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Hsun HS700UTV, Maintenance Handbook

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Hsun HS700UTV Maintenance Handbook Download Page 1

                                                       

FOREWORD                                                             

 

                                                                                                                                                 

Brief introduction to maintenance handbook of HS700UTV 

 

The handbook is edited by Chongqing Hsun Industries (Group) Ltd, and is supplied to 

dealers and technicians as document of technique. 

Mainly, the handbook gives methods to check, maintain and repair UTV, and supplies 

some relevant technique and performance data. Some techniques and method inside may 

be used to check, maintain and repair other models of UTV, although it is mainly for 

HS700UTV. 

Please 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 design, and they are subject to changes according to the product’s 

improvement without prior notice. 

 

 

 

 

 

 

Brief introduction to maintenance handbook of HS700UTV 

 

 

second version , June,2009 

Published by Chongqing Hsun Industries (Group) Ltd 

Chongqing Hsun Industries (Group) Ltd holds the copy right. 

No publishing and reprinting without permission. 

 

 

 

Summary of Contents for HS700UTV

Page 1: ... 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 design and they are subject to changes a...

Page 2: ...labels 1 5 SERIAL NUMBERS 1 6 FASTENERS 1 6 Torque specifications 1 6 Self locking fasteners 1 6 Washers 1 7 Cotter pins 1 7 Snap Rings and E clips 1 7 SHOP SUPPLIES 1 8 Lubricants and Fluids 1 8 Engine oils 1 8 Greases 1 9 Brake fluid 1 9 Coolant 1 9 Cleaners degreasers and solvents 1 10 Gasket sealant 1 10 Applying RTV sealant 1 10 Gasket remover 1 10 Thread locking Compound 1 10 BASIC TOOLS 1 1...

Page 3: ...inch micrometer 1 21 Telescoping and Small Bore Gauges 1 22 Dial Indicator 1 22 Cylinder bore gauge 1 23 Compression gauge 1 23 Multimeter 1 23 Ohmmeter analog calibration 1 23 ELECTRICAL SYSTEM FUNDAMENTALS 1 23 Voltage 1 24 Resistance 1 24 BADIC SERVICE METHODS 1 24 Removing frozen fasteners 1 26 Removing broken fasteners 1 26 Repairing damaged threads 1 26 Stud Removal Installation 1 27 Removin...

Page 4: ...g the engine after a fall or after the engine stalls 1 36 Flooded engine 1 36 ENGINE WILL NOT START 1 37 Identifying the Problem 1 37 Spark Test 1 37 Starter Does Not Turn Over or Turns Over Slowly 1 39 POOR ENGINE PERFORMANCE 1 39 Engine Starts But Stalls and is Hard to Restart 1 39 Engine Backfires Cuts Out or Misfires During Acceleration 1 40 Engine Backfires on Deceleration 1 41 Poor fuel mile...

Page 5: ...re 1 49 Oil level too low 1 49 Oil contamination 1 49 CYLINDER LEAKDOWN TEST 1 49 ELECTRICAL TESTING 1 52 Preliminary Checks and Precautions 1 52 Intermittent problems 1 52 Electrical component replacement 1 54 Test equipment 1 54 Ammeter 1 54 Self powered test light 1 54 Ohmmeter 1 55 Jumper wire 1 55 Test procedures 1 56 Voltage drop test 1 56 Peak voltage test 1 57 Continuity test 1 57 Testing ...

Page 6: ...tion of unit 2 1 GEBERAR SPECIFICATIONS 2 2 ENGINE SPECIFICATIONS 2 5 CHASSIS SPECIFICATIONS 2 12 ELECTRICAL SPECIFICATIONS 2 14 TIGHTENING TORQUES 2 16 Engine tightening torques 2 16 Chassis tightening torques 2 19 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 21 LUBRICATION PIONTS AND LUBRICANT TYPES 2 22 Engine 2 22 HYDROGRAPHIC CHART 2 23 LUBRICATION OIL WAY 2 24 CHAPTER 3 MAINTENCE AND ADJUSTMEN...

Page 7: ...ecking the rear brake pads 3 24 Checking the brake hoses and brake pipes 3 25 Bleeding the hydraulic brake system 3 25 Adjusting the select lever shift rod 3 26 Adjusting the brake light switch 3 27 Checking the final gear oil level 3 27 Changing the final gear oil 3 28 Checking the differential gear oil 3 28 Changing the differential gear oil 3 29 Checking the constant velocity joint dust boots 3...

Page 8: ... 4 26 BALANCER GEARS AND OIL PUMP GEARS 4 31 PRIMARY AND SECONDARY SHEAVES Primary and secondary sheaves 4 34 Primary sheave 4 35 Secondary sheave 4 36 CLUTCH 4 41 CRANKCASE Starter motorand oil filter 4 45 Crankcase 4 47 Crankcase bearings 4 48 CRANKSHAFT AND OIL PUMP Crankshaft and oil pump 4 52 Oil pump 4 53 TRANSMISSION Transmission 4 56 Drive axle assembly 4 57 MIDDLE GEAR Middle drive shaft ...

Page 9: ...ont brake calipers 5 24 Assembling the front brake calipers 5 25 Installing the front brake calipers 5 26 Rear brake disc 5 27 Checking the rear brake disc 5 28 Rear brake caliper and brake pads 5 29 Replacing the rear brake pads 5 32 Disassembling the rear brake caliper 5 33 Assembling the rear brake caliper 5 34 Installing the rear brake caliper 5 37 Brake master cylinder 5 38 Checking the maste...

Page 10: ...74 Rear arm shaft 5 75 Checking and service of rear suspension 5 76 Checking the stabilizer and shock absorber 5 77 Installing the rear arms and rear shock absorber 5 78 COOLING SYSTEM 5 79 Radiator 5 79 Checking the radiator 5 82 Installing the radiator 5 83 Checking the oil cooler 5 84 Water pump 5 85 Disassembling the water pump 5 87 Checking the water pump 5 88 Assembling the water pump 5 89 S...

Page 11: ... 6 23 If the headlights fail to come on 6 23 If the headlights fail to come on 6 24 SIGNALING SYSTEM 6 25 CIRCUIT DIAGRAM 6 25 TROUBLESHOOTING 6 26 CHECKING THE SIGNAL SYSTEM 6 27 If the brake lights fail to come on 6 27 If the neutral lights fail to come on 6 28 If the parking brake indicator light fails to come on 6 29 If the reverse indicator light fails to come on 6 30 If the coolant temperatu...

Page 12: ...OR MEDIUM AND HIGH SPEED PERFORMANCE 7 3 Poor medium and high speed performance 7 3 FAULTY GEAR SHIFTING 7 3 Shift lever does not move 7 3 Jumps out of gear 7 4 OVERHEATING 7 4 Overheating 7 4 FAULTY BRAKE 7 4 Poor braking effect 7 4 SHOCK ABSORBER MALFUNCTION 7 5 Malfunction 7 5 UNSTABLE HANDLING 7 5 Unstable handling 7 5 LIGHTING SYSTEM 7 6 Head light is out of work 7 6 Bulb burnt out 7 6 ...

Page 13: ...release levers 13 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 Steering wheel 25 Starter choke 26 Main switch 27 On Command four wheel drive and differential lock switches 28 Multi function meter unit 29 Auxiliary DC jack 30 Drive select lever 31 Pa...

Page 14: ...GENERAL INFORMATION 1 2 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 15: ...when a specific heading is called out in a step it will be italicized as it indicated as being in this section it is located within the same main heading For example the sub heading handling Gasoline safely is located within the main heading SAFETY This chapter provides general information on shop safety tools and their usage service fundamentals and shop supplies WARNINGS CAUTIONS AND NOTES The t...

Page 16: ...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 into the eyes or skin Never direct compressed air at anyone Do not allow children to use or play with any compressed air equipment 15 When using compressed air to dry rotating parts hol...

Page 17: ... 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 than one type of cleaning solvent at a time If mixing chemicals is required measure the prope...

Page 18: ...s originally installed by the manufacturer doing so may cause equipment failure and or damage Torque Specifications The material used in the manufacturing of the UTV may be subjected to uneven stresses if the fasteners of the 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 acc...

Page 19: ...ner to align the holes If the holes 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 pin Snap Rings and E clips Snap rings Figure 1 are circular shaped metal retaining clips They secure parts in place on parts such as shafts External type snap rings are ...

Page 20: ...endations for lubricant types Engine oils Engine oil for four stroke motorcycle UTV engine use is classified by three standards the American Petroleum Institute API service classification The Society of Automotive Engineers SAF viscosity rating Standard classification The API and SAE information is on all oil container labels Two letters indicate the API service classification The number or sequen...

Page 21: ... of Transportation DOT Current designations for brake fluid are DOT 3 DOT 4 and DOT 5 this classification appears on the fluid container Each type of brake fluid has its own definite characteristics Do 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 ...

Page 22: ...tioning of components without damaging gaskets Moisture in the air causes the RTV sealant to cure Always install the cap as soon as possible after applying RTV sealant RTV sealant has a limited shelf life and will not cure properly if the shelf life has expired Keep partial tubes sealed and discard them if they have surpassed the expiration date Applying RTV sealant Clean all old gasket residues f...

Page 23: ...Those with a large tool kit may be able to replacement However in some cases the specialized equipment or expertise may make it impractical for the home mechanic to attempt the procedure When necessary such operations are recommended to have a dealership or specialist perform the task It may be less expensive to have a professional perform these jobs especially when considering the cost of equipme...

Page 24: ...ecess to prevent engine oil contamination Wrenches Open end box end and combination wrenches figure 5 are available in a variety of types and sizes The number stamped on the wrench refers to the distance of the fastener head The box end wrench is an excellent tool because it grips the fastener on all sides This reduces the chance of the tool slipping The box end wrench is designed with either a 6 ...

Page 25: ...ed on the socket is the size of the work area and must the fastener head As with wrenches a 6 point provides superior holding ability While a 12 point socket needs to be moved only half as for to reposition it on the fastener Sockets are designated for either hand or impact use Impact sockets are made of thicker material for more durability Compare the size and wall thickness of a 19 mmhand socket...

Page 26: ... 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 Allen bolts are sometimes called socket bolts Torque Wrenches Use a torque wrench with a socket torque adapter or similar extension to tighten a fastener to a measured torque Torque wrenches come in several drive si...

Page 27: ...red because the effective length has not changed To recalculate a torque reading when using a torque adapter use the following formula and refer to Figure 14 TW TA L L A TW is the torque setting or dial reading on the wrench TA is the torque specification and the actual amount of torque that is applied to the fastener A is the amount that the adapter increases or in some cases reduces the effectiv...

Page 28: ... specialized pliers with tips that fit into the ends of snap rings to remove and install them Snap ring pliers Figure 17 are available with a fixed action either internal or external or convertible one tool works on both internal and external snap rings They may have fixed tips or interchangeable ones of various sizes and angles For general use select a convertible type pliers with interchangeable...

Page 29: ... determine which components require replacement or further service Each type of measuring instrument is designed to measure a dimension with a certain degree of accuracy and within a certain range When selecting the measuring tool make sure it is applicable to the task As with all tools measuring tools provide the best results if cared for properly Improper use can damage the tool and cause inaccu...

Page 30: ...d 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 instructions ...

Page 31: ...adjust 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 ...

Page 32: ...dle 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 millimeter 0 01 mm ...

Page 33: ...ements 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 and refer to Figure 27 1 Read the...

Page 34: ... 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 dimensions and movements ...

Page 35: ...s using a specific 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 ...

Page 36: ...function even though it tests acceptable during a resistance test Resistance generally Increases with temperature Perform all testing with the component or circuit at room temperature Resistance tests performed at high temperatures may indicate high resistance readings and cause unnecessary replacement of a component Amperage Amperage is the unit of measurement for the amount of current within a c...

Page 37: ... performed by a shop equipped with the necessary equipment Do not use makeshift equipment that may damage the motorcycle 13 Repairs are much faster and easier if the UTV is clean before starting work Degrease the motorcycle with a commercial degreaser follow the directions on the container for the best results Clean all parts with cleaning solvent when removing them CAUTION Do not direct high pres...

Page 38: ...r 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 35 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 scre...

Page 39: ...o nuts Removing Hoses When removing stubborn hoses do not exert excessive force 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 Apply a spray lubricant under the hose and carefully twist the hose off the fitting Clean the fitting of any corrosion or ru...

Page 40: ...aft Instead use a brass or aluminum rod between the hammer and shaft Figure 41 and make sure to support both bearing races with wooden blocks as shown 3 The ideal method of bearing removal is with a hydraulic press Note the following when using a press a Always support the inner and outer bearing races with a suitable size wooden or aluminum spacer Figure 42 If only the outer race is supported pre...

Page 41: ...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 may cause bearing damage Instead heat the bearing before installation Note the following a Secure the shaft so it is ready for bearing installation b Clean all residues from the bearing surface of the shaft Remove burrs with a file or sa...

Page 42: ...ontact with the bearing or housing The direct heat will destroy the case hardening of the bearing and will likely warp the housing b Remove the housing from the oven or hot plate and hold onto the housing with welding gloves It is hot NOTE Remove and install the bearings with a suitable size socket and extension c Hold the housing with the bearing side down and tap the bearing out Repeat for all b...

Page 43: ...l months of non use can cause a general deterioration of the motorcycle UTV This is especially true 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 Selection When selecting a storage area consider the following 1 The storage area must be dry A heated are...

Page 44: ...acturer s instructions for each type of product being used 9 Place the UTV on a work stand with both wheels off the ground 10 Cover the UTV with old bed sheets or something similar Do not cover it with any plastic material that will trap moisture Returning the UTV to Service The amount of service required when returning a UTV to service after storage depends on the length of non use and storage co...

Page 45: ...nclude the engine stop switch fuel quantity and condition fuel vale position and spark plug cap tightness Proper maintenance as described in Chapter Three reduces the necessity for troubleshooting Even with the best of care however the motorcycle may develop problems that require trouble shooting If the problem cannot be solved Stop and evaluate all conditions prior to the problem If the motorcycl...

Page 46: ...e fuel tank 3 If the air temperature is below 0 32 F Open the throttle two or three time to allow the acceleration pump to feed additional fuel to the engine If the air temperature is below 35 95 pull the choke knob all the way out to richen the air fuel mixture 4 When the engine starts allow it to idle for approximately one minute then push the choke all the way in If the idle is smooth use the t...

Page 47: ...ob is fully closed pushed in 3 Open the throttle fully and hold in this position Then start the engine firmly through its entire stoke ten times to clear the engine Close the throttle 4 Release the hot start lever as soon as the engine starts 5 If the engine still does not start refer to Engine will Not Start this chapter Engine cold with air temperature Between 10 35 50 95 F 1 Shift the transmiss...

Page 48: ...ke can be fully closed NOTE Do not race the engine during the warm up period The carburetor accelerator pump can overly richen the air fuel mixture and cause the engine to stall Engine is hot 1 Shift the transmission into neutral 2 Turn the fuel valve on NOTE Do not open the throttle when starting the engine in Step 3 This will allow the accelerator pump to feed more fuel to the engine possibly fo...

Page 49: ...f the engine does not start perform the following steps in order while remembering the Engine Principals and Operating Requirements described in this chapter If 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 ...

Page 50: ...ion system is producing adequate spark This test should be performed with a spark tester A spark tester looks 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 be...

Page 51: ...ulty fuel system component b Flooded engine c engine damage low compression 7 If the spark was weak white or yellow or if there was no spark perform the peak voltage checks described under Ignition System Testing 8 Reinstall the fuel tank Starter Does Not Turn Over or Turns Over Slowly Refer to Starting System Testing POOR ENGINE PERFORMANCE If the engine runs but performance is unsatisfactory ref...

Page 52: ...ure can cause these engine performance problems Check for the following conditions a Incorrect float level adjustment b Plugged pilot jet or pilot system 2 Faulty accelerator pump 3 Loose exhaust pipe to cylinder head connection 4 Intake air leak 5 Incorrect ignition timing or a damaged ignition system can cause these conditions Perform the Peak Voltage Tests to isolate the damaged ignition system...

Page 53: ...r filter element 2 Poor fuel filter or fuel hose 3 Faulty accelerator pump assembly 4 Contaminated or stale fuel 5 Incorrect carburetor adjustment 6 Leaking head gasket 7 Intake air leak 8 Incorrect ignition timing 9 Low engine compression Low Engine Power 1 Support the UTV in a stand with the rear wheel off the ground then spins freely If the wheel does not spin freely Check for the following con...

Page 54: ...ondition effects the incoming air fuel mixture on the intake stroke and reduces engine power 4 Check for retarded ignition timing A decrease in power results when the plugs fire later than normal 5 Check for one or more of the following problems a Low engine compression b Worn spark plug c Fouled spark plug d Incorrect spark plug heat range e Weak ignition coil f Incorrect ignition timing g Plugge...

Page 55: ...nd worn or damaged valve springs can cause poor high speed performance If the camshaft was timed just before the UTV experiencing this type of problem The cam timing may be incorrect If the cam timing was not set or changed And all the other inspection procedures in this section failed to locate the problem Inspect the camshaft and calve assembly FUEL SYSTEM The following section isolates common f...

Page 56: ...eat 5 Worn or damaged float valve and seat 6 Leaking or damaged float 7 Clogged carburetor jets 8 Incorrect carburetor jetting Lean Mixture The following conditions can cause a lean air fuel mixture 1 Intake air leak 2 Float level too low 3 Clogged fuel line fuel filter or fuel shutoff valve 4 Partially restricted fuel tank breather hose 5 Plugged carburetor air vent hose 6 Damaged float 7 Damaged...

Page 57: ...engine more water collects As this water mixes with the oil in the crankcase sludge is produced Sludge can eventually cause engine damage as it circulates through the lubrication system and blocks off oil passages Large amounts of steam can also be caused by a cracked cylinder head or cylinder block surface that allows coolant to leak into the combustion chamber Perform a Coolant System Pressure T...

Page 58: ...lant level 2 Air in cooling system 3 Clogged radiator hose or engine coolant passages 4 Worn or damaged radiator cap 5 Damaged water pump Engine Overheating Engine 1 Improper spark plug heat range 2 Low oil level 3 Oil not circulating properly 4 Valves leaking 5 Heavy carbon deposits in the combustion chamber 6 Dragging brake s 7 Slipping clutch Preignition Preignition is the premature burning of ...

Page 59: ... 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 Consider the following when troubleshooting engine noises 1 Knocking or pinging during acceleration can be caused by using a lower octane fuel than recommended May also be caused by poor fuel Pinging can als...

Page 60: ...em quickly leads to engine seizure Check the engine oil level and oil pressure 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 o...

Page 61: ...rmed by applying compressed air to the cylinder through a special tester and then measuring the percent of leakage A cylinder leakdown tester and an air compressor are needed to perform this test When performing a leakdown test the engine is first set 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 ...

Page 62: ...troke Second view the gauge on the leakdown 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 crankshaft is 360 off these indicators will not be present NOTE The decompress or mechanism will click loudly once during each crankshaft revolution This is normal 7 ...

Page 63: ...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 carburetor the air is leaking through on open valve Check the index mark to make sure the engine is at TDC on the compression stroke If the engine is remaining at TDC but there is still a large amount of air escaping from the engine th...

Page 64: ...e battery 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 pushed all the way into the connector If not Carefully push them in with a narrow blade screwdriver 5 Check the wires where they connect to the terminals for damage 6 Make sure all terminals wit...

Page 65: ...ction is bad c To check a component wait until the engine is clod then start and run the engine Note operational 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 in meter readings indicates a temperature problem CAUTION A heat gun or hair dryer will quic...

Page 66: ... circuit the ammeter determines if current is flowing through the circuit and if that current flow is excessive because of a short in the circuit Current flow is often referred to as current draw Comparing actual current draw in the circuit or component to the manufacturer s specified current draw provides useful diagnostic information Self powered test light A self powered test light can be const...

Page 67: ...a jumper wire installed an open exists between the two jumper points in the circuit To troubleshoot with a jumper wire fist use the wire to determine if the problem is on the ground side or the load side of a device Test the ground by connecting a jumper between the lamp and a good ground If the lamp does not come on with the jumper installed The lamp s connection to ground is good so the problem ...

Page 68: ...e within I volt of battery voltage If the voltage is less There is a problem in the circuit Voltage drop test The wires Cables Connectors and switches 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 resistance in a circuit A higher than normal amoun...

Page 69: ...ntegrity of a circuit wire or component A circuit has continuity if it forms a complete circuit that is if there are no opens in either the electrical wires or components within the circuit A circuit with an open On the other hand has no continuity This type of test can be performed with a self powered test light or an ohmmeter An ohmmeter gives the best results If using an analog ohmmeter calibra...

Page 70: ... that point in the harness BRAKE SYSTEM The front and rear brake units are critical to riding performance and safety Inspect the front and rear brakes frequently and repair any problem immediately When replacing or refilling the brake fluid use only DOT 4 brake fluid from a closed container Always check the brake operation before riding the motorcycle Soft or Spongy Brake Lever or Pedal Operate th...

Page 71: ...master cylinder cups and or cylinder bore 12 Worn or damaged brake caliper piston seals 13 Contaminated master cylinder assembly 14 Contaminated brake caliper assembly 15 Brake caliper not sliding correctly on slide pins 16 Sticking master cylinder piston assembly 17 Sticking brake caliper pistons Brake Drag When the brakes drag the brake pads are not capable of moving away from the brake disc whe...

Page 72: ...e 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 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 not sliding correctly on slide pins 7 Mismatc...

Page 73: ...jo 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 74: ...m m cm mm 0 6214 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 1 Unit Read Definition Measurement mm cm Millimetre Centimetre 1 mm 10 3 Meter 1 cm 10 2 Meter Length Length kg Kilogram 1 kg...

Page 75: ...m Liquid cooled 4 stroke Water cool Forward inclined single cylinder 686cm3 100 84 0mm 3 94 3 31in 9 1 1 Electric starter Wet sump Engine oil Final gear oil Differential gear oil Engine oil Periodic oil change With oil filter replacement Total amount Final gear case oil Periodic oil change Total amount Differential gear case oil Periodic oil change Total amount API service SG type or higher JASO s...

Page 76: ...utomatic Sub transmission ratio Low High Reverse gear V belt Shaft drive 41 21 24 18 33 9 9 544 V belt automatic Right hand operation 2 37 0 91 1 35 17 2 058 28 19 1 473 25 14 1 471 Chassis Frame type Camber angle Trail Toe in Steel tube frame 5 26 0mm 1 02 in 0 10 mm 0 00 0 39 in Tire Type Size Front Rear Pressure of front wheel Pressure of rear wheel Tubeless 25 8 12 NHS 25 10 12 NHS 70kpa 70kpa...

Page 77: ...oil damper 185 mm 7 3 in 185 mm 7 3 in Electrical Ignition system Generator system Battery type Battery capacity C D I A C magneto U1L 11 12 V 32 0Ah Headlight type Bulb wattage quantity Headlight Tail brake light Neutral Reverse Coolant temperature Parking brake Four wheel drive Differential gear lock Krypton bulb 12V30 3W 30 0W 2 12V5 0W 21 0W 2 20 MA 0 06 W 1 LED 20 MA 0 06 W 1 LED 20MA 0 06 W ...

Page 78: ...9372 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 1 1854 1 1894 in 36 50 36 60 mm 1 4370 1 4409 in 1 1795 in 29 96 mm 35 59 mm 1 4012 in 30 01 mm 1 1815 in 36 40 mm 1 4331 in Camshaft runout limit 0 03 mm 0 0012 in ...

Page 79: ...iameter 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 mm 1 1772 1 1850 in 31 9 32 1 mm 1 2559 1 2638 in 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 85 1 15 mm 0 0335 0 0453 in 0 85 1 15 mm 0 0335 0 0453 in ...

Page 80: ...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 32 63 mm 1 28 in 36 46 mm 1 44 in 27 5 mm 1 08 in 31 0 mm 1 22 in 100 0 115 7 N 10 20 11 80 kg 22 49 26 01 lb 120 6 138 3 N 12 30 14 10 kg 27 12 31 09 lb Clockwise Clockwise 31 0 mm 1 22 in 34 6 mm ...

Page 81: ...22 015 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 2nd ring Type Dimensions B T End gap installed Side clearance Barrel 1 2 3 8 mm 0 0472 0 1496 in 0 30 0 45 mm 0 0118 0 0177 in 0 04 0 08 mm 0 0016 0 0031 in Taper 1 2 4 0 mm 0 0472 0 1575 in 0 30 ...

Page 82: ...A Runout 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 mm 0 0394 in Balancer Balancer drive method Gear Automatic centrifugal clutch Clutch shoe thickness Clutch in revolution Clutch stall revolution 1 5 mm 0 06 in 1 900 2 300 r min 3 350 3 850 r m...

Page 83: ...e Tip clearance Side clearance Body clearance Bypass valve setting pressure Oil pressure hot Pressure check location Foam Trochoid 0 15 mm 0 0059 in 0 03 0 10 mm 0 0012 0 0039 in 0 09 0 17 mm 0 0035 0 0067 in 441 0 637 0 kPa 4 41 6 37 kg cm2 62 7 90 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 Si...

Page 84: ... pressure Radiator capacity including all routes Coolant reservoir Capacity From low to full level 238 mm 9 37 in 24 mm 0 94 in 107 9 137 3 kPa 1 079 1 373 kg cm2 15 35 19 53 psi 2 5 L 2 20 Imp qt 2 64 US qt 0 35 L 0 31 Imp qt 0 37 US qt 0 20 L 0 15 Imp qt 0 21 US qt ...

Page 85: ... Spring 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 material Rim runout limit radial lateral Panel wheel 12 6 0 AT Steel 2 0 mm 0 08 in 2 0 mm 0 08 in Rear wheel Type Rim size Rim material Rim runout limit radial lateral Panel wheel 12 7 5 AT Ste...

Page 86: ...0 3 5 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 thicknessmm outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Single or Dual 165 0 5 0 mm 6 50 0 20 in 5 6 mm 0 22 in 5 6 mm 0 22 in 17 4 mm 0 69 in 32 0 mm 1 26 in ...

Page 87: ... 68 F 6 32 9 48 kΩat 20 C 68 F Spark plug cap Resistance 10 kΩ Charging system Nominal output Charging coil resistance color 14 V 23 A at 5 000 r min 0 32 0 43Ωat 20 68 F White White Rectifier regulator Regulator type No load regulated voltage DC Capacity Withstand voltage Semi conductor short circuit 14 1 14 9 V 18 A 200 V Battery Specific gravity 1 32 Circuit breaker Type Main fuse Lighting syst...

Page 88: ...l 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 Radiator fan Running rpm 2 950 r min ...

Page 89: ...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 Carburetor joint 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 ...

Page 90: ... 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 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 ...

Page 91: ...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 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...

Page 92: ...ial gear case cover M8 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 fin...

Page 93: ...nd 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 10 1 0 7 2 Rear brake pad holding bolt M8 17 1 7 12 Rear brake caliper and Install seat M10 40 4 0 29 Rear brake hose union bolt M10 27 2 7 19 Parking brake case and rear brake caliper M8 22 2 2 16 Parking brake lever asse...

Page 94: ...ge tighten 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 ...

Page 95: ...e and 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 splines Drive axle driven sprocket high wheel gear and low wheel gear Middle drive gear and clutch dog shift fork groove Driven chain sprocket Shift drum Shift fork guide bar Shift drum stopper ba...

Page 96: ...GENERAL SPECIFICATIONS 2 23 HYDROGRAPHIC CHART Hydrographic chart Pressure splash ...

Page 97: ...GENERAL SPECIFICATIONS 2 24 LUBRICATION OIL WAY ...

Page 98: ...y Air filter element clean Replace if necessary Every20 40hours More often in wet of dusty areas Carburetor Check and adjusted idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks of damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check fuel hose for c...

Page 99: ...ust if necessary Drive shaft universal joint Lubricate with lithium soap based grease Axle boots Check operation Replace if damaged Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary 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 bra...

Page 100: ...to the touch Adjust 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 Valve cover intake Valve cover exhaust spark plug cap spark plug 2 Remove the cooling fan Fan cover Fan impeller As manhole covers ...

Page 101: ...e cold Intake 0 10 0 15 mm 0 0039 0 0059 in Exhaust 0 15 0 20 mm 0 0059 0 0079 in 5 Adjust valve clearance Lock nut Valve thickness gauge gap Regulation Regulator Adjust tools Loosen the locknut Insert a thickness gauge between the adjuster end and the valve end Turn the adjuster clockwise or counterclockwise with the tappet adjusting tool until the proper clearance is obtained In order to avoid t...

Page 102: ...e Lower the cargo bed console passenger seat driver seat Refer to SEATS in chapter 5 IDLE ADJUSTMENT 1 Starting engines thorough warm machine 2 Remove Lift the cargo bed up driver seat passenger seat console Refer to SEATS in chapter 5 3 Install Engine tachometer 4 Confirm speed Standard Engine Idle speed Beyond the standard Adjust 5 Adjust Engines idle speed adjustment a Turn the throttle stop sc...

Page 103: ... adjusted properly before adjusting the engine idle speed Idle adjusting lever External shaft cover Throttle Cable Solenoid Adjusting Screw Throttle Valves Throttle Cable 1 Remove following parts driver seat passenger seat console 2 Remove Throttle valve cover 3 Check throttle cable Slack 6 Remove the slack 4 Adjust throttle cable a Will loosen the locknut b Adjusted by regulator Turning in Slack ...

Page 104: ... Do not remove the starter plunger from the starter cable b Measure the starter plunger stroke distance a of the starter choke knob fully close to fully open position If the distance is out of specification adjust it as described below starter plunger stroke distance 13mm 0 51in A Fully closed position B Fully open position c Pull back the boot d Loosen the locknut e Turn the adjuster i n or out u...

Page 105: ... carbon is there then check the pole clearance by thickness gauge It is qualified 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 plug with a spark plug cleaner or wire brush 6 Install spark plug 18 Nm 20 Nm 1 8 m kg 13 ft lb Then hook up the spark plug c...

Page 106: ...ng fan according to the reference of adjusting valve clearance 5 Check ignition timing a Warm up the engine and keep it at the specified speed Engine speed 1 400 1 500 r min b Remove the timing plug 3 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 In...

Page 107: ...e 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 Compression pressure with oil introduced into ...

Page 108: ...3 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 3 in when checking the oil level Recommended oil Follow the left chart No...

Page 109: ...el surface 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 engine oil filler plug dipstick engine oil drain bolt Drain the engine oil from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure Remove the oil filter cartridge with an oil...

Page 110: ...all engine oil filler plug 9 Warm up the engine for a few minutes then stop the engine 10 Check engine for engine oil leaks oil level Refer to THE ENGINE in chapter 4 11 Check engine oil pressure a Slightly loosen the oil gallery bolt b Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so th...

Page 111: ...3 14 Oil gallery bolt 7 Nm 0 7 m kg 5 1 ft lb 12 Install console passenger seat driver seat Refer to SEATS in chapter 5 ...

Page 112: ...sible 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 Damaged Replace 3 Clean air filter element a Wash the element gently but thoroughly in solvent WARNING Use a cleaning solvent which is designed to clean parts only Never use gasoline or low flash point solven...

Page 113: ...lant level wait a few minutes until the coolant has settled coolant level The coolant level should be between the minimum level mark A and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level CHANGING THE COOLANT 1 Remove driver seat passenger seat console Lift the hood up coolant reservoir cap Disconnect coolant reservoir hose Adding water instead of c...

Page 114: ...is hot Scalding hot fluid and steam may be blown out which could cause serious injury When the engine has cooled open the radiator cap as follows Place a thick rag or 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 ...

Page 115: ...qt Coolant reservoir capacity 0 35 L 0 31 Imp qt 0 37 US qt Note The specified amount of coolant is a standard amount Fill the cooling system with coolant until coolant comes out of the hole for the air bleed bolt Coolant is potentially harmful and should be handled with special care WARNING If coolant splashes in your eyes thoroughly wash them with water and consult a doctor If coolant splashes o...

Page 116: ...g 6 5 ft lb radiator cap Fill coolant reservoir with the recommended coolant to the maximum level mark a 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 console Install passenger seat ...

Page 117: ...ch ON Coolant temperature warning light does not come on Turn the main switch to START with the transmission in neutral position Coolant temperature warning light comes on Coolant temperature and electrical circuit are OK Go ahead with riding Coolant temperature warning light come on momentarily Check the electrical circuit Coolant temperature warning light does not come on Coolant temperature war...

Page 118: ...ry 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 console passenger seat 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 an...

Page 119: ...f the muffler with a shop towel Stop the engine and allow the exhaust pipe to cool CHASSIS 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 brake master cylinder Brake pedal free play 0 mm 0 0 in 2 Adjust brake pedal free play a Loosen the locknut b Turn brake rod in or out until the correct free play is ...

Page 120: ...ut c Turn the adjuster in or out until the cor rect free play is obtained Turning in Free play is increased Turning out Free play is decreased d Tighten the locknut e Slide the adjuster cover 1 to its original position 5 Install console passenger seat driver seat Refer to SEATS in chapter 5 CHECKING THE BRAKE FLUID LEVEL 1 Place the vehicle on a level surface NOTE When checking the brake fluid lev...

Page 121: ...when refilling Water will significantly lower the boiling point of the fluid and may result in a vapor lock 4 Close the hood CHECKING THE FRONT BRAKE PADS 1 Remove front wheels 2 Check brake pads Wear indicator groove 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 ...

Page 122: ...l 5 Install console passenger seat 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 brak...

Page 123: ...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 disappeared k Add brake fluid to the proper level WARNING Check the operation of the brake after bleeding the brake system ADJUSTING THE SELECT LEVER SHIFT ROD Neutral ...

Page 124: ...1 Check brake light operation timing Incorrect Adjust 2 Adjust brake light operation timing a Hold the main body of the brake light switch so that it does not rotate and turn the adjusting nut in direction a or b until the brake light comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later CHECKING THE FINAL GEAR OIL LEVEL 1 Place the vehicle on a...

Page 125: ...inal gear case Periodic oil change 0 25 L 0 22 Imp qt Total amount 0 28 L 0 25 Imp qt WARNING Take care not to allow foreign material to enter the final gear case Install oil filler plug 23 Nm 2 3 m kg 17 ft lb CHECKING THE DIFFERENTIAL GEAR OIL 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 prop...

Page 126: ...et drain plug If it is damaged replace it with new one 6 Fill differential gear case Periodic oil change 0 32 L 0 28 Imp qt 0 34 US qt Total amount 0 33 L 0 29 Imp qt 0 35 US qt 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 care not to allow foreign...

Page 127: ...n and back and forth Excessive play Replace the steering shaft assembly 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 tie rod end s Raise the front end of the vehicle so that there is no weight on the front wheels Check ball joints and or wheel bea...

Page 128: ...NING Be sure that both tie rods are turned the same amount If not the vehicle will drift right or left even though the steering wheel is positioned straight This may lead to mishandling and an accident After setting the toe in to specification run the vehicle slowly for some distance with both hands lightly holding the steering wheel and check that the steering wheel responds correctly If not turn...

Page 129: ...ions 1 Adjust spring preload Turn the adjuster to increase or decrease the spring preload Standard position 2 Minimum Soft position 1 Maximum Hard position 5 ADJUSTING THE REAR SHOCK ABSORBERS 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 ...

Page 130: ...ere riding conditions The following are minimu ms Front 63 kPa Rear 63 kPa c Use no more than Front 77 kPa Rear 77 kPa when seating the tire beads Higher pressures may cause the tire to burst Inflate the tires slowly and carefully Fast inflation could cause the tire to burst MAXIMUM LOADING LIMIT a Vehicle loading limit total weight of cargo operator passenger and accessories and tongue weight 843...

Page 131: ...e and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires 2 Check tire surfaces Wear damage a Replace Tire wear limit a Front and rear 3 0 mm 0 12 in WARNING It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately CHE...

Page 132: ...amaged 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 drops of lubricant to the cable 2 Apply lithium soap based grease onto end of the cable lithium soap based ...

Page 133: ...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 beaten egg or vegetable oil Get immediate medical attention WARNING This is a sealed battery Never remove the sealing caps because the balance between ...

Page 134: ... lead Remove battery Check battery charge a Connect a pocket tester to the battery terminals Positive tester probe positive battery terminal Negative tester probe negative battery terminal NOTE The charge state of an MF battery can be checked by measuring its open circuit voltage i e the voltage when the positive terminal is disconnected No charging is necessary when the open circuit voltage equal...

Page 135: ...y charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring ...

Page 136: ... 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 amperage Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 ...

Page 137: ...perage 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 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 R...

Page 138: ...attery lead and then the negative battery lead Check battery 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 ...

Page 139: ...lated electrical devices d If the fuse immediately blows again check the electrical circuit Description Current rating Quantity Main 30 A 1 Lighting system fuse 15 A 1 Ignition 10 A 1 Terminal Auxiliary DC jack 10 A 1 4WD Four wheel drive 3 A 1 Signaling system fuse 10 A 1 Carburetor heater fuse 10 A 1 Backup fuse 10 A 1 Reserve 30 A 1 Reserve 15 A 1 Reserve 10 A 1 Reserve 3 A 1 WARNING Never use ...

Page 140: ...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 2 Install bulb new Secure the new bulb with the headlight bulb holder Note Avoid touching the glass part of the bulb Keep it free from oil...

Page 141: ...nds away from 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 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 ...

Page 142: ...the 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 l...

Page 143: ...No Name part Qty Remarks Removing carburetor and intake manifold Remove the parts in the order listed 1 Carburetor 1 2 Carburetor joint intake manifold 1 3 Intake manifold 1 4 Drain plug 1 For installation reverse the removal procedure ...

Page 144: ... remove drain plug please prepare vessel for containing oil and cotton yarn INSTALL Install intake manifold Install intake manifold bolt Install carburetor joint Install carburetor NOTE When installed don t make an object from the intake fell into the cabinet ...

Page 145: ...d Remove 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 tensioner cap bolt 1 9 Timing chain tensioner gasket 1 1 10 Timing chain guide exhaust side 1 11 Thermo switch 1 1 12 Cylinder head 1 ...

Page 146: ...CYLINDER HEAD 4 5 No Name part Qty Remarks 13 Thermo switch 1 1 For installation reverse the removal procedure ...

Page 147: ...r head 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 b Removing the screwdriver and slowly release the timing chain tensioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough moveme...

Page 148: ...stion chamber Use a rounded scraper NOTE Do not use a sharp instrument to avoid damaging or scratching 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 ...

Page 149: ...ead gasket cylinder 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 cloc...

Page 150: ...en tighten the timing chain tensioner bolts to the specified torque WARNING Always use a new gasket NOTE The 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 ...

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