 Hexagon flange bolt M8 25 4...

Page 215: ...Hexagon flange nut M12 1 25 1 23 Decoration cover for steering column 1 24 Down cover for steering wheel 1 25 Washer 10 20 2 4 26 Spring washer 10 4 27 Washer 8 16 1 6 4 28 Washer 15 28 2 1 29 Cross s...

Page 216: ...arks Removing the steering wheel parts 1 Steering mechanism comp 1 2 Driving gear 1 3 Steering wheel comp 1 4 Spring washer 8 6 5 Upper cover steering wheel 1 6 Middle cover steering wheel 1 7 Socket...

Page 217: ...Hexagon flange bolt M10 1 25 35 4 13 Ball joint steering mechanism 2 14 Hexagonal nut M12 2 15 Steering drive axle 1 16 Hexagon flange bolt M8 30 2 17 Steering column 1 18 Hexagon flange bolt M8 25 4...

Page 218: ...5 4 23 Screw M5 12 2 24 Ignition switch 1 25 Hexagon flange nut M12 1 25 1 26 Washer 5 4 27 Small washer d 5 4 28 Screw 4 29 Light switch assy 1 30 Cross big plate head screw M5 16 4 31 Cross plate he...

Page 219: ...Clamp F4 2 3 35 Washer 5 15 1 2 3 36 Decoration cover steering column 1 37 Rubber cushion ignition switch cover 1 38 Lower cover steering wheel 1 39 Washer 10 20 2 4 40 Spring washer 10 4 41 Washer 8...

Page 220: ...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 1N...

Page 221: ...s in the check it should be service immediately to ensure the normal work of the steering system DIASSEMBLING THE STEERING COLUMN PARTS Remove engine covers connection covers part steering wheel cover...

Page 222: ...al axis whether is wear out if so instead the central axis 3 Check The spline in the tow ends of the central axis whether have wear if dose instead the central axis 4 Check The steering column tube an...

Page 223: ...in to the dust boots 2 Check tie rod end 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...

Page 224: ...in may causes the serious accident or the death REINSTALLS THE STEERING SYSTEM PARTS 1 Connecting the direction machine with four pieces bolt M10 30 on the frame then use two pieces of locknut to conn...

Page 225: ...Nm 2 4m kg 17 ft lb 4 Use one piece of flange self lock nut M12 1 25 fix the steering wheel on the steering column tube then cover the direction column plastic center lid Steering wheel tight of forc...

Page 226: ...herwise 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 p...

Page 227: ...rake hose 1 3 Hexagon flange bolt M6 25 1 4 Hexagon flange bolt M6 12 5 5 Oil pipe clip front disc brake 2 6 Clip oil pipe 3 7 Rear right brake caliper 1 8 Rear left brake caliper 1 9 Rear right brake...

Page 228: ...CHASSIS 215 No Part Name Qty Remarks 14 Front brake pad 2 15 Cooper seal 1 16 Strainer bolt 4 17 Cooper seal 8 18 Rear right Brake Hose 1 19 Rear left Brake Hose 1...

Page 229: ...CHASSIS 216 FRONT AND REAR BRAKE DISCS No Part Name Qty Remarks Removing the brake discs 1 Brake caliper assembly 1 2 Brake disc 1 3 Bolt 4 4 Turn join 4 5 Bolt 4 6 Brake disc guard 1...

Page 230: ...t of 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 sp...

Page 231: ...AKE PADS No Part Name Qty Remarks Removing the brake pads Remove the parts in the order listed 1 Brake caliper mounting bolt 2 2 Brake pad holding bolt 2 3 Brake pad 2 For installation reverse the rem...

Page 232: ...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 calip...

Page 233: ...arks Removing the brake caliper Remove the parts in the order listed Brake fluid 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake pad holding bolt 2 5 Brake caliper mounting bolt 2 6 Brake cali...

Page 234: ...bling the brake caliper Remove the parts in the order listed 1 Brake pad holding bolt 2 2 Brake pad 2 3 Pad spring 1 4 Brake caliper piston 1 5 Dust seal 2 6 Caliper piston seal 2 7 Bleed screw 2 For...

Page 235: ...e 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 body WARNING Never try to pry out a caliper p...

Page 236: ...seals whenever the brake caliper is disassembled ASSEMBLING THE FRONT AND REAR BRAKE CALIPERS WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before in...

Page 237: ...he brake caliper make sure that the brake pipe touches the projection a on the brake caliper WARNING Proper brake hose routing is essential to insure safe vehicle operation 2 Fill brake reservoir Must...

Page 238: ...NG BRAKE DISC No Part Name Qty Remarks Removing the parking brake disc Remove the parts in the order listed Brake caliper assembly Final drive gear 1 Parking brake disc 1 For installation reverse the...

Page 239: ...Check brake disc Galling damage Replace 2 Measure brake disc deflection Out of specification Replace Brake disc maximum deflection 0 10 mm 0 004 in brake disc thickness a Out of specification Replace...

Page 240: ...and brake pads parking skid plate Brake fluid 1 Parking brake switch coupler 1 2 Spring 1 3 Parking brake cable 1 Parking brake lever assembly mounting 4 Bolt 1 5 Parking brake lever assembly 1 6 Uni...

Page 241: ...ston side 1 13 Brake pad 1 14 Insulator pad shim 2 2 15 Pad spring 1 16 Brake caliper bracket 1 17 Parking brake arm nut 1 18 Parking brake arm 1 19 Set bolt 1 20 Parking brake arm shaft 1 21 Parking...

Page 242: ...CHASSIS 229 No Part Name Qty Remarks 25 Dust seal 1 26 Caliper piston seal 1 27 Bleed screw 1...

Page 243: ...ling Bleed the brake system DISASSEMBLING THE PARKING BRAKE CALIPER WARNING Brake caliper is one of the most important security components Disassembly and maintenance must have a rich experience in te...

Page 244: ...liper assembly brake caliper body Cracks damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air 1WARNING Replace the caliper piston seals and dust seals w...

Page 245: ...arm set bolt parking brake arm nut 1NOTE Apply lithium soap based grease to the parking brake arm shaft and set bolt a Screw in the parking brake arm shaft counterclockwise completely so that the pun...

Page 246: ...th insulator and pad shim 1NOTE Align the projection a on the piston side of the brake pad with the groove in the brake caliper piston 6 Install brake pad holding bolts 17Nm 1 7 m kg 12 ft lb INSTALLI...

Page 247: ...ainted 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 MIN level line Add the recommended br...

Page 248: ...No Part Name Qty Remarks Removing the brake master cylinder Brake fluid 1 Brake master cylinder 2 Hexagon flange bolt M6 16 3 3 Hexagon flange bolt M6 20 1 4 Oil pipe hoop 4 5 Connecting fork 1 6 Spl...

Page 249: ...Replace as a set 3 Check brake fluid reservoir brake fluid reservoir diaphragm Cracks damage Replace ASSEMBLING THE BRAKE MASTER CYLINDER 1WARNING All internal brake components should be cleaned and...

Page 250: ...Must use DOT4 Brake Fluid 1NOTE 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...

Page 251: ...rew M5 16 14 3 Axle cover 1 4 Insulation paper 1 5 Lamp switch rear break 1 6 Hexagon flange self lock nuts M6 2 7 Nut Clip M6 9 8 Right footrest protector 1 9 Dustproof plate brake pedal 1 10 Cross l...

Page 252: ...1 2 16 Spring 2 12 5 47 1 17 Welding parking pedal 1 18 Spring 2 12 5 52 1 19 Throttle cable 1 20 Washer 5 10 1 0 14 21 Parking system 1 22 Parking sensor 1 23 Screw M4 12 1 24 Spring 1 2 7 28 1 25 P...

Page 253: ...rt Name Qty Remarks 28 Expansion bolt plastic 4 29 Mudguard for brake pump 1 30 Hexagon flange bolt M8 20 2 31 Clamp L 370 13 32 Clamp L 200 15 33 Clamp L 300 11 34 Push ties 5 35 Cross large plate he...

Page 254: ...ame Qty Remarks Removing the front wheel 1 Front rim 2 2 Front tyre 2 3 Nut M10 8 4 Wheel decoration cover 2 5 Nut M22 1 5 2 6 Front hub 2 7 cotter pin 3 2 50 2 8 Bolt M10 30 4 1WARNING Securely suppo...

Page 255: ...emarks Removing the rear wheel 1 Rear rim 2 2 Rear tyre 2 3 Rear hub 2 4 Bolt M10 30 4 5 Nut M10 8 6 Wheel decoration cover 2 7 Nut M22 1 5 2 8 Cotter pin 3 2 50 2 1WARNING Securely support the vehicl...

Page 256: ...alance Adjust Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in 1WARNING The profile depth falls below 3mm Please replace the tyre immediately CHECKING THE WHEEL HUB 1 Check wheel hub Cr...

Page 257: ...ile depth is necessary To ensure maximum security and longer life expectancy of the wheel please periodically inspect the tyre pressure and profile depth Insufficient tyre pressure can result in not o...

Page 258: ...ks 1 Circlip 1 2 Double off set joint assembly 2 3 Circlip 2 4 Circlip 2 5 Hoop A dust P shed 80 4 6 Outer rubber dust P cover C 1610 2 7 Hoop B dust P shed 32 4 8 Joint shaft 1 9 Inner rubber dust p...

Page 259: ...Front differential assy 1 2 Front differential case 1 3 Front differential case 1 4 Drive driven gears assy 1 5 Connection fork 1 6 Hexagon flange nut M14 1 5 1 7 O type ring 6 8 14 1 8 Oil seal 48 65...

Page 260: ...ocket hexagon screw M8 10 1 14 Hexagon flange bolt M10 1 25 15 1 15 Clip D0 62 1 16 Pin 5 75 1 17 Transfer case assembly 1 18 Divide device connection 1 19 Rack 1 20 O Ring 2 81 transfer case 1 21 O R...

Page 261: ...35 62 9 1 25 Bolling bearing 15 21 12 1 26 Screw 1 27 Copper washer 13 1 5 1 28 Hexagon flange nut M10 1 25 1 29 Shaft fork 6 30 Clamp 20 32 1 31 Universal joint 1 32 Clip D0 62 1 33 Vent pipe L 700 1...

Page 262: ...1 39 Spring 25 2 3 28 1 40 Rear dustproof rubber cover 19 31 28 1 41 Front dustproof rubber cover 19 38 50 1 42 Hexagon flange bolt M10 1 25 30 2 43 Hexagon flange bolt M10 1 25 142 1 44 Block ring 4...

Page 263: ...the left and right transmission shaft from the differential device DISASSEMBLING THE UNIVERSAL JOINT Remove universal joint a Remove the circlips b Place the universal joint in a press c With a suitab...

Page 264: ...replace it Disassembly the left and right transmission shaft cleaning and assemble it again 1NOTE 1 The dustproof rubber wrap on the ball cage is not allow to contact with the gas and diesel oil 2 Th...

Page 265: ...the oil seal front box output shaft and oil seal front box input shaft and differential gear assembly CHECKING THE GEAR MOTOR Check gear motor a Connect two C size batteries to the gear motor terminal...

Page 266: ...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 pl...

Page 267: ...int mark on the gear motor case CAUTION Do not use a 12 V battery to operate the pinion gear c Insert bolts into the gear motor and use them as a guide to set the motor on the differential gear assemb...

Page 268: ...ality gear grease into the front bridge differential device and screws tight the oil filler bolt Fastening Torque of Conical Nut 23 Nm 2 3m kg 17 ft lb 3 Install the front bridge differential device o...

Page 269: ...irclip 2 2 Double off set joint assembly 2 3 Hoop A dust P shed 80 4 4 Inner rubber dust P cover C 1520 2 5 Hoop B dust P shed 32 4 6 Double off set joint assembly 2 7 Inner rubber dust p cover C 1605...

Page 270: ...ssy 1 2 Rear reducer case 1 3 Bearing 22 30 13 1 4 Bearing 55Bm6720 55 67 20 1 5 Drive driven gears 1 6 Bearing 25 62 17 1 7 Mount bracket rear disk brake plate 1 8 Oil seal 61 35 9 1 9 Fuel drain O s...

Page 271: ...ket hexagon screw M8 25 1 17 Rear adjustment gasket 1 18 Speed sensor comp 1 19 O ring gasket fuel injection 2 3 19 4 1 20 Vent pipe rear reducer 1 21 Rear reducer case 1 22 Socket hexagon screw M8 45...

Page 272: ...el drain screw plug 1 31 Hexagon flange nut M10 1 25 25 1 32 Hexagon flange bolt M8 12 4 33 Rear transmission shaft comp 1 34 Spring 18 5 2 30 1 35 Rear transmission shaft 1 36 Circlip D0 19 2 37 Join...

Page 273: ...ks 40 Front dust cover 25 53 35 1 41 Rear dust cover 20 5 48 30 1 42 Vent pipe rear reducer 1 43 Steel wire clamp 8 1 44 Clip 11 1 45 Clamp 20 32 2 46 Hexagon flange bolt M10 1 25 120 2 47 Impaction r...

Page 274: ...ame Qty Remarks Removing the speed reducer 1 Rear differential case 1 2 Rear differential case 1 3 Oil seal 52 35 7 2 4 Bearing 32008E 1 5 C V Axle rear right axle 1 6 Rear axle transmission shaft 1 7...

Page 275: ...18 5 2 30 1 11 Bearing 32010E 1 12 Bearing 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 1...

Page 276: ...of shift fork 1 22 Dustproof rubber cover 19 38 50 1 23 Oil fill plug 1 24 O ring gasket fuel injection 1 25 Block ring 1 26 Hexagon flange nut M10 1 25 2 27 Rear axle transmission assy 1 28 Criss cr...

Page 277: ...1 32 Rear adjustment gasket 3 33 Front dust cover rear axle transmission shaft 25 53 35 1 34 Adjust bushing 1 35 Gasket adjust bushing 1 36 Adjust bushing 1 37 Bearing 32206E 2 38 O ring gasket 1 39 U...

Page 278: ...locked nut M14 1 5 1 43 Magnetic valve 1 44 Hexagon flange bolt M10 1 25 20 2 45 Overflow pipe 1 46 Steel wire clamp 8 1 47 Bushing 10 5 22 15 2 48 Connection fork 1 49 Connection fork 1 50 Needle sl...

Page 279: ...e same as the front bridge parts please refer to the before mentioned to operate 1NOTE Apply lithium soap based grease to the bearing assembly and o ring and bearing and driven gear and oil seal and d...

Page 280: ...rse mechanism 1 Gearshift knob 1 2 Gearshift boot 1 3 Gearshift assy 1 4 Gear shift rod 1 5 Adjust nut M8 1 6 Gearshift tie assy 1 7 Washer 6 18 1 6 1 8 Hexagon flange bolt M6 16 1 9 Hexagon flange bo...

Page 281: ...No Part Name Qty Remarks 13 Clip 14 1 14 Draining tube 1 15 Adjust nut M8 L 1 16 Gear shifting support 1 17 Hexagon flange bolt M6 12 2 18 Reverse cable 1 19 Spring washer 6 1 20 Plug 1 21 Hexagon fla...

Page 282: ...NOTE The select lever shift rod locknut select lever side has left handed threads To loosen the locknut turn it clockwise c Adjust the shift rod length for smooth and correct shifting d Tighten the lo...

Page 283: ...se mechanism whether is rupture if so instead the connecting rod 4 Check the intension of the pull off spring whether is enough 5 Check whether the gear is nicety whether have jump or drop If so infor...

Page 284: ...s Removing front suspension and arm 1 Left front upper swing arm 1 2 Joint A suspension 4 3 Circlip D0 30 4 4 Right front upper swing arm 1 5 Left front lower swing arm 1 6 Right front lower swing arm...

Page 285: ...B 16 11 Hexagon nut M12 1 25 4 12 Cotter Pin 2 5 30 4 13 Front shock absorber 2 14 Hexagon flange bolt M10 1 25 50 2 15 Protective board swing arm 2 16 Screw thread clip M6 5 4 17 Cross big plate head...

Page 286: ...Press block rear anti roll bar 2 22 Hexagon flange bolt M8 22 4 23 Front anti roll bar 1 24 Spring washer 8 4 25 Hexagon flange bolt M10 1 25 75 2 26 Dust proof rubber boot 4 27 Washer 13 24 2 2 28 Sp...

Page 287: ...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 Installing Use 16 pieces of Hexagon Flange Bolt M10 70 and 16 pi...

Page 288: ...Wear damage Replace 3 Check Front upper gimbal Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint CHECKING THE FRONT SHOCK ABSORBER 1 Check sh...

Page 289: ...with lithium soap based grease Be sure to position the bolts so that the bolt head faces outward Temporarily tighten the nuts b Install the front shock absorber Nut 45 Nm 4 5 m kg 32 ft lb c Install t...

Page 290: ...gon flange bolt M12 1 25 70 2 3 Hexagon flange bolt M12 1 25 65 2 4 Hexagon flange nut M12 1 25 4 5 Rear anti roll bar 1 6 Left tie rod anti roll bar 1 7 Right tie rod anti roll bar 1 8 Hexagon flange...

Page 291: ...CHASSIS 278 No Part Name Qty Remarks 12 Spring washer 8 4 13 Washer 8 16 1 6 2 14 Washer 10 20 2 2...

Page 292: ...1 2 Rear left lower swing arm 1 3 Rear right lower swing arm 1 4 Middle rubber tube swing arm 8 5 Hexagon flange bolt M10 1 25 70 8 6 Hexagon flange nut M10 1 25 10 7 Rear left upper swing arm 1 8 Dus...

Page 293: ...CHASSIS 280 No Part Name Qty Remarks 11 Cross large plate head screw M6 16 4 12 Nut clip M6 4...

Page 294: ...ch in the rear shock absorber whether is credible 1NOTE After disassemble the rear shock absorber check if there exists any distortion or crack on the frame connection hole and the rear shock absorber...

Page 295: ...RMS AND REAR SHOCK ABSORBER 1 Install rear arms rear shock absorber a Install the rear upper arm and rear lower arm 1NOTE Lubricate the bolts with lithium soap based grease Be sure to position the bol...

Page 296: ...1 1 Rear right water pipe 1 2 Clamp 20 32 8 3 Clip metal water pipe 6 4 Hexagon flange bolt M6 16 8 5 Metal water pipe 2 6 Front water pipe 2 7 Rear left water pipe 1 8 Radiator fan assy 1 9 Installat...

Page 297: ...sor 1 14 Auxiliary water tank cover 1 15 Rubber pipe 7 11 750 1 16 Clip 10 1 17 Flanging bushing 6 9 22 6 5 2 18 Clip 9 2 19 Rubber pipe 5 9 550 1 20 Radiator cover 1 21 Auxiliary water tank assy 1 22...

Page 298: ...over 1 2 Oil cooler 1 3 Oil cooler assy 1 4 Screw hoop 12 20 12 5 Pressure proof rubber oil pipe 10 17 260 2 6 Hexagon flange bolt M6 12 5 7 M shaped fixed pipe clamps 4 8 M shaped fixed pipe clamps 4...

Page 299: ...rt Name Qty Remarks 12 Pressure proof rubber oil pipe 10 17 150 2 13 shaped rubber washer 12 14 Front right metal oil pipe 1 15 Front left metal oil pipe 1 16 Rear right metal oil pipe 1 17 Rear left...

Page 300: ...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...

Page 301: ...OIL COOLER CHECKING THE OIL COOLER 1 Check oil cooler if the oil cooler is distortion and leak oil To adjust the distortion one and welding the leak one If it can not solve instead the oil cooler 2 Ch...

Page 302: ...t M6 45 1 3 Bolt M6 65 1 4 Bolt M6 10 1 5 Water pipe 1 6 O ring 20 7 2 6 1 7 Water pipe 1 8 Water pipe clip 2 9 Cylinder inlet water joint 1 10 Bolt M6 20 2 11 O ring 33 4 2 4 1 12 Water pipe 1 13 Cli...

Page 303: ...Save temperature cover 1 17 Bolt M6 20 2 18 Water pump housing cover 1 19 Gasket 1 20 Circlip 1 21 Impeller assembly 1 22 Water pump seal 1 23 Oil seal 1 24 Bearing 1 25 Water pump housing 1 26 O rin...

Page 304: ...pump housing 3 Remove bearing oil seal water pump housing 1NOTE 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 e...

Page 305: ...ilt 0 15 mm 0 006 in ASSEMBLING THE WATER PUMP 1 Install oil seal into the water pump housing 1NOTE Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil sea...

Page 306: ...tall rubber damper rubber damper holder 1NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface Make sure that the rubber damper and rubber damper holder are flush...

Page 307: ...assy 2 2 Safety belt placing plate 2 3 Seat mounting board 2 4 Hexagon flange bolt M8 30 8 5 Hexagon flange Nut M8 16 6 Seat locker 2 7 Hexagon flange bolt M6 40 4 8 Hexagon flange Nut M6 4 9 Locker...

Page 308: ...5 8 16 Hexagon flange nut M10 1 25 4 17 Hexagon flange step bolt M10 1 25 20 14 5 2 18 Hexagon flange bolt M10 1 25 20 4 19 Washer 10 25 3 6 20 Safety belt buckle 2 21 Safety belt assy 3 point type 1...

Page 309: ...No Part Name Qty Remarks Removing the fuel tank 1 Fuel tank 1 2 Insulation paper 1 3 Shock absorption rubber 15 6 4 4 Fuel pump connection wire assy 1 5 Cover fuel pump 1 6 Rubber tube 1 7 Plug for fu...

Page 310: ...e 1 11 fuel pipe 8 14 885 1 12 fuel pipe 8 14 330 1 13 fuel pump assy 1 14 plug fuel inlet 1 15 lid for fuel tank 1 16 seal gasket for fuel pump 1 17 high voltage fuel filter 1 18 Clip 16 1 19 Fuel pi...

Page 311: ...CHASSIS 298 No Part Name Qty Remarks 21 Aluminum foil insulation bellows 14 17 100 2 22 Aluminum foil insulation bellows 14 17 855 1 23 Vent pipe 7 11 690 fuel tank 1...

Page 312: ...tem 1 Disassemble the oil cooler 2 Disassemble the connecting steel oil pipe 3 Disassemble the connecting pressure resistance rubber pipe CHECKING AND SERVICE THE OIL COOLING SYSTEM Check if the oil c...

Page 313: ...pressure resistance inspection pass over 0 03MPA compressed air through the connecting oil cooler steel oil pipe and Rubber Pipe for 3 minutes do not leak 3 According to the disassembly order reverse...

Page 314: ...whether crankshaft speedmeter magneto ignition signal normal 7 Check whether ECU plugged or damaged 8 Check whether air filter plugged 3 Fail to electric start 9 Check whether oil circuit smooth 1 Che...

Page 315: ...ator fan 3 Gear motor 4 Brake light switch 5 Parking brake switch 6 Pickup coil stator assembly 7 Speed sensor 8 Diode 1 9 Circuit breaker radiator fan motor 10 Thermo switch 1 11 Ignition coil 12 Gea...

Page 316: ...ELECTRICAL COMPONENTS 303 1 Relay assy 2 Starter relay 3 Battery 4 Rectifier regulator 5 Speedmeter 6 On Command four wheel drive switch and differential gear lock switch 7 Main switch 8 Light switch...

Page 317: ...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 on...

Page 318: ...nuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled 1 Fuse 2 Brake light switch 3 On Command four wheel drive switch and differential gear l...

Page 319: ...ulb bulb socket or both 1WARNING 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 rem...

Page 320: ...ORRECT 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 rotat...

Page 321: ...cap resistance Remove the spark plug cap Connect the pocket tester 1k to the spark plug cap Check that the spark plug cap has the specified resistance Spark plug cap resistance 10 k at 20 C 68 F MEETS...

Page 322: ...ster lead White Red terminal Tester lead White Green terminal Check the pickup coil for the specified resistance Pickup coil resistance 459 561 at 20 C 68 F White Red White Green MEETS SPECIFICATION 9...

Page 323: ...10 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 370 page OUT OF SPECIFICATI...

Page 324: ...f the starter motor 6 Gear position switch 7 Brake light switch 8 Diode 1 9 Wiring connection the entire starting system 1NOTE Remove the following part s before troubleshooting 1 Console 2 Front fram...

Page 325: ...CH CORRECT 7 Brake light switch Refer to CHECKING THE SWITCH CORRECT 8 Diode 1 Remove the diode from the coupler Connect the pocket tester 1 to the diode terminals as shown Check the diode for continu...

Page 326: ...er lead 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 CIR...

Page 327: ...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 s...

Page 328: ...tor 3 Measure mica undercut Out of specification Scrape the mica using a hacksaw blade 1NOTE Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutat...

Page 329: ...t diagram See 371 page ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 1NOTE Align the projection on the brush seat 1 with the slot on the yoke 2 Install yoke brackets 1NOTE Align the match marks...

Page 330: ...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 450r min 1NOTE Use a fully charged battery O...

Page 331: ...minal Tester lead White terminal Measure the charging coil resistance Charging coil resistance 0 32 0 43 at 20 C 68 F MEETS SPECIFICATION 5 Wiring connections Check the connections of the entire charg...

Page 332: ...he 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 e...

Page 333: ...rminal 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 Gr...

Page 334: ...d 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 Thi...

Page 335: ...gnal 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...

Page 336: ...C 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...

Page 337: ...he 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 c...

Page 338: ...onnect 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 SPECIFICATIO...

Page 339: ...nnect 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 SPECIFICATI...

Page 340: ...ect the pocket tester 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...

Page 341: ...ould 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 T...

Page 342: ...r lock indicator light relay terminals Check the differential gear lock indicator light relay for continuity as follows Tester lead Black White terminal Tester lead Black Terminal Continuity Battery t...

Page 343: ...ght assembly 1 coupler Tester lead Brown terminal Tester lead Black Green terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION This circuit is not faulty OUT OF SPECIFICATION...

Page 344: ...ndicator light relay terminals Check the four wheel drive indicator light relay for continuity as follows Tester lead White Yellow terminal Tester lead Black terminal Continuity Battery terminal Brown...

Page 345: ...Tester lead Brown terminal Tester lead White Yellow terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION This circuit is not faulty COOLING SYSTEM Circuit diagram See 374 pag...

Page 346: ...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 1NOTE Remove the following part s before troubles...

Page 347: ...o 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 circu...

Page 348: ...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...

Page 349: ...ltage 12 8 V or more at 20 C 68 F CORRECT 3 Main switch Refer to CHECKING THE SWITCH CORRECT 7 On Command four wheel drive switch and differential gear lock switch 8 Gear motor 9 Wiring connections th...

Page 350: ...Check the four wheel drive relay 1 for continuity CONTINUITY 5 Four wheel drive relay 2 Remove the four wheel drive relay 2 from the wire harness Connect the pocket tester 1 and the battery 12 V to t...

Page 351: ...wn Red terminal Battery terminal Yellow Black terminal Tester lead Blue Red terminal Tester lead Gray terminal Check the four wheel drive relay 3 for continuity CONTINUITY 7 On Command four wheel driv...

Page 352: ...s counterclockwise B Check that the pinion gear turns clockwise Make sure that the drive gear shift fork sliding gear operates correctly NOTE When installing the differential gear case in the gear mot...

Page 353: ...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...

Page 354: ...ons 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 optimizin...

Page 355: ...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...

Page 356: ...amage 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 Sto...

Page 357: ...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 lu...

Page 358: ...proper 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 disch...

Page 359: ...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 Inje...

Page 360: ...n 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...

Page 361: ...iption 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...

Page 362: ...n 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 t...

Page 363: ...prayed 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 conditio...

Page 364: ...outs 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 are...

Page 365: ...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...

Page 366: ...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 u...

Page 367: ...sconnecting 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 d...

Page 368: ...pler 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...

Page 369: ...dule 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...

Page 370: ...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 Dr...

Page 371: ...or 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...

Page 372: ..._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_Sh...

Page 373: ...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 S...

Page 374: ...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...

Page 375: ...iston 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 Imp...

Page 376: ...oken inlet pressure temperature sensor 6 Air throttle position sensor loose Air filter Clogged air filter element Muffler Clogged muffler Set out The reverse signal error trigger FAULTY GEAR SHIFTING...

Page 377: ...l 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 damag...

Page 378: ...rods 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...

Page 379: ...ttery 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...

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