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Huansong UTV 700 2009, Service Manual

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Huansong UTV 700 2009 Service Manual Download Page 55

                                             

GENERAL INFORMATION                 

   

                       

1-43 

Poor Idle or Low Speed Performance 

1.  Check for an incorrect pilot screw adjustment 

2.  Check for damaged or loose intake pipe and air filter housing hose clamps. These 

conditions will cause an air leak 

3.  Perform the spark test in this chapter. Note the following: 

a.  If the spark is good. Go to Step 4 

b. 

If the spark is weak. 

Perform the Peak Voltage Testing 

4.  Check the ignition timing. If ignition timing is correct. Perform Step 5. If the timing is 

incorrect. Perform the 

Peak Voltage Testing

 

5.  Check the fuel system as described in this chapter 

 

Poor High Speed Performance 

1.  Check ignition timing. If the ignition timing is correct. Perform Step 2. If the timing is incorrect. 

Perform the

 Peak Voltage

 

2.  Check the fuel system as described in this chapter 

3.  Check the valve clearance as described. Note the following: 

a.  If the valve clearance as correct. Perform Step 4 

b.  If the clearance is incorrect. adjust the valves as described in Chapter Three 

4.  Incorrect valve timing and 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 fuel system problems under specific complaints. If there is a 

good spark. Poor fuel flow may 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 fuel in the rank 

3.  After attempting to start the engine. Remove the spark plug and check for fuel on the plug tip. 

Note the following: 

a.  If there is no fuel visible in the plug. Check for a clogged fuel shutoff valve. Fuel filter or fuel 

line 

b.  If there is fuel present on the plug tip. And the engine has spark. Check for an excessive 

intake air leak or the possibility of contaminated or stale fuel 

 

NOTE 

If the UTV was not used for some time. And was not 

properly stored. The fuel may have gone stale. Where 

Summary of Contents for UTV 700 2009

Page 1: ...HUANSONG UTV 700 SERVICE MANUAL 2009 ...

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 ...

Page 151: ...d camshaft Remove the parts in the order listed 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 shaft1 O ring 1 1 8 Rocker arm 1 1 9 Rocker arm 2 1 10 Wave washer 11 Locknut 12 Valve adjuster ...

Page 152: ...RMS AND CAMSHAFT 4 11 Order Job Part Qty Remarks 13 Decompress or cam guide plate 4 14 Camshaft sprocket 5 15 Camshaft 5 16 Cylinder head 2 17 Cylinder head gasket For installation reverse the removal procedure ...

Page 153: ... inside diameter of the rocker arm holes Out of specification Replace d Check the surface of the rocker arm shafts Worn pitting scratches Replace e Measure the external diameter of rocker arm shaft with micrometer Out of specification Replace Rocker arm shaft outside diameter repairing limit value Φ11 96mm f Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rock...

Page 154: ...on camshaft sprocket rotor I mark Out of alignment 3 Checking the camshaft sprocket camshaft sprocket Wear damage Replace the camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct Timing chain Sprocket 4 Checking the decompression system decompression system Check while the camshaft sprocket is installed on the camshaft a Check that the decompressor lever pin projects from the cam...

Page 155: ...mshaft camshaft sprocket a Turn the crankshaft counterclockwise with a T sleeve b Align the I mark on the rotor with the stationary pointer on the A C magneto cover When the I mark is aligned with the stationary pointer the piston is at the Top Dead Center TDC CAUTION Do not turn the crankshaft during the camshaft installation c Temporarily install the camshaft sprocket on the camshaft Do not inst...

Page 156: ...t NOTE Check that each part is positioned as shown in the illustration Punch mark on decompressor spring lever Top front of cylinder head e Install the decompressor cam guide plates and camshaft sprocket bolts Camshaft sprocket bolt 20 Nm NOTE Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide intake side inward f Remove the retaining wire ...

Page 157: ...lves and valve 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 Valve stem seal 5 8 Valve spring seat 5 For installation reverse the removal procedure ...

Page 158: ...diameter larger than the body of the stem Replace valve seats Pitting wear Reface the valve seat MEASURE 1 Measure The valves surface width Repairing limit value 2 0mm stem to guide clearance Stem to guide clearance valve guide inside diameter valve stem diameter NOTE If the mating surface is coarse corrode or cannot contact with valve seat normally replace it Stem to guide clearance repairing lim...

Page 159: ...er head b Press the valve through the valve guide and onto the valve seat to make a clear pattern c Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed Valve spring free length Valve spring squareness Out of specification Replace Valve spring free length Intake 32 5mm Exhaust 36 2mm Valve spring squareness Intake 0 10mm Exhaust 0 10mm compre...

Page 160: ...ve guide installer b After installing the valve guide bore the valve guide using a valve guide reamer to obtain proper stem to guide clearance NOTE After replacing the valve guide reface the valve seat c If the valve seat is to wide or narrow or cracked grind it to ensure impermeability 3 Lap valve face valve seat NOTE After reface the valve seat or replacing the valve and valve guide the valve se...

Page 161: ...pping results lightly tap the valve seat while rotating the valve back and forth between your hands d Apply a fine lapping compound to the valve face and repeat the above steps NOTE After every lapping operation be sure to clean off all of the compound from the valve face and valve seat e Install the valve into the cylinder head g Press the valve through the valve guide and onto the valve seat to ...

Page 162: ...TE Install the valve springs with the larger pitch a facing upwards b Smaller pitch valve cotters NOTE Install the valve cotters while compressing the valve spring with the valve spring compressor and valve spring compressor attachment To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood CAUTION Hitting the valve tip with excessive force could damage the v...

Page 163: ...cylinder 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 7 Piston 1 8 Piston ring set 1 For installation reverse the removal procedure ...

Page 164: ...iston groove is cracked and abraded 3 Checking the piston pin piston pin Blue discoloration grooves Replace then check the lubrication system MEASURE At the top the middle and the bottom of the piston stroke NOTE Measure the bore diameter at directions of right angle intersection Repairing limit value Out of roundness 0 005mm Taper 0 005mm The external diameter 10mm above the bottom of the piston ...

Page 165: ...he side clearance Side clearance Standard Limit Top ring 0 04 0 08mm 0 13mm 2nd ring 0 03 0 07mm 0 13mm piston pin to piston clearance a Measure the piston pin outside diameter Repairing limit value 0 02mm b Measure the piston pin bore inside diameter Repairing limit value 0 02mm c Calculate the piston pin to piston clearance with the following formula Piston pin to piston clearance Piston pin bor...

Page 166: ...the piston pin piston rings and piston Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase 2 Installing the cylinder cylinder O ring bolts M10 42Nm bolts M6 10Nm NOTE Install the cylinder with one hand while compressing the pisto...

Page 167: ... and A C magneto 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 magneto coupler 2 6 Engine cooling fan pulley base 1 7 A C magneto cover gasket 1 1 8 Dowel pin 2 9 Stator lead holder 1 ...

Page 168: ...Job Part Qty Remarks 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 installation reverse the removal procedure ...

Page 169: ...to rotor When installing apply the locking agent a Install the starter wheel gear onto the starter clutch and hold the starter clutch NOTE Install the starter wheel gear with the groove a facing the A C magneto rotor b Turn the starter wheel gear counterclockwise to check that the starter clutch and wheel gear engage If the starter clutch and wheel gear do not engage replace the starter clutch c T...

Page 170: ...g the rotor clean the outside of the crankshaft and the inside of the rotor After installing the rotor check that the rotor rotates smoothly If not reinstall the key and rotor dowel pins gasket New replacement A C magneto cover 10Nm NOTE When installing the A C magneto cover use a long rod to hold the A C magneto rotor in position from the outside This will make assembly easier Be careful not to d...

Page 171: ...cooling fan pulley do not forget to install the O ring engine cooling fan 7Nm NOTE Install the bolts in the holes in the collar of the engine cooling fan air shroud 10Nm engine cooling fan air duct assembly NOTE Install the engine cooling fan air duct assembly with the arrow mark a towards the air shroud 1 ...

Page 172: ...rs and oil pump 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 8 9 Pin 4 10 Timing chain guide intake side 1 11 Timing chain 1 For installation reverse the removal procedure ...

Page 173: ...place the balancer 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 Cracks stiff Replace the timing chain and camshaft sprocket as a set timing chain guides Wear damage Replace INSTALL pins springs balancer drive gear onto the buffer boss plate circlip ...

Page 174: ...nch mark b on the balancer driven gear lock washer new replacement balancer driven gear nut 110Nm NOTE Place an aluminum plate between the teeth of the balancer drive gear and balancer driven gear Apply the molybdenum disulfide grease to the thread of axle and nut 4 Bend the lock washer tabs along the balancer driven gear nut ...

Page 175: ... primary and secondary sheaves 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 Secondary sheave assembly 1 9 Drive belt case 1 10 Rubber gasket 2 For installation reverse the removal procedure ...

Page 176: ... Disassembling the primary sheave Remove the parts in the order listed Primary pulley sheave cap 1 Primary pulley slider 4 Spacer 4 Primary pulley cam 1 Primary pulley weight 8 Collar 1 Oil seal 2 Primary sliding sheave 1 O ring 1 For assembly reverse the disassembly procedure ...

Page 177: ...art Qty Remarks Disassembling the secondary Sheave Remove the parts in the order listed Nut Spring seat Compression spring Spring seat Guide pin Secondary sliding sheave O ring Secondary fixed sheave Oil seal Oil seal For assembly reverse the disassembly procedure ...

Page 178: ... sheave splines 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 smooth operation secondary sliding sheave smooth operation Scratches damage Replace as a set torque cam grooves Wear damage Replace guide pins Wear damage Replace secondary sheave spring D...

Page 179: ...sliding sheave face primary fixed sheave face collar weights primary sliding sheave cam face NOTE Remove any excess grease 2 Install weights NOTE Apply grease 90 g to the whole outer surface of the weights and install Apply grease to the inner surface of the collar Apply grease to the inner surface of the primary sliding sheave spacer sliders primary pulley cam primary sliding sheave cap 3 Nm ...

Page 180: ...ide pins spring seat compression spring spring seat nut a Attach the sheave 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 compress the spring d Install the nut and tighten it to the specified torque using the locknut wrench Nut 90Nm e Remove the sheave sp...

Page 181: ...ush the secondary sliding sheave away causing the gap between the secondary 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 NOTE Use the sheave holder to hold the primary sheave First tighten the primary sheave nut then tighten the secondary sheave nut ...

Page 182: ...Removing 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 For installation reverse the removal procedure ...

Page 183: ...t Qty Remarks Disassembling the clutch housing Remove the parts in the order listed Oil seal 1 Circlip 1 Bearing housing 1 Circlip 1 Bearing 1 Circlip 1 Bearing 1 Clutch housing 1 For assembly reverse the disassembly procedure ...

Page 184: ...ring 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 assembly is faulty Replace it c When turning the clutch housing counter clockwise b the clutch housing and crank shaft should be engaged If not the one way clutch assembly is faulty Replace it clutc...

Page 185: ...way clutch bearing NOTE 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 10 Nm NOTE Tighten the bolts in stages using a crisscross pattern After tightening the bolts check that the clutch housing assembly to counterclockwise rotates smoothly ...

Page 186: ... filter 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 2 4 Oil pipe adapter O ring 1 1 5 Relief valve assembly 1 6 Speed sensor 1 7 Shift drum stopper 1 8 Gear position switch 1 ...

Page 187: ...CRANKCASE 4 46 Order Job Part Qty Remarks 9 Reverse switch 1 10 Oil filler cap 1 11 Oil delivery pipe 1 1 For installation reverse the removal procedure ...

Page 188: ... crankcase 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 Crankshaft seal 1 For installation reverse the removal procedure ...

Page 189: ... Remarks 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 9 For installation reverse the removal procedure ...

Page 190: ...e 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 Check crankcase Cracks damage Replace oil delivery passages Clogged Blow out with compressed air 4 Checking the bearings 1 Check bearings Clean and lubricate then rotate the inner race with a finger Roughness Replace ...

Page 191: ...e 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 bolts 26Nm follow the proper tightening sequence A Left crankcase B Right crankcase NOTE Tighten the bolts in stages using a crises cross pattern Apply sealant Quick Gasket to the thread of the bolt sh...

Page 192: ...ASE 4 51 2 Installing the shift levers shift lever 2 assembly 14Nm shift lever 1 NOTE When installing the shift lever 1 align the punch mark a on the shift lever 1 with the punch marks b on the shift lever 2 ...

Page 193: ... Job Part Qty Remarks Removing 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 6 Crankshaft 1 For installation reverse the removal procedure ...

Page 194: ...3 Oil pump Order Job Part Qty Remarks Disassembling the oil pump Remove the parts in the order listed Rotor cover 1 Pin 2 Shaft 1 Pin 1 Inner rotor 1 Outer rotor 1 Oil pump housing 1 For assembly reverse the disassembly procedure ...

Page 195: ...ainer oil strainer O ring Damage Replace Contaminants Clean with engine oil MEASURE 1 Measure the oil pump tip clearance a between the inner rotor and the out rotor side clearance b between the outer rotor and the pump housing body clearance c between the outer rotor and the pump housing Out of specification Replace the oil pump Tip clearance Limit 0 23 mm Side clearance Limit 0 17 mm Body clearan...

Page 196: ... properly interconnected with a tolerance of less than 1 mm 0 04 in CAUTION The buffer boss and woodruff key should be replaced when removed from the crankshaft INSTALL 1 Assembling the oil pump inner rotor outer rotor oil pump shaft with the recommended lubricant 2 Installing the crankshaft and balancer crankshaft NOTE Hold the connecting rod at the Top Dead Center TDC with one hand while turning...

Page 197: ... parts in the 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 Secondary shaft 1 10 Drive axle assembly 1 11 Chain 1 For installation reverse the removal procedure ...

Page 198: ...mbly Order Job Part Qty Remarks Disassembling the drive axle assembly Remove the parts in the order listed Clutch dog 1 High wheel gear 1 Middle drive gear 1 Driven sprocket 1 Drive axle 1 For assembly reverse the disassembly procedure ...

Page 199: ...ce guide bar Roll the guide bar on a flat surface Bends Replace WARNING Do not attempt to straighten a bent guide bar shift fork movement on the guide bar Unsmooth operation Replace the shift fork and the guide bar springs Cracks damage Replace 2 Checking the shift drum shift drum grooves Scratches wear damage Replace ...

Page 200: ...cracks missing portions Replace gear movement Unsmooth Repeat steps 1 or replace the defective parts circlip Bends looseness 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 looseness damage Replace ...

Page 201: ... secondary shaft and driven sprocket as a set Measure axle runout Use a centering device and a dial gauge Out of specification Replace the bent axle Drive axle runout limit 0 06 mm INSTALL 1 Assembling the shift fork guide bar shift fork 2 long spring shift fork 1 short spring ...

Page 202: ...ission chain drive axle assembly secondary shaft shift fork assembly shift drum low wheel gear NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely ...

Page 203: ...rks Removing the 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 retainer 2 For assembly reverse the disassembly procedure ...

Page 204: ...iddle drive 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 8 Middle driven pinion gear 1 9 Bearing retainer 1 10 Bearing retainer 1 ...

Page 205: ...MIDDLE GEAR 4 64 Order Job Part Qty Remarks 11 Middle driven shaft 1 For installation reverse the removal procedure ...

Page 206: ... Selecting the middle middle drive and driven gear shims When the drive and driven gear bearing housing assembly and or crankcase replaced be sure to adjust the gear shims and middle drive gear shim middle driven gear shim 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 hole of the right...

Page 207: ...is incorrect adjust the gear lash by middle driven pinion gear shims and or middle drive pinion gear shim s INSTALL 1 Installing the middle driven shaft bearing retainer Bearing retainer 80 Nm NOTE Attach the ring nut wrench CAUTION The middle driven shaft bearing retainer has left handed threads To tighten the retainer turn it counterclockwise bearing retainer a Place a rag in the vise b Secure t...

Page 208: ...kwise Bearing retainer 110Nm shims bearing housing NOTE Install the shims so that the tabs are positioned as shown in the illustration universal joint yoke washer nut NOTE Use the universal joint holder to hold the yoke Universal joint yoke nut 150 Nm universal joint a Install the opposite yoke into the universal joint b Apply wheel bearing grease to the bearings ...

Page 209: ...ke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place d Press each bearing into the universal joint using a suitable socket NOTE The bearing must be inserted far enough into the universal joint so that the circlip can be installed e Install the circlip into the groove of each bearing ...

Page 210: ...E Use the coupling gear middle shaft tool 2 to hold the drive shaft coupling 2 Installing the middle drive shaft 1 Tighten middle drive pinion gear nut 145Nm NOTE Secure the middle drive shaft in the vise with a clean rag 2 Lock the threads with a drift punch ...

Page 211: ...etor assembly 1 2 Screw on upper cover 1 3 Plunger spring 1 4 oil needle component 1 5 Big diaphragm 1 6 Plunger 1 7 Diaphragm circlip 1 8 Screw M4 8 1 9 External shaft cover 1 10 Seal ring of external shaft cover 1 11 Accelerator pull cable locating dowel loop 1 12 ACV valve diaphragm component 1 13 Idle metering air jet 1 ...

Page 212: ...chamber 16 Float 17 Idle metering jet 1 18 High speed jet 1 19 Needle jet 1 20 Pilot jet 1 21 Starting jet 22 Mixture ratio adjusting screw component 1 23 Suction pipe 1 24 Fuel inlet pipe 1 25 Adjusting screw component 1 For assembly reverse the disassembly procedure ...

Page 213: ...ntamination wear damage Replace as a set NOTE Always replace the needle valve and valve seat as a set piston valve Scratches wear damage Replace rubber diaphragm Rupture Replace Piston valve oil stick Bent Worn out Replace NOTE If the piston valve is damaged inject the petrol into valve Replace it when there is oil leakage vacuum chamber cover spring Cracks damage Replace ...

Page 214: ...ee movement piston valve Sticks Replace the piston valve guide and the piston valve Insert the piston valve into the carburetor body and check for free movement free movement throttle valve Sticks Replace MEASURE float height a Out of specification Adjust Float height F H 13 mm 0 51 in a Hold the carburetor in an upside down position b Measure the distance from the front mating surface of the floa...

Page 215: ...osen the drain screw d Hold the gauge vertically next to the float chamber line e Measure the fuel level a with the gauge f If the fuel level is incorrect adjust the fuel level g Remove the carburetor h Check the valve seat and needle valve i If either is worn replace them both j If both are fine adjust the float level by bending the float tang slightly k Install the carburetor l Recheck the fuel ...

Page 216: ... exceeded limits or polluted by friction material such as oil 1 Check whether brake plate deformed 3 Grinding noises emerged from front brake or brake plate become red during drive 2 Check whether hydraulic cylinder of brake clamp locked or brake clamp assembly parts deformed 1 Check whether brake plate deformed 2 Check whether hydraulic cylinder of brake clamp locked or brake clamp assembly parts...

Page 217: ...er and frame damaged 1 Check whether rear axle bearing damaged 2 Check whether sliding bearing connected to rear axle bearing housing and rocker loosen or damaged 3 Check whether rear wheel and axle locknut loosen or damaged 4 Check whether rear wheel hub inner spline and rear wheel axle outer spline worn or loosen 4 Rear wheel tramp during drive 5 Check whether rubber cushion connected to rear su...

Page 218: ...rubber boot damaged 7 Front and rear axles arise abnormal sound during drive or universal joint damaged 1 Check whether four wheel drive switch normal 2 Check whether power divider damaged 8 Fail to shift into four wheel drive or lock differential 3 Check whether differential mechanical conversion agency locked or damaged ...

Page 219: ...rt Name Qty Remarks Removing the structure of the steering 1 Steering machine parts 1 2 Drive gear wheel 1 3 Circlip 1 4 Bearing 1 5 Adjuster 1 6 spring 1 7 Pressure pad 1 8 Circlip 1 9 Oil seal 1 10 Plastic locking tie L 200 2 11 Dust boots 2 12 Flange bolt M10x30 M10 30 4 ...

Page 220: ...5 5 DIRECTION SYSTEM THE STRUCTURE OF THE STEERING No Part Name Qty Remarks 13 Tie rod end 2 14 Tie rod end locknut M10 2 15 Steering joint 1 16 Flange bolt M8 20 2 17 Notch nut M12 2 18 Pin 3 2 32 2 ...

Page 221: ...IRECTION SYSTEM THE STRUCTURE OF STEERING WHEEL PART No Part Name Qty Remarks Removing steering wheel part 1 Flange bolt M8x16 4 2 Steering shaft 1 3 Steering wheel 1 4 Washerφ12 5 1 5 Flange nut M12x1 25 1 ...

Page 222: ...EEL Check Steering wheel crack break Replace loose play Adjust the steering wheel to rotate whether nimble do not have stagnation Adjust the torque of the steering wheel whether obviously increase Adjust Note The steering force cutting which exerts to transfers in steering wheel outflow boundary is smaller than 245N the reverse running clearance whether does surpass the limited stipulation Adjust ...

Page 223: ...line between the steering wheel and steering column whether have damaged if the attrition is serious must replace the steering wheel Note The tolerance clearance between the internal spline on the steering wheel and outer spline on the steering column is smaller than 0 1mm If find some problems in the check it should be service immediately to ensure the normal work of the steering system ...

Page 224: ... Takes down the parts of the front panel engine covers and the connection covers part and the display board and the steering wheel center covers b Take down the steering wheel c Loose the bolt which is on the steering drive axle the top of spline draws out the cross gimbal d Loose the fastening four piece M8 16 bolt on the steering column take down the steering column from the frame ...

Page 225: ...ng and retaining ring whether ware or damaged according to the inspection situation to instead the parts 2 Check the two ends of the spline on the central 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 and welding line of the branch whether have crack ...

Page 226: ... axle pull out the lower of the steering drive axle CHECKING AND SERVICE THE STEERING DRIVE AXLE Inspect the cross gimbal turn agility with no stagnation If does dismantle and check the cross axis needle bearing and the bearing hole on the cross gimbal fork whether have wear and corrosion to instead the parts based on the check Note Install the cross gimbal daub the lithium grease on the surface o...

Page 227: ...TS DIASSEMBLING THE STEERING MACHINE PART 1 Loose the four piece of nut dismantle the direction machine from the frame 2 Loose the open groove nut on the L R turning steering knuckle take down the steering tension rod from the steering knuckle ...

Page 228: ...age Replace dust boots Damage degradation Replace Note When replace the dust boots of the ball must enter 1 2 volume in lithium grease in to the dust boots 3 Check tie rod free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 4 Check tie rods Bends damage Replace 5 Check steering joint Crack distortion Replace ...

Page 229: ...ck Whether the inspection gear drive reverse gap does surpass the rating If it does adjust the gap and the bolt If cannot reduce the gap through the adjustment instead the gear rack Do not use the welding to repair the steering joint Note When replace the direction machine cleaning all the parts and daub the lithium grease in to the movement Note Continue to use the hidden danger Ball pin may caus...

Page 230: ...lt M8 20 3 Connecting the steering transmission shaft and steering column tube with one piece of flange bolt M8 20 then use four pieces of flange nut M8 16 fix the steering column tube on the frame 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 Bolt M10 30 40 Nm 4 0m kg 29 ft lb Nut M10 36 Nm 3 ...

Page 231: ...between 20mm 30mm Otherwise please adjust the screw to meet required travel distance 1 Inspect the brake pedal does maintain the certain counter tension When checks disk brake plate the saved liquid in the oil cup will pour automatically into the pressure pipe and the liquid level along with it to reduce the periodic inspection the disk brake plate liquid volume will be an important project 2 Peri...

Page 232: ...ENTS No Part Name Qty Remarks Removingfront disk brake components 1 Belt 3 L 150 2 2 Belt4 L 200 4 3 Belt 6 L 150 4 4 Bolt M6 30 1 5 Bolt M6 20 1 6 Disc brake pipe clip 3 7 Flange bolt M6 20 4 8 Wire clip fixed plate 2 9 Disk brake assembly 1 ...

Page 233: ...5 18 BRAKE SYSTEM FRONT BRAKE DISCS No Part Name Qty Remarks Removing the brake discs 1 Brake disc 1 2 Brake caliper assembly 1 ...

Page 234: ...e brake disc deflection Out 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 Out of specification Replace Brake disc minimum thickness 3 0 mm 0 12 in Note Apply the locking agent to the 30Nm bolt with screw down ...

Page 235: ...PADS No Part Name Qty Remarks Removing the front 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 removal 4 Pad spring 1 procedure ...

Page 236: ...et a Connect a suitable hose 1 tightly to the brake caliper bleed screw 2 Put the other end of this hose into an open container b Loosen the brake caliper bleed screw and using a finger push the caliper piston into the brake caliper c Tighten the brake caliper bleed screw Brake caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb d Install the retaining bolts and brake caliper Brake pad holding bolt 18 Nm ...

Page 237: ... Removing the front 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 caliper assembly 1 For installation reverse the removal procedure ...

Page 238: ...ks Disassembling the front 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 assembly reverse the disassembly 1 procedure ...

Page 239: ...per cylinder b Remove the dust seals and caliper piston seals All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort 1 Check brake caliper pistons Scratches rust wear Replace the brake caliper assembly brake caliper cylinders Wear scratches Replace the brake caliper assembly brake caliper body Cracks damage Replace ...

Page 240: ...omponents should be cleaned and lubricated with new brake fluid only before installation Must use DOT4 Brake Fluid Replace the caliper piston seals and dust seal whenever a brake caliper is disassembled 1 Install caliper piston seals dust seals 2 Install brake caliper pistons ...

Page 241: ...e on the brake caliper make sure that the brake pipe touches the projection a on the brake caliper Proper brake hose routing is essential to insure safe vehicle operation 2 Fill brake reservoir Must use DOT4 Brake Fluid Note Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately 3 Air bleed brake system 4 Check brake fluid level Brake fluid level i...

Page 242: ...EM REAR BRAKE DISC No Part Name Qty Remarks Removing the rear brake disc Remove the parts in the order listed Brake caliper assembly Final drive gear 1 Rear brake disc 1 For installation reverse the removal procedure ...

Page 243: ...C 1 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 Brake disc minimum thickness 3 0 mm 0 12 in ...

Page 244: ...per and brake pads Rear skid plate Brake fluid 1 Parking brake switch coupler 1 2 Spring 1 3 Parking brake cable 1 4 Parking brake lever assembly mounting 1 Bolt 5 Parking brake lever assembly 1 6 Union bolt 1 7 Copper washer 2 8 Brake hose 1 9 Brake caliper mounting bolt 2 10 Brake caliper mounting bolt 2 ...

Page 245: ...2 Brake pad piston 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 brake case bolt 2 22 Parking brake case 1 23 Gasket 1 24 Brake caliper piston 1 25 Dust seal 1 ...

Page 246: ...5 31 BRAKE SYSTEM No Part Name Qty Remarks 26 Caliper piston seal 1 27 Bleed screw 1 ...

Page 247: ...ce the brake pads as a set Brake pad wear limit 1 5 mm 0 06 in 2 Install brake pads brake pad spring Note Always install new brake pads new brake pad shims new insulators and a new brake pad spring as a set 3 Check brake fluid level 4 Check brake pedal operation Soft or spongy feeling Bleed the brake system ...

Page 248: ...ned in new brake fluid only Do not use solvents as they will cause seals to swell and distort 1 Check brake caliper pistons Scratches rust wear Replace the brake caliper assembly brake caliper cylinders Wear scratches Replace the brake caliper assembly brake caliper body Cracks damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air Replace the caliper ...

Page 249: ...r a brake caliper is disassembled 1 Install caliper piston seal dust seal 2 Install brake caliper piston Turn the brake caliper piston clockwise until section a of the brake caliper piston is level with the surface of the brake caliper body Note Align an end b of the groove in the brake caliper piston with the punch mark c on the brake caliper body 3 Install gasket parking brake case parking brake...

Page 250: ...hreads If the punch mark a on the parking brake arm shaft is not between the alignment marks b when the parking brake arm shaft is screwed in completely remove the parking brake arm shaft and screw it in from a different starting position b Turn the parking brake arm shaft approximately 60 clockwise c Install the parking brake arm to the parking brake arm shaft so that the punch mark c on the park...

Page 251: ...Install brake pad piston side with insulator and pad shim Note 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 ...

Page 252: ...e brake hose as shown Proper brake hose routing is essential to insure safe vehicle operation 2 Fill brake reservoir Must use DOT4 Brake Fluid Note Brake fluid may damage painted surfaces or 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 brake fluid to the proper leve...

Page 253: ...Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Brake fluid reservoir float 1 4 Union bolt 1 5 Copper washer 2 6 Brake hose 1 Disconnect 7 Brake pipe 1 Disconnect 8 Brake master cylinder 1 For installation reverse the removal procedure ...

Page 254: ... Blockage Blow out with compressed air 2 Check brake master cylinder kit Scratches wear damage Replace as a set 3 Check brake fluid reservoir brake fluid reservoir diaphragm Cracks damage Replace ASSEMBLING THE BRAKE MASTER CYLINDER All internal brake components should be cleaned and lubricated with new brake fluid only before installation Must use DOT4 Brake Fluid Whenever a master cylinder is di...

Page 255: ...b copper washers brake hose union bolt 27Nm 2 7 m kg 19 ft lb 3 Fill brake fluid reservoir Must use DOT4 Brake Fluid Note Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately 4 Air bleed brake system 5 Check brake fluid level Brake fluid level is under the MIN level line Fill up 6 Adjust brake pedal free play ...

Page 256: ...arks 1 Left footrest 1 2 Screw M6 16 2 3 Footrest cover 1 4 Sheathing paper 1 5 Screw M6 20 4 6 Nut spring M6 4 7 Right footrest 1 8 Rubber 1 9 Screw 5 10 Rear brake bump holder 1 11 Flange bolt M8 12 3 12 Speedup footrest 1 13 Washer Φ22 Φ15 2 2 14 Cotter clip 1 ...

Page 257: ...ing 1 16 Rear brake pedal 1 17 Washer Φ22 Φ15 2 2 18 Cotter clip 1 19 Spring 1 20 Throttle cable 1 21 Belt 7 L 200 1 22 Belt 4 L 150 1 23 Belt 3 L 200 1 24 Rubber of dust proof 1 25 Brake assembly 1 26 Brake piece 1 27 Handle brake piece 1 28 Screw 2 29 Flange bolt M6 20 1 ...

Page 258: ...5 43 FOOTREST ASSEMBLY FOOTREST ASSEMBLY No Part Name Qty Remarks 30 Cable 1 31 Clip 1 L 150 1 32 Nut choke cable 1 33 Belt7 L 200 1 34 Cable clip 5 35 Flange bolt M6 10 5 36 Choke cable 1 ...

Page 259: ...PARTS FRONT WHEELS No Part Name Qty Remarks Removing the front wheel 1 Front wheel rim 2 2 Front wheel 2 3 Valve cap 2 4 Nut 5 Center cap 1 6 Axle nut 1 Securely support the vehicle so 7 Front wheel hub 1 There is no danger of it falling over ...

Page 260: ...HEELS No Part Name Qty Remarks Removing the rear wheel Securely support the vehicle so There is no danger of it falling over 1 Rear wheel 1 2 Center cap 1 3 Axle nut 1 For installation reverse the removal 4 Rear wheel hub 1 procedure ...

Page 261: ...heel bearing play 3 Check wheel balance Out of balance Adjust Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in The profile depth falls below 3mm Please replace the tyre immediately CHECKING THE WHEEL HUB 1 Check wheel hub Cracks damage Replace splines wheel hub Wear damage Replace nuts wheel hub loosen or distorted Replace or Tighten ...

Page 262: ... m kg 190 ft lb INSTALLING THE WHEEL TYRE 1 Install wheel Note The arrow mark on the tyre must point in the direction of rotation A of the wheel 2 Tighten wheel nuts Tapered wheel nuts are used for both the front and rear wheels Install each nut The angle of the conical bores is 60 ...

Page 263: ...pressure and profile depth Insufficient tyre pressure can result in not only intensified wearing of the tyre but also instability during the course of operating the vehicle such as hard turning Excessive tyre pressure can also reduce the friction force between the tyre and ground causing spinning or lose of control Therefore please ensure the tyre pressure strictly complies with figures shown in t...

Page 264: ...N SYSTEM Transmission System Front Bridge No Part Name Qty Remarks 1 Circlip 1 2 Double off set joint assembly 2 3 Circlip 1 4 Circlip 2 5 Boot band 2 6 Dust boot 2 7 Boot band 2 8 Joint shaft 1 9 Half axle assembly 1 ...

Page 265: ...e front bridge 1 Transmission shaft part front bridge 1 2 Differential gear case 1 3 Differential gear case cover 1 4 Drive pinion gear 1 5 Universal joint yoke 1 6 Nut M14 1 25 1 7 O ring Φ14 d Φ7 1 8 Oil seal Φ48 Φ65 9 1 9 Oil seal front box input shaft 2 10 Shim 0 1T 1 Shim 0 2T 1 Shim 0 5T 1 ...

Page 266: ...l gear assembly 1 13 Bolt M8 25 1 14 Bolt M8 10 1 15 Oil change bolt M10 16 1 16 Circlip 1 17 Column pinφ5 80 1 18 Gear motor 1 19 Coulping shaft device 1 20 Rack 1 21 O ring divide moved Φ2 Φ81 1 22 O ring front box cover d Φ2 4 Φ140 4 23 Bearing 6007 RΦ35 Φ62 14 1 24 Bearing 6912Φ60 Φ85 13 1 ...

Page 267: ...Bearing 16007 Φ35 Φ62 9 1 26 Bearing HK152112Φ15 Φ21 12 1 27 Bolt M14 15 10 1 28 Washer Φ14 2 1 29 Nut M10 1 30 Washer Φ10 2 31 Shaft fork 4 6 32 Universal joint 1 33 Bolt M14X15 3 34 Block ring 2 35 HoseΦ4 5 L 710 1 36 Clip pipe 1 1 37 Clamp 2 38 Intermediate shaft 2 ...

Page 268: ... 53 TRANSMISSION SYSTEM Front Bridge No Part Name Qty Remarks 39 Circlip 2 40 Cushion piece 1 41 Spring D Φ25 Φ2 3 28 1 42 Dustproof rubber 1 43 Dustproof rubber 1 44 Bolt M10 25 1 45 Washer 2 46 Screw 2 ...

Page 269: ...nt disk brake clip cotter pin open groove nut cushion and front wheel hub 3 Disassembly the left and right arm rocker and cross steering knuckle 4 Disassembly the differential device 5 Take down the front bridge from the frame 6 Emit the oil in the differential device 7 Pull out the left and right transmission shaft from the differential device ...

Page 270: ...ion shaft movement is Smooth ceaseless If it is stagnation and obvious becoming less loosen replace it Disassembe the left and right transmission shaft cleaning and assemble it again Note 1 The dustproof rubber wrap on the ball cage is not allow to contact with the gas and diesel oil 2 The dustproof rubber wrap does not allow to be scratched a slight scratches can damage the dustproof rubber wrap ...

Page 271: ...eals O rings Damage Replace 2 Check drive shaft splines universal joints drive pinion gear splines Wear damage Replace spring Fatigue Replace Move the spring up and down 3 Check front drive shaft Bends Replace torque limiter Loose Replace the front drive shaft Apply lithium soap based grease to the oil seal front box output shaft and oil seal front box input shaft and differential gear assembly ...

Page 272: ...L 4 the high quality gear grease into the front bridge differential device and screws tight the oil filler bolt 3 Install the front bridge differential device onto the frame with two pieces of hexagon boltsM10 110 two pieces of nutsM10 and two pieces of flat gasket Fastening Torque of Conical Nut 23 Nm 2 3m kg 17 ft lb Fastening Torque of the Bolt 40 45 Nm 4 0 4 5 m kg 29 33 ft lb ...

Page 273: ... Bridge No Part Name Qty Remarks 1 Circlip 2 2 Boot band 2 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint assembly 1 7 Circlip 1 8 Circlip 1 9 Double off set joint assembly 1 10 Joint shaft 1 11 Half axle assembly 1 ...

Page 274: ...mbly 1 4 Bearing HK556720Φ55 Φ67 20 1 5 Final drive pinion gear 1 6 Bearing 6305Φ25 Φ62 17 1 7 Drive shaft coupling 1 8 Oil seal Φ61 Φ35 9 1 9 Bearing 55BM6720Φ55 Φ67 20 1 10 O ring Φ3 1 Φ63 8 1 11 Flat gasket Φ12 4 Φ30 1 12 Flange nut M12 1 25 1 13 Final drive pinion gear bearing housing 1 14 rear adjustment gasketⅠ 0 1T 1 ...

Page 275: ...lt M8 35 4 16 Washerφ8 5 3 17 rear adjustment gasket II 1 7T 1 rear adjustment gasket II 1 8T 1 rear adjustment gasket II 1 9T 1 rear adjustment gasket II 2 0T 1 rear adjustment gasket II 2 1T 1 18 Speed sensor assembly 1 19 O ring d Φ2 3 Φ19 4 1 20 Vent rear speed reducer 1 21 Ring gear bearing housing 1 22 Ring gear stopper M8 1 ...

Page 276: ...4 24 Flange nut M8 2 25 Oil seal Φ65 Φ90 9 2 26 Bearing 16017Φ85 Φ130 14 1 27 O ring d Φ3 1 Φ150 2 28 Washer 0 1T 1 Washer 0 2T 1 29 Bolt M8 25 1 30 Washerφ8 5 1 31 Bolt M10 1 25 25 1 32 Bolt M8x20 4 33 Washerφ8 5 2 34 Spring Φ16 5 d Φ2 30 1 35 Middle driving axes rear bridge 1 ...

Page 277: ...iddle driving axes 1 38 Circlip d 17 5 δ 1 1 39 Self lock flange nut 1 40 Front dustproof cover 2 rear bridgeΦ23 5 Φ46 35 1 41 Rear dustproof cover 1 rear bridge Φ19 Φ40 7 30 1 42 Oil hoseΦ4 5 1320 1 43 Oil hose clipΦ7 2 d 1 1 44 Washer 1 45 Clip 1 46 Clip 1 47 Driven gear 1 48 Boot band 2 49 Flange bolt M10 1 25 125 1 ...

Page 278: ...parts is as the same as the front bridge parts please refer to the before mentioned to operate Note Apply lithium soap based grease to the bearing assembly and o ring and bearing and driven gear and oil seal and drive shaft coupling and final drive pinion gear bearing housing ...

Page 279: ...assembled 1 2 Lever sheath of gearshift 1 3 Gearshift dust proof rubber 1 4 Gearshift assembly 1 5 Rod of gearshift 1 6 Ball assembly gearshift 1 7 Pulling ball assembly gearshift 1 8 Washer φ6 1 9 Bolt M8 12 1 10 Bolt M8 16 3 11 Plastic bolt 1 12 Clip clamp 1 13 Make water pipe clip 1 ...

Page 280: ...5 65 REVERSE MECHANISM PARTS Reverse mechanism parts No Part Name Qty Remarks 14 Make water pipe cap 1 15 Nut M6 1 16 Nut M6 L 1 ...

Page 281: ...our foot off the accelerator pedal Otherwise the transmission may be damaged 1 Adjust Select lever shift rod a Make sure the select lever is in NEUTRAL b Loosen both locknuts 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 locknuts Locknut 15 Nm 1 5 ...

Page 282: ... connecting nut on the striking fork to have contraposition then fasten the reverse mechanism again 3 Disassemble the reverse mechanism to check the connecting rod of the reverse 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 inform the special serviceman...

Page 283: ...cker assembly 1 2 Front upper gimbal 1 3 Elasticity block ring 1 4 Upper right rocker assembly 1 5 Front upper gimbal 1 6 Block ring shaft 1 7 Front lower left rocker assembly 1 8 Front lower right rocker assembly 1 9 Middle bushing 8 10 Flange bolt M10 70 8 11 Locknut M10 x1 25 8 12 Washer 16 ...

Page 284: ...rm No Part Name Qty Remarks 13 Locknut M10x1 25 4 14 Pin 3 2x32 4 15 Front shocker absorber left right 2 16 Locknut M10x1 25 4 17 Flange bolt M10 1 25 52 4 18 Rocker baffle 2 19 Flange nut M6 4 20 Flange bolt M6x12 4 21 Front upper gimbal 2 ...

Page 285: ...d the torsional spring is rupture If it is rupture or nearly to rupture instead the shock absorber whether it leak oil if so instead the same spec shock absorber According to the different request if there is a oil cup on the rocker must check it whether complete and refuels 2 Installing Use 16pieces of Hexagon Flange BoltM10 70 and 16pieces of bolt to connect the front upper left and right rocker...

Page 286: ...ieces of Hexagon Flange Bolts M10 70 and 2 pieces of self lock nuts M10 Note 1 Put on the butter to each part when it is assemble 2 Do not scratches the surface of the spare part surface To check whether put on the butter before fix then fix the upper and lower rockers and L R front shock absorber etc ...

Page 287: ...pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint CHECKING THE FRONT SHOCK ABSORBER 1 Check shock absorber rod Bends damage Replace the shock absorber assembly shock absorber assembly Oil leaks Replace the shock absorber assembly spring Fatigue Replace the shock absorber assembly Move the spring up and down ...

Page 288: ... and front lower arm Note Lubricate the bolts 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 the ball joints Nut 30 Nm 3 0 m kg 22 ft lb d Install the new cotter pins e Tighten the nuts Nut 45 Nm 4 5 m kg 32 ft lb ...

Page 289: ...2 Flange bolt M12 1 25 70 2 3 Flange bolt M12 1 25 65 2 4 Nut M12x1 25 4 5 Stabilizer 1 6 Left balling rod balancing pole 1 7 Right balling rod balancing pole 1 8 Locknut M8 4 9 Cushion rubber cover rear balancing pole 2 10 Board balancing pole 2 11 Flange bolt M8x16 4 12 cushion plate 2 ...

Page 290: ...mbly 1 2 Rear lower right swing arm assembly 1 3 Rear lower left swing arm assembly 1 4 Tube rear rocker 8 5 Flange bolt M10 1 25 70 8 6 Locknut M10x1 25 8 7 Rear upper swing arm 1 8 Gasket buffer cover rocker arm 16 9 Rear lower right arm sheeting 1 10 Rear lower left arm sheeting 1 ...

Page 291: ...egrant According to the front Suspension 3 The cotter pin on the head of the install axis which in the rear shock absorber whether is credible Note After disassemble the rear shock absorber check if there exists any distortion or crack on the frame connection hole and the rear shock absorber if so inform the special serviceman to inspect and service first or install the rear shock absorber on the ...

Page 292: ...heck rear arms Bends damage Replace 2 Check Tube rear rocker Wear damage Replace CHECKING THE REAR SHOCK ABSORBER 1 Check shock absorber rod Bends damage Replace the shock absorber assembly shock absorber assembly Oil leaks Replace the shock absorber assembly spring Move the spring up and down Fatigue Replace the shock absorber assembly ...

Page 293: ...ear upper arm and rear lower arm NOTE Lubricate the bolts with lithium soap based grease Be sure to position the bolts so that the bolt head faces inward Temporarily tighten the nuts b Install the rear shock absorber Nut 45 Nm 4 5 m kg 32 ft lb c Install the rear knuckle Nut 45 Nm 4 5 m kg 32 ft lb d Tighten the nuts Nut 45 Nm 4 5 m kg 32 ft lb ...

Page 294: ...emarks 1 Former left rubber hose 1 2 Left metal hose 1 3 After left rubber hose 1 4 Right rubber hose 2 5 Right metal hose 1 6 Former right rubber hose 1 7 Bolt clip 8 8 Clip 4 9 Bolt M6 4 10 Cooler water tank 3 11 Radiator fan assembly 1 12 Phillip screw M6 25 3 ...

Page 295: ...Nut clip M5 3 15 Water tank cap 1 16 Oil cooler on the mounting bracket 1 17 Oil cooler under mounting bracket 1 18 radiator 1 19 radiator cover 3 20 Oil cooler 1 21 Bolt M6 20 4 22 Plain cushion φ6 4 23 Bolt M6 20 2 24 Plain cushion φ6 2 25 Bush 2 26 Water tank rubber cushion 2 ...

Page 296: ...5 81 COOLING SYSTEM RADIATOR No Part Name Qty Remarks 27 Standby water bottle 1 28 Oil cooler shield 1 29 Hose 1 30 Clip Φ8 2 31 Overflow hoseφ7 φ12 1 32 Clip Φ11 2 ...

Page 297: ...clip the tightness of Bolt clip If loosen please have the hoop tightened immediately 4 Check radiator fan Damage Replace Malfunction Check and repair 5 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 107 9 137 3 KPa 1 079 1 373 kg cm2 15 35 19 53 psi a Install the radiator cap tester and adapter onto the radiator cap b Apply...

Page 298: ... level stop to change then screw the exhaust nut cover the water tank lid The water tank inspection is finished 2 Check cooling system Leaks Repair or replace any faulty part Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and water mixing ratio 1 1 Total amount 1 8L 1 58 lmp qt 1 90 US qt Coolant reservoir capacity up ...

Page 299: ...e Cracks damage Replace 3 To take a pressure resistance inspection to the Oil Cooling System after maintain the pressure is 0 3MPA 4 After take the 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 5 When it is finished assembly pour the L engine oil then start the engine for 10 minutes to chec...

Page 300: ...t M6 45 1 3 Bolt M6 65 1 4 Bolt M6 10 1 5 Water pipe Ⅱ 1 6 O ring 20 7 2 6 1 7 Water pipe Ⅲ 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 Ⅰ 1 13 Clip Ⅱ 2 14 Pipe clip Ⅱ 1 18 19 20 25 21 22 24 23 26 10Nm 1 0m kg 7 2 ft lb 12Nm 1 2m kg 8 7 ft lb ...

Page 301: ... 16 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 ring 1 18 19 20 25 21 22 24 23 26 10Nm 1 0m kg 7 2 ft lb 12Nm 1 2m kg 8 7 ft lb ...

Page 302: ...r shaft 2 Remove water pump seal Water pump housing Note Tap out the water pump seal from the inside of the water pump housing 3 Remove bearing oil seal water pump housing Note Tap out the bearing and oil seal from the outside of the water pump housing Apply lithium soap based grease to the oil seal and apply engine oil to the bearing ...

Page 303: ...ear Replace Note Apply lithium soap based grease to the o ring 2 Check water pump seal oil seal water pipe Cracks damage wear Replace bearing Rough movement Replace Note Apply lithium soap based grease to the oil seal and Apply engine oil to the bearing 3 Measure impeller shaft tilt Straightedge Impeller Out of specification Replace Max impeller shaft tilt 0 15 mm 0 006 in ...

Page 304: ...l water pump seal into the water pump housing mechanical seal installer and water pump seal installer water pump seal installer Note Never lubricate the water pump seal surface with oil or grease Install the water pump seal with the special tools 3 Install rubber damper rubber damper holder Note Before installing the rubber damper apply tap water or coolant onto its outer surface Make sure that th...

Page 305: ... Plate cushion 2 3 Setting board seat 2 4 Flange bolt M8 30 8 5 Flange locknut M8 1 25 8 6 Flange bolt M8 30 1 7 Lock hook parts seat 2 8 Bolt M6 38 4 9 Nut M6 4 10 Locker seat 2 11 Air control switch seat 4 12 Bushing battery 4 13 Bushing Φ10 5 2 14 Side armrest 2 ...

Page 306: ... Pillow part 2 17 Bolt M8 30 1 18 Nut M10 1 25 1 19 Bolt M10 25 Φ14 5 2 20 Flange locknut M10 1 25 20 2 21 Cover 2 22 Locker 2 23 Life belt assembly 2 24 Accelerate nut M10 1 25 2 25 Special bolt M10 1 25 22 2 26 Special bolt M10 1 25 25 2 27 Washer Φ6 6 28 Cushion 2 ...

Page 307: ...ng 2 3 Tubeφ12 1 4 Inlet vittaφ6 φ9 210 1 5 Clip φ10 2 6 Minus press bump minus press pipe Ⅰ 1 7 Clip φ10 4 8 Flange bolt M6x20 1 9 Oil line φ7 φ11 1 10 Cannulation 1 11 Clip φ12 1 12 Insulator 1 13 Insulator 1 14 Foam shock absorber 1 30Nm 3 0m kg 22 ft lb 7Nm 0 7m kg 5 1 ft lb ...

Page 308: ...board 2 16 Flange bolt M8 25 2 17 Line clip φ13 1 18 Tank 1 19 Vitta connection 1 20 O type ring 1 21 Flange screw M5x10 4 22 Fuel sensor 1 23 Cushion 1 24 Screw 4 25 Fuel tank 1 26 Filter 1 27 Clip 2 28 Fuel pipeφ5 5 φ12 1 30Nm 3 0m kg 22 ft lb 7Nm 0 7m kg 5 1 ft lb ...

Page 309: ...3 Pump suction trigeminal tubeφ3 1 34 Fuel tank insulation paperⅡ 1 35 Fuel tank insulation paperⅢ 1 36 Small fuel tank cover 1 37 Small fuel tank return pipeφ8 φ12 1 38 Carburetor into tubingφ8 φ15 400 1 39 Clip φ12 2 40 Small fuel tank breathing tube φ4 5 φ8 210 1 41 Clip φ14 1 42 Minus press bump minus press pipeⅡ 1 30Nm 3 0m kg 22 ft lb 7Nm 0 7m kg 5 1 ft lb ...

Page 310: ...RATION 1 Remove driver seat passenger seat console right protector 2 Place a container under the end of the fuel hose 3 Check fuel pump operation a Suck on the end of the vacuum hose 4 Install right protector console passenger seat driver seat ...

Page 311: ... pipe CHECKING AND SERVICE THE OIL COOLING SYSTEM Check 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 1 Check if the steel oil pipe is distortion and leak To adjust instead the serious distortion one and leak oil pipe 2 Check if Rubber Pipe is torn aged worn out or distorted 3 Check if the O rubber gask...

Page 312: ...he 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 carries on the assembly 4 When it is assemblied pour the L engine oil then start the engine for 10 minutes to check whether leaks If it is not the Oil Cooling System maintain is finish ...

Page 313: ...heck whether carburetor plugged or damaged 8 Check whether air filter plugged 3 Fail to electric start 9 Check whether oil circuit smooth 1 Check whether sensor damaged 2 Check whether meter damaged 4 Abnormal speed indication between meter and mileage 3 Check whether sensor surface polluted by iron scrap 1 Check whether neutral switch damaged 2 Check whether meter damaged 5 Neutral indicator of m...

Page 314: ...1 Thermo switch 2 2 Radiator 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 Gear position switch 13 Reverse switch ...

Page 315: ...ay 3 5 Differential gear lock indicator light relay 6 Four wheel drive indicator light relay 7 Fuse box 8 C D I unit C D I 9 Battery 10 Rectifier regulator 11 Indicator light assembly 1 12 Indicator light assembly 2 13 On Command four wheel drive switch and differential gear lock switch 14 Main switch 15 Light switch ...

Page 316: ...e when testing the switch for continuity Turn the switch on and off a few times when checking it The terminal connections for switches main switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indicates the terminals with continuity The example chart shows t...

Page 317: ...inuity 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 lock switch 4 Main switch 5 Light switch 6 Parking brake switch 7 Reverse switch 8 Four wheel drive switch ...

Page 318: ...ocket or both Since the bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the bulb to keep it free from oil otherwise the transparency of the glass the life of the...

Page 319: ...n direction detection coil resistance 10 Wiring connection the entire ignition system NOTE 1 Cushion 2 Front frame 3 Front fender Check and repaire with following special tools 1 Fuses main ignition CONTINUITY 2 Battery CORRECT 3 Spark plug Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse s Check the battery condition Refer to CHECKING AND CHARGING THE INCORRECT Clean the battery termin...

Page 320: ...on coil Tester lead Orange lead terminal Tester lead Ignition coil base Check that the primary coil has the specified resistance INCORRECT Repair or replace the spark plug Disconnect the spark plug cap from the spark plug Connect the pulse ignition spark checker or ignition checker as shown Spark plug cap Turn the main switch to ON Check the ignition spark gap a Crank the engine by pushing the sta...

Page 321: ...to the pickup coil terminal Tester lead White Red terminal Tester lead White Green terminal Check the pickup coil for the specified resistance Pickup coil resistance 459 561 Ω at 20 C 68 F White Red White Green 9 Rotor rotation direction detection coil resistance Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Ω 1 to the rotor rotation direction detection coil te...

Page 322: ...tection coil resistance 0 063 0 077 Ω at 20 C 68 F Red White Blue MEETS SPECIFICATION 10 Wiring connection Check the connections of the entire ignition system Refer to CIRCUIT DIAGRAM CORRECT Replace the C D I unit OUT OF SPECIFICATION POOR CONNECTION Replace the pickup coil stator assembly Properly connect the ignition system ...

Page 323: ...ELECTRIC STARTING SYSTEM 6 11 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Switch C D I Relay Motor Battery ...

Page 324: ...efer to CHECKING THE SWITCH CONTINUITY 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT 3 Starter motor Connect the battery terminal and starter motor cable using a jumper lead Check the operation of the starter motor TURNS NO CONTINUITY Replace the fuse s INCORRECT错误 Clean the battery terminals R...

Page 325: ...ontinuity CONTINUITY 5 Main switch Refer to CHECKING THE SWITCH CORRECT 6 Gear position switch Refer to CHECKING THE SWITCH CORRECT 7 Brake light switch Refer to CHECKING THE SWITCH CORRECT正确 8 Diode 1 Remove the diode from the coupler Connect the pocket tester Ω 1 to the diode terminals as shown Check the diode for continuity as follows Repair or replace the starter motor NO CONTINUITY Replace th...

Page 326: ...ster 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 CIRCUIT DIAGRAM NOT E When you switch the tester s positive and negative probes the readings in the left chart will be reversed INCORRECT Replace the diode 1 POOR CONNECTION Properly connect the starti...

Page 327: ...ead Starter motor O ring 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure Disassembling the starter motor Bracket 1 Washer kit Bracket 2 Shims Brush seat 1 brush seat 2 Armature coil 1 Yoke 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ASSEMBLING THE STARTER MOTOR ...

Page 328: ...Out of specification Scrape the mica using a hacksaw blade NOTE Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator 4 Check armature coil insulation continuity Defects Replace the starter motor a Connect the pocket tester for the continuity check and insulation check b Measure the armature resistances c If the resistance is incorrect replac...

Page 329: ...Fatigue out of specification Replace as a set 7 Check oil seal bushing O rings Wear damage Replace ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 NOTE Align the projection a on the brush seat 1 with the slot b on the yoke 2 Install yoke brackets NOTE Align the match marks a on the yoke with the match marks b on the brackets ...

Page 330: ...CHARGING SYSTEM 6 18 CHARGING SYSTEM CIRCUIT DIAGRAM Ignition coil C D I Magneto Rectifier ...

Page 331: ...AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT 3 Charging voltage Connect the engine tachometer to the spark plug lead Connect the pocket tester DC 20 V to the battery Tester lead Battery terminal Tester lead Battery terminal Start the engine and accelerate to about 1 000 r min Charging voltage 14 V at 1 000 r min NOTE Use a fully charged battery OUT...

Page 332: ...hite terminal Tester lead White terminal Measure the charging coil resistance Charging coil resistance 0 32 0 43 Ω at 20 C 68 F MEETS SPECIFICATION 5 Wiring connections Check the connections of the entire charging system Refer to CIRCUIT DIAGRAM CORRECT Replace the rectifier regulator OUT OF SPECIFICATION Replace the pickup coil stator assembly POOR CONNECTION Properly connect the charging system ...

Page 333: ...LIGHTING SYSTEM 6 21 LIGHTING SYSTEM CIRCUIT DIAGRAM Flash Relay switch Rectifier Battery Light ...

Page 334: ... the battery INCORRECT Replace the main switch INCORRECT Replace the light switch POOR CONNECTION Properly connect the lighting system 1 Fuses main lighting system Refer to CHECKING THE SWITCH CONTINUITY 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT 3 Main switch Refer to CHECKING THE SWITCH CO...

Page 335: ...V to the headlight couplers Tester lead Green terminal or Yellow terminal Tester lead Black terminal A When the light switch is on B When the light switch is on Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Green and Yellow leads on the bulb socket connector NO CONTINUITY Replace the bulb and or bulb socket OUT OF SPECIFICATION The wiring circuit from the mai...

Page 336: ...t couplers Tester lead Blue lead terminal Tester lead Black lead terminal Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Blue lead on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty NO CONTINUITY Replace the bulb and or bulb socket OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repai...

Page 337: ...SIGNALING SYSTEM 6 25 SIGNALING SYSTEM CIRCUIT DIAGRAM Flash Relay switch Rectifier Battery Light ...

Page 338: ...THE SWITCH CONTINUITY 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT 3 Main switch Refer to CHECKING THE SWITCH CORRECT 4 Wiring connections Check the connections of the entire signal system Refer to CIRCUIT DIAGRAM CORRECT Check the condition of each of the signal system s circuits Refer to CHE...

Page 339: ... 20 V to the bulb socket connector Tester lead Yellow terminal Tester lead Black terminal Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Yellow lead on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace the brake light switch OUT OF SPECIFICATION The wiring circuit fr...

Page 340: ...the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal Tester lead Sky blue terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION This circuit is not faulty NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace the gear position switch OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket c...

Page 341: ...nnect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal Tester lead Blue Red terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION This circuit is not faulty NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace the parking brake switch OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb so...

Page 342: ...ect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal Tester lead Green Blue terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION Replace the C D I unit NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace the Reverse switch OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket conne...

Page 343: ...e thermo switch 1 Immerse the thermo switch 1 in coolant Check the thermo switch 1 for continuity While heating the coolant use a thermometer to record the temperatures A The thermo switch 1 circuit is open and the coolant temperature warning light is off B The thermo switch 1 circuit is closed and the coolant temperature warning light is on Test step Coolant temperature Continuity 1 Less than 120...

Page 344: ...ge 12 V MEETS SPECIFICATION 4 Diode 2 Remove the diode from the coupler Connect the pocket tester Ω 1 to the diode terminals as shown Check the diode for continuity as follows Tester lead Blue Black terminal Tester lead White Blue terminal Continuity Tester lead White Blue terminal Tester lead Blue Black terminal No continuity CORRECT This circuit is not faulty OUT OF SPECIFICATION The wiring circ...

Page 345: ... as follows Tester lead Black Green terminal Tester lead Black terminal Continuity Battery terminal Brown terminal Battery terminal Black red terminal Tester lead Black Green terminal Tester lead Black terminal No continuity CONTINUITY 3 Four wheel drive switch Refer to CHECKING THE SWITCH CONTINUITY 4 Voltage Connect the pocket tester DC 20 V to the indicator light assembly 1 coupler Tester lead ...

Page 346: ...SIGNALING SYSTEM 6 34 MEETS SPECIFICATION This circuit is not faulty The wiring circuit from the main switch to the bulb socket connector is faulty repair it ...

Page 347: ...attery terminal Brown terminal Battery terminal White Black terminal Tester lead White Yellow terminal Tester lead Black terminal No continuity CONTINUITY 3 Four wheel drive switch Refer to CHECKING THE SWITCH CONTINUITY 4 Voltage Connect the pocket tester DC 20 V to the indicator light assembly 1 coupler Tester lead Brown terminal Tester lead White Yellow terminal Turn the main switch to ON Check...

Page 348: ...COOLING SYSTEM 6 36 COOLING SYSTEM CIRCUIT DIAGRAM Temperature control switch fan motor Battery Circuit breaker switch ...

Page 349: ... CHECKING THE SWITCH CONTINUITY 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT 3 Main switch Refer to CHECKING THE SWITCH CORRECT 4 Radiator fan motor Disconnect the radiator fan motor coupler Connect the battery 12 V as shown Battery lead Blue terminal Battery lead Black terminal NO CONTINUITY ...

Page 350: ...Connect the pocket tester Ω 1 to the thermo switch 3 Immerse the thermo switch 3 in coolant Check the thermo switch 3 for continuity While heating the coolant use a thermometer to record the temperatures A The thermo switch 3 circuit is closed B The thermo switch 3 circuit is open Test step Coolant temperature Continuity 1 Less than 75 3 C 167 5 4 F No 2 More than 75 3 C 167 5 4 F Yes 3 More than ...

Page 351: ...t to a strong shock or allow it to be dropped Should it be dropped it must be replaced Thermo switch 3 28 Nm 2 8 m kg 20 ft lb GOOD CONDITION 7 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM CORRECT This circuit is not faulty BAD CONDITION Replace the thermo switch 3 POOR CONNECTION Properly connect the cooling system ...

Page 352: ...2WD 4WD SELECTING SYSTEM 6 40 2WD 4WD SELECTING SYSTEM CIRCUIT DIAGRAM Transfer Switch Relay Battery Motor Indicator ...

Page 353: ...ses main four wheel drive Refer to CHECKING THE SWITCH CONTINUITY连续性 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT 3 Main switch Refer to CHECKING THE SWITCH CORRECT 4 Four wheel drive relay 1 Remove the four wheel drive relay 1 from the wire harness Connect the pocket tester Ω 1 and the batter...

Page 354: ...our wheel drive relay 2 for continuity CONTINUITY 6 Four wheel drive relay 3 Remove the four wheel drive relay 3 from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the four wheel drive relay 3 terminals Battery terminal Brown Red terminal Battery terminal Yellow Black terminal Tester lead Blue Red terminal Tester lead Gray terminal Check the four wheel drive relay 3 for co...

Page 355: ...k 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 motor refer to FRONT CONSTANT VELOCITY JOINTS DIFFERENTIAL GEAR AND DRIVE SHAFT in chapter 3 CORRECT 9 Wiring connection switch and differential gear lock switch INCORRECT Replace the gear motor Check the connections of the enti...

Page 356: ...ose 2 Damaged vacuum hose Air filter Clogged air filter element Carburetor 1 Fuel is deteriorated or polluted 2 Starting nozzle is clogged 3 Air tube is clogged 4 Sucked in air 5 Deformed float 6 Worn needle valve 7 Improperly sealed valve seat 8 Improperly adjusted fuel level 9 Improperly set pilot jet 10 Clogged starter jet 11 Starter plunger malfunction ELECTRICAL SYSTEM Spark plug 1 Improper p...

Page 357: ...nder head 1 Loose spark plug 2 Loose cylinder head or cylinder 3 Broken cylinder head gasket 4 Broken cylinder gasket 5 Worn damaged or seized cylinder Piston and piston rings 1 Improperly installed piston ring 2 Worn fatigued or broken piston ring 3 Seized piston ring 4 Seized or damaged piston Valve camshaft and crankshaft 1 Improperly sealed valve 2 Improperly contacted valve and valve seat 3 I...

Page 358: ... 5 Faulty ignition coil Valve train Improperly adjusted valve clearance Air filter Clogged air filter element POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE Carburetor 1 Improper jet needle clip position 2 Improperly adjusted fuel level 3 Clogged or loose main jet 4 Deteriorated or contaminated fue Air filter Clogged air filter element FAULTY GEAR SHIFTING SHIFT LEVE...

Page 359: ...m 1 Improper carburetor main jet improper setting 2 Improper fuel level 3 Clogged air filter element Compression system Heavy carbon deposit Engine oil 1 Improper oil level 2 Improper oil viscosity 3 Inferior oil quality Brake Brake drag Cooling system 1 Low coolant level 2 Clogged or damaged radiator 3 Damaged or faulty water pump 4 Faulty fan motor 5 Faulty thermo switch Oil cooling system Clogg...

Page 360: ...damper rod Damaged oil seal lip Fatigued shock absorber spring UNSTABLE HANDLING UNSTABLE HANDLING Steering wheel Improperly installed or bent Steering 1 Incorrect toe in 2 Bent steering shaft 3 Improperly installed steering shaft 4 Damaged bearing 5 Bent tie rods 6 Deformed steering knuckles Tires 1 Uneven tire pressures on both sides 2 Incorrect tire pressure 3 Uneven tire wear Wheels 1 Deformed...

Page 361: ...cessories 3 Hard charging broken stator coil and or faulty rectifier regulator 4 Incorrect connection 5 Improperly grounded 6 Bulb life expired BULB BURNT OUT BULB BURNT OUT 1 Improper bulb 2 Faulty battery 3 Faulty rectifier regulator 4 Improperly grounded 5 Faulty main and or lights switch 6 Bulb life expired ...

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