Joyner JNSZ1600DL Owner'S Manual Download Page 39

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Valve mechanism and cylinder head removal, check and installation

1.Valve mechanism for 480 engine

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Fig.44

2.Cylinder cover bolts removal and cylinder head assembly installation

Fig.45

Fig.46

Summary of Contents for JNSZ1600DL

Page 1: ...PORTANT SAFETYINFORMATION MINIMUM RECOMMENDED OPERATOR AG FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only USA only It does not confirm to federal motor vehicle sa...

Page 2: ...600DL during the 90 days warranty period please contact your nearest authorized dealer for repairs What is not covered under this warranty This warranty does not cover any sold vehicle that has been s...

Page 3: ...READY TO DRIVE 8 6 IS YOUR VEHICLE READY TO DRIVE 10 7 SAFE DRIVING PRECAUTIONS 12 8 SPECIFICATIONS 13 9 OPERATIONS 14 10 SERVICE INSTRUCTIONS 20 11 REPAIR 26 12 ABOUT ENGINE 27 13 PERIODICAL CHECK A...

Page 4: ...Plug K7RTC Torque Of Spark Plug 17 0 30 0Nm Fuel type RQ90 unleaded Lubricate oil SAE 10W 40 CAPACITIES Maximum load 300kg Fuel tank 58 0L Engine oil 3860ml Coolant 6000ml Starting 5s Climbing 20 25...

Page 5: ...ushed all the way forward the assembly is working smoothly and returns to idle when released Do not operate if pedal or engine throttle linkage fail to return to idle If unable to correct the problem...

Page 6: ...ress the throttle slightly and turn the key clockwise to the on position release the key and the throttle when the engine starts Each time prior to starting the engine check the throttle assembly to e...

Page 7: ...l Level Check for transmission Oil Level Check for leaks add oil if required 2 Check the coolant Check for leaks add the coolant if required 3 Check for Fuel Level Add fuel as necessary and do not ove...

Page 8: ...The seat must always be securely fastened in the position which best allows the operator control of the foot pedals steering wheel and the remote stop key Fig 4 a Pull seat adjustment handle upward t...

Page 9: ...hen push the parking lever to the bottom b Adjust the parking cable if necessary Park brake OFF Fig 5 Park brake On Fig 6 F Gear Shift Adjustment 1 Loosen the bolts 2 Press down the clutch pedal fully...

Page 10: ...st 1000 km Max speed in each gear 1st Gear 25km h 2nd Gear 45km h 3rd Gear 70 km h 4th Gear 100km h H Starting And Operating Instructions a Before starting the engine be sure that the driver is seated...

Page 11: ...if the filter cover and the air filter is dusty please clear the filter cover and replace with a new air filter B Engine Lubrication Engine oil replacement You must change the oil in the crankcase af...

Page 12: ...gine oil out fully see Fig 9 c Tighten the engine oil outlet plug d Remove the oil filler cap see Fig 10 fill oil SAE 10W 30 50 about 3 86 liters to the engine e Pull out the engine oil dip stick see...

Page 13: ...nge the oil in the transmission after the first 5 hours of operating of your new engine and after 10 hours of use thereafter That will insure proper lubrication of internal parts and prevent costly re...

Page 14: ...Remove the plug see Fig 13 fill oil API 80 75 W 90 GL 3 Gear Oil about 2 0 liters Check transmission oil If the color of transmission oil changes you need to replace oil Replace transmission oil as ab...

Page 15: ...re injury Never open the radiator cap while the engine is hot New and used coolant can be hazardous Children and pets may be harmed by new or used coolant Continuous or brief contact with coolant may...

Page 16: ...t to be operated for periods in excess of 30 days or at the end of each driving season prepare for storage as follows a Drain fuel tank by allowing engine to run out of fuel or use a fuel stabilizer b...

Page 17: ...of the wheels The proper toe in dimension A should be 0 63 inches greater than dimension B 3 To adjust the alignments loose the lock nuts on both sides of Front Tie Rods To make Dimension B smaller t...

Page 18: ...ctrolyte of accumulator should be sufficient Don t operate it at high speed at once after starting the engine You should preheat it step by step You d better drive it on cement pavement or asphaltum p...

Page 19: ...gnition I 9 Air cleaner C I 10 Throttle cable I A L I R A 11 Fuel tank cover Breathe hose and joint I I R 12 Idle I 13 Breathe hose I 14 Fuel hose and joints I I I R Control system 15 Wire and plugs I...

Page 20: ...mshaft oil seal removal and installation 47 8 Valve mechanism and cylinder head removal check and installation 48 9 Piston and connecting rod assembly removal and installation 57 10 Flywheel assembly...

Page 21: ...control fuel injection system and multipoint electric control fuel injection system of the above engines are developed though the joint effort with Italy M M Corp With advanced product performance re...

Page 22: ...21 ENGINE CONFIGURATION VIEW AND SECTIONAL VIEW Fig 22 Fig 23...

Page 23: ...22 Fig 24 1 Temperature regulator seat assembly 11 Camshaft thrust plate 2 Temperature regulator seat 12 Camshaft timing gear 3 Distributor 13 Timing belt...

Page 24: ...trokes water cooling Type Cylinder bore diameter mm 79 94 Stroke mm 79 52 Total displacement L 1 596 Compression ratio 9 75 1 Nominal power RPM 62 5500 kW r min Totalpower Output maximum torque RPM 12...

Page 25: ...re at 10 or more SAE10W 30 50 grade SF Gasoline 93 SH0041 Common unleaded Gasoline Engine oil pressure Idling 100kPa min 2000r min 80 280kPa min Engine oil capacity L 3 86 New oil filter Oil pump pres...

Page 26: ...6 Connecting rod Forged steel Flat insection Without small end bushing Connecting rod stem and cover are retained by 2 spring dowels Piston and cylinder block is lubricated by oil spray from connecti...

Page 27: ...by pass valve in it 24 Fuel pump Diaphragm type Driven by upper camshaft eccentric cam Electric fuel pump for electric control engine In fuel tank 25 Push rod Made from low alloy steel Carbonization q...

Page 28: ...tube for cracking Check PCV valve Check spark plugs Per16000km Check accessories drive belt Check timing belt and tension pulley Check radiator and hoses for leaking Per30000km Replace fuel filter Pe...

Page 29: ...r filter core and clean case Check accessory driving belts Check radiator and hoses for leaking Replace spark plugs Replace timing belt Replace fuel filter Check high tension wires Check lambda sensor...

Page 30: ...ft pulley aligns with the TDC mark 0 on timing gear cover Note Before rotation spark plugs may be removed to reduce effort Fig 27 Check whether the TDC mark on the camshaft gear aligns with the mark o...

Page 31: ...timing gear cover assemblies removal and installation Fig 29 Removal Loosen and remove 2 bolts for upper timing gear cover assembly Remove upper timing gear cover and seal assembly Remove seal gasket...

Page 32: ...ck tightening torque is 9 11Nm 3 Crankshaft pulley removal and installation Fig 30 Removal If engine is equipped with starter remove three M10 30 or M10 35 bolts and remove starter Block flywheel ring...

Page 33: ...lts and finger screw in Block flywheel ring gear with screwdriver preventing crankshaft from turning Tighten bolts to 100 115Nm Fig 32 4 Valve cover and seal gasket removal and installation Fig 33 Rem...

Page 34: ...s diagram showed Step 1 Tighten to 4 0 6 0Nm Step 2 Tighten to 8 0 10 0Nm 5 Timing belt removal installation and adjustment Removal Rotate crankshaft to no 1 cylinder compression TDC Loosen 2 tension...

Page 35: ...ooth with gear teeth grooves Recheck both gears there should be no movement Loosen 2 tension pulley mounting bolts push tension pulley right to the extreme viewed from the direction of pulley tighten...

Page 36: ...learance if suspected replace appropriate parts immediately Crankshaft should be positioned at no 1 cylinder compression TDC Install belt tension pulley finger screw in 2mounting bolts then tighten to...

Page 37: ...t is positioned at compression TDC 3 Crankshaft gear Removal Block crankshaft and remove belt Pull out crankshaft gear with puller or 2 large screwdrivers then remove semicircular key Installation Che...

Page 38: ...head be sure not damage the oil seal hole Installation Clean the oil seal hole in cylinder head apply clean engine oil on oil seal edge and camshaft oil seal journal install oil seal on oil seal journ...

Page 39: ...48 8 Valve mechanism and cylinder head removal check and installation 1 Valve mechanism for 480 engine Fig 44 2 Cylinder cover bolts removal and cylinder head assembly installation Fig 45 Fig 46...

Page 40: ...be deposits in tapped hole or fluid pressure resulting from bolts screwing may possibly results in cylinder block cracking Rotate crankshaft until no 1 cylinder piston is 20mm or so under the deck of...

Page 41: ...ing rotating torque angle torque wrench or line plotting methods may be applied 3 Rocker arm mechanism and hydraulic lifting rod removal and installation Rocker arm mechanism removal Loosen rocker arm...

Page 42: ...r arm rocker arm support then finger screw in new nut tighten to 25 29Nm Note Before installing each rocker arm and tightening nut appropriate hydraulic lifting rod should be at thelowest position Hyd...

Page 43: ...ure camshaft end play clearance should be 0 049 0 129mm Loosen thrust washer bolt remove thrust washer bolt as shown in diagram Remove thrust washer Pull camshaft assembly out from the rear end of cyl...

Page 44: ...45 62 45 64 45 663 45 688 4 45 87 45 89 45 913 45 938 5 46 12 46 14 45 163 45 188 Installation If camshaft needs to be replaced check the shape of the rear end of camshaft to select appropriate camsha...

Page 45: ...valve spring compression locking pieces may be taken out After locking piece is taken out remove compression tools by unbolting slowly Remove valve spring seat and valve spring take out valve oil sea...

Page 46: ...der head valve or valve guide Lubricate the valve stem and guide with clean engine oil Install the valve Notice that the intake and exhaust valve for 480 are not interchangeable Refer to the previous...

Page 47: ...ize of intake valve seat and cylinder head valve seat hole Diameter of intake valve seat Diameter of the cylinder head valve seat hole Press fit clearance Standard 43 877 0 01 44 763 0 025 0 079 0 124...

Page 48: ...fore removal Remove the connecting rod bolts and remove the rod cap Take the connecting rod bushing out and stick on cylinder marks and labels on the upper or lower halves Push the connecting rod and...

Page 49: ...Fig 75 Fig 76 Grind the cylinder bore with the service gauge and the figured twins angle is 50 60 Measure the diameter of each piston of the carburetor engine Measurement should be taken at the posit...

Page 50: ...625 Red 20 625 20 628 Blue 20 628 20 631 Fig 77 Measure cotter intermission of piston ring First compression ring 0 30 0 50mm Second compression ring 0 30 0 50mm Steel combination oil ring 0 40 1 40m...

Page 51: ...iston head means the front arrow The outer end of piston pin means the front lug which should has a same direction with F near the large end of the connecting rod with 480 mark on some blanks and the...

Page 52: ...engine oil on the connecting rod bushing Mount connecting rod cap Retain connecting rod body and cap with two elastic retaining pins Tighten connecting rod bolt to 30 36Nm apply engine oil on the bol...

Page 53: ...seal Remove carrier sealing gasket of the real oil seal Use chisel or screwdriver to pry the real oil seal from the carrier of the real seal oil Note please don t damage the carrier of real oil seal...

Page 54: ...d such as possible Check dial indicator The reading is end play The end play of the crankshaft should be 0 092 0 303mm If dial indicator is not available the end play of the crankshaft may be checked...

Page 55: ...ed in the cover of plastic clearance gauge Check the bearing clearance from the third main bearing and extending to the two sides The clearance of main bearing is 0 011 0 058m m Check clearance of con...

Page 56: ...e diameter of main bearing bore of cylinder body The thickness of main bearing half shell Standard 57 98 58 00 62 2935 0 0065 2 131 2 138 Oversize 0 4 57 98 58 00 62 6935 0 0065 2 331 2 338 Undersize...

Page 57: ...4 0 03 29 205 29 255 2 516 0 025 Installation Before installation use the second screw tap taps the threaded hole in cylinder body especially the threaded hole of cylinder head bolt and main bearing b...

Page 58: ...ess fit clearance is 0 025 0 145mm After installation the surface of the first and the fifth main bearing caps should be even or lower than the front and back end surface of cylinder body Fig 94 Fig 9...

Page 59: ...gh oil passage in the crankshaft There is a small oil port in the connecting rod bearing bore near the exhaust side in the connecting rod body The oil sprays out from this small oil port to lubricate...

Page 60: ...e of oil pan of cylinder body and oil pump case and carrier of real oil seal Put the new rubber seal gasket on the cylinder body and have the two sides of sealing gasket enter into the grooves of carr...

Page 61: ...ith spring Installation Install a new sealing gasket of oil collector on the flange face of oil pump and then install oil collector assembly Screw two bolts with gasket by hand Fig 101 Fig 102 Screw t...

Page 62: ...l flange surface bolts Remove the bolts as the figure indicates Remove oil pump with oil seal assembly Pry out the front oil seal of crankshaft by screwdriver or chisel Note Don t damage the front oil...

Page 63: ...tor of oil pump The radial clearance between inner rotor and outer rotor of oil pump should be 0 05 0 18mm Check the end play of rotor The end play of rotor should be 0 014 0 100mm Remove horizontal h...

Page 64: ...nto the oil pump bore Screw 3 8 plug screw into the oil pump house Keep it in place Tightening torque is 20 25Nm Stick the new oil pump sealing gasket on the front end of cylinder block Install the oi...

Page 65: ...r Removal Remove the oil filter Rotate oil filter counterclockwise during removal Remove the oil pressure sensor Installation Apply engine oil on the sealing gasket of oil filter and screw into the co...

Page 66: ...temperature reaches the point for thermostat to open the coolant for cooling cylinder block going through the opened thermostat combusting chamber and behind the valve seat will go into the right wate...

Page 67: ...nce temperature 70 159 21 3 90 86 7 11 110 52 3 6 3 124 28 2 2 8 Operating voltage 12V Coolant draining 1 Remove pressure cap of expansion water tank 2 Connect a container under the radiator Remove th...

Page 68: ...and tight 2 Remove the pressure cap and add coolant by the filler of expansion tank slowly Since the expansion tank is in the highest point of cooling system with the coolant level raising the air in...

Page 69: ...lock Remove water pump assembly Remove sealing gasket of water pump Installation Install new sealing gasket of water pump on the water pump Install the water pump assembly inside the cylinder block an...

Page 70: ...move thermostat seat with thermostat assembly Pry out spring clip by chisel or screwdriver Take out the thermostat Take out sealing gasket Remove sealing gasket of thermostat seat Measure the opening...

Page 71: ...in and tighten to 7 0 10 0Nm 15 The intake and exhaust system of the engine 1 Description for the intake and exhaust system of carburetor engine The intake system of Carburetor Engine 480 includes air...

Page 72: ...g efficiency 99 filtering resistance 2kPa The air filter is equipped with a intake air temperature controller When the temperature is low the hot air intake valve controlled by the temperature control...

Page 73: ...gizing or deenergizing is controlled by the intake preheating switch and relay The intake preheating switch is installed in the M22 bolt hole in the thermostat seat with the hole plugged by plug screw...

Page 74: ...h equal length using two M8 nuts Assembly Apply lotite sealant 201 on the cylinder head bolt threads and screw six studs into the cylinder head Assemble the new sealing gasket onto the studs Install t...

Page 75: ...orque is install the rear lug and tighten allen screw with hands tightening torque is 50 60Nm 5 For oxygen sensor and 3 way catalyst Converter See CAC480M Engine s single port injection system 16 Posi...

Page 76: ...fle assembly PCV pipe cylinder block PCV hose PCV valve 3 way connector valve chamber cover connecting hose and ventilation hose 2 2 PCV valve s function Under the low speed condition the vacuum of in...

Page 77: ...he carburetor engine Fig 134 Fig 135 1 1 Description of the fuel supply system The fuel in the tank flows into oil filter pumped by the fuel pump and goes into carburetor after being filtered through...

Page 78: ...to the rod s hole of the cylinder head and install the push rod into the hole The gap between push rod and hole is 0 035 0 055mm Screw in the studs into the threaded hole and tighten with the nuts Ins...

Page 79: ...djustment The other adjustment and service should be done by professionals Fig 140 Fig 141 Fig 142 schematic drawing of engine 480M fuel system Adjustment of Peirburg 2E3 carburetor Idle speed adjustm...

Page 80: ...thermo switch and idle speed solenoid valve of carburetor 1 Alternator Output voltage 14V Rated output current 90A B Output D to the charging indicator filling in bit Battery is not permitted to be co...

Page 81: ...90 Fig 143 Fig 144 Fig 145 The JFZ1913 4 alternator for independent assembly Fig 146 Fig 147 The JFZ18D13 ZB alternator for independent assembly...

Page 82: ...e QDY1258 SD6RA78 The flywheel gear ring for vehicle and the one for independent engine assembly is different and also the starter gear modulus is different so different starters need to be applied Th...

Page 83: ...ontroller Type ZJ5701F HB or KH 3A 5 Breakerless distributor Type FDW451 with ZJ5701F HB Ignition controller or JFD459 with KH 3A Ignition controller Removing Turn the crankshaft to cylinder 1 s TDC B...

Page 84: ...1 Engine does not run during starting Cause Correction 1 Battery wires are loose or corroded Reconnect or replace the wires 2 Battery is discharged or damaged Recharge or replace the battery 3 Starter...

Page 85: ...ged for example camshaft Check and service 9 Fuel pump is damaged Replace pump 10 Carburetor float chamber needle valve is binding or oil strainer is blocked Check service and clean 11 Idle cut off va...

Page 86: ...ifice blocked Check and clean mail measuring orifice 5 Idle cut off valve damaged and not open Check circuit and solenoid 6 Idle speed too low Adjust engine idle speed 7 Idle speed fuel outlet port or...

Page 87: ...ice 10 PCV hose loose leaking or damaged Connect or replace 9 Engine Stalls within operation speed range Cause Correction 1 Fuel filter blocked Replace fuel filter 2 Fuel pump working incorrectly or l...

Page 88: ...ice 12 Engine power is not enough Cause Correction 1 Incorrect Ignition timing Check or adjust distributor 2 Incorrect Timing belt assembly or Adjust teeth belt tension or tension incorrect belt tensi...

Page 89: ...binding or spring deformed Check or replace 6 Oil collector blocked or loose Clean or replace or tighten 15 Engine self ignited Cause Correction 1 Too high idle speed too lean mixture or Adjust idle...

Page 90: ...onnecting rod bushing worn out generally severe Check and service knocking may be relieved under load b Main bearing half shell worn out booming or Check and service knocking noise may be relieved und...

Page 91: ...ust idle speed 3 Choke not widely open or auto choke damaged djust or service 4 Load enrichment diaphragm damaged or check and replace vacuum pipe blocked 5 Carburetor acceleration pump ball valve che...

Page 92: ...800 AK Ignition coil The whole system includes fuel pump fuel filter RPM sensor absolute pressure sensor sensor and so on Fig 159 1 Fuel tank 2 Fuel pump 3 Fuel filter 4 Check valve 5 Fuel pressure r...

Page 93: ...tion As a sensor fails the diagnosis system may resumes the operation using the stored value preset diagnosis for faulty Actuator condition Even if stopped as a system part fails the warning indicator...

Page 94: ...stem Throttle Valve 30MM12 30MM12 throttle valve is one of the main system parts Most sensors and actuators are assembled in the throttle valve Throttle valve features small accessories compact struct...

Page 95: ...volume of pump is about 80L h through filter and pipe to fuel pressure regulator chart 137 The regulator is designed to keep the specified fuel pressure at 1bar 0 9 1bar and redundant fuel will recir...

Page 96: ...brated by socket head bolt and will never changed under any circumstance Fuel injector 1 Socket head regulator screw 5 Spring 2 Spring 6 Sealing valve 3 Fuel output pipe 7 Diaphragm 4 Fuel return pipe...

Page 97: ...ning of injector Once maximum current is attained the circuit will automatically change to and keep the current I 1A 0 3 A Mean Injection duration is showed on the 2 dimension figure as a function of...

Page 98: ...sensor case structure also the relationship between output characteristic output signal and throttle valve opening ange Fig 166 Sensor component is consisted of a potentiometer The slipping ruler of p...

Page 99: ...again Notice Don t adjust the potentiometer bolt if it does not return to the specified value of throttle valve opening angle The potentiometer should be replaced because it fails Engine idle speed ac...

Page 100: ...It is designed to work with ethyl as its standard fuel and equipped with a check valve and a pressure override valve vibration pressure is 2 6bar It is installed inside the fuel tank and equipped with...

Page 101: ...gnal impulses produced by the 58 teeth which are arranged equally with a interval of 6 The RPM sensor position in the flywheel signal wheel is on the surface of the twentieth tooth before the top dead...

Page 102: ...three different teeth with a equal interval of 120 The value should be 2 0 6mm A Speed sensor signal B ECU power signal C Current circle for primary coil circuit a Ignition advance angle relative to c...

Page 103: ...pplies a absolutely constant 5V voltage the change of output voltage caused by the change of resistance is indicated in figure 174 Sensor supplies the most important data to ECU for calculating the in...

Page 104: ...ed parameters pressure rpm and calculate the dynamic compensation according to the engine working condition Fig 175 The following is for checking primary coil and secondary coil resistance R1 0 55 10...

Page 105: ...he pollution problem only carbon monoxide exists largely in the form of bulk Nitrogen oxides is composed of the oxidized mixture The main ingredients are as following Dinitrogen oxide nitrogen monosid...

Page 106: ...or installed in the relatively rear area of exhaust pipe sensor inspection To check all sensors and actuators injection system ECU has a complete high efficiency self diagnosis system When failure occ...

Page 107: ...he unburned fuel in the converter is another factor for the catalytic converter failure In the catalytic converter the temperature is 800 Even so if fuel only remains in the converter for 30 seconds t...

Page 108: ...pressure the multi function valve 4 will permit the fuel vapor to reach the charcoal canister 6 and be absorbed by the activated carbon granule The operation when engine is running figure 179 Solenoid...

Page 109: ...attraction Under the specified accelerating load the steel ball is released from the magnetism stillness and begins to move up the cone seat with the travel of the movement depending on the cone angle...

Page 110: ...l cylinder 1 4 9 Dual relays A ECU B fuel pump 11 Fuel pump 10 sensor 4 Fuel injector 12 Fuel vapor recirculation solenoid 5 2 ignition coil cylinder 2 3 13 ECU 6 Ignition switch 7 25A system insuranc...

Page 111: ...120 Fig 181...

Page 112: ...unter 27 Throttle valve position sensor 8 Ignition coil 1 cylinder 1 4 28 Main ground wire of engine 9 Ignition coil 2 cylinder 2 3 29 Absolute pressure sensor 10 Fuel vapor recirculation solenoid 30...

Page 113: ...nection line 23 Fuel pump relay speed counter signal 11 Tacho sensor negative input 24 A C relay signal see note 12 sensor negative input 25 Without connection line 13 Water temperature sensor negativ...

Page 114: ...tem service Fig 183 A C input and signal if euipped Note 1 All connector are viewed from the intake side of the cable 2 Cable color and number indicates the 35 pin ECU connector connection of injectio...

Page 115: ...ter temperature sensor 18 Fuel vapor recirculation solenoid 10 Absolute pressure sensor 19 sensor connector 11 Intake air temperature sensor Self diagnosis system The information is stored permanently...

Page 116: ...nding signal channel fails the above program is also applied When a failure is detected and the corresponding substitute value is applied the warning light on the instrument panel will turn on Warning...

Page 117: ...nsor from the case During reassembling grease should be applied on threads Antiseize boron nitrogen grease is recommended Tightening torque 0 5 0 6Nm At ambient temperature The resistance indicated by...

Page 118: ...Throttle valve body 30MM4 1 check the throttle valve cable for proper adjustment smooth movement 2 if the throttle valve cable is correctly adjusted and may move smoothly remove it Check the throttle...

Page 119: ...130 3 Structural Type and Applicability 131 4 Service and Operation 131 5 Drive System Schematic Drawing 131 6 Transmission Assembly Schematic Drawing 132 7 Dismantlement and Installation Transmissio...

Page 120: ...560 4th Speed 32 31 1 207 Reverse Speed 38 12 3 167 Rated Power 65KW Rated Torque 133Nm Rated Speed 6300r min Lubricating Oil Capacity 2 0L Lubricating Oil Type API 80 75 W 90 GL 3 Gear Oil Input Shaf...

Page 121: ...t weight good sealing performance smooth driving low noise and long service life etc The transmission is mainly matched with CAC480 series of engines single point injection and multi point injection S...

Page 122: ...smission Assembly schematic Drawing Fig 191 1 Clutch Housing 2 Input Shaft 3 Output Shaft 4 1st Speed 5 Reverse Speed 6 2nd Speed 7 3rd Speed 8 4th Speed 9 Transmission Case 10 Rear Case 11 Main reduc...

Page 123: ...screwed off The oil is drained away Fig 192 The release lever of clutch is drawn out Fig 193 The bolts connecting the rear case and the transmission are screwed off The rear case assembly is removed A...

Page 124: ...ift shaft is screwed off with special tool The spreader spring and shift shaft assembly are taken out Fig 196 The locking screw of reverse speed shaft is removed Fig 197 5th speed driven gear clamping...

Page 125: ...and its up and down spring are taken out And then 5th speed fork guiding plate and 5th speed fork sleeve component the reverse speed fork guiding plate 3rd and 4th speed fork and 1st and 2nd speed for...

Page 126: ...ar needle bearing and synchronizer ring are removed If necessary the special tool may be used Fig 203 The idler shaft is tapped upward with the reverse speed idler Until the idler and idler shaft are...

Page 127: ...When the differential assembly is installed on the clutch housing the output flange will be not installed temporarily 2 The output assembly is installed And the output shaft mid bearing seat is set T...

Page 128: ...gear are installed When the 3rd speed driven gear is installed the shoulder side is toward the 2nd speed driven gear Fig 210 7 After the 3rd speed driven gear is installed the axial size should be adj...

Page 129: ...212 9 The fork assembly is installed in the right postion 1 1st and 2nd speed fork 2 3rd and 4th speed fork 3 5th speed fork guiding plate and sleeve 4 reverse speed fork guiding plate Fig 213 10 The...

Page 130: ...h 25Nm of force moment The input shaft rear bearing retainer is screwed down with 15Nm force moment Notice The fork shaft is not drawn from 5th speed sleeve Otherwise the fork shaft in the case and th...

Page 131: ...nd nut Bearing When the needle bearing is installed the thick and big wall side is toward the installation tool When installed the bearings are lubricated with the transmission lubrication oil Before...

Page 132: ...Shaft Adjusted Not Adjusted Output Shaft Mid bearing Seat Adjusted Not Adjusted Differential Case Not Adjusted Adjusted Output Shaft Mid Bearing Adjusted Not Adjusted Output Shaft Front Bearing Adjus...

Page 133: ...installed to the position that is shown in the figure And then the release shaft the spring and the clamper are installed When the spring in installed its position is show in the figure The new rear c...

Page 134: ...ion case As the figure shown the bearing is tapped till the bearing is stretched out Fig 221 Fig 223 Maintenance of Shift Shaft Assembly When the shift shaft assembly is maintained the transmission as...

Page 135: ...The process of installation is reversal process of above mentioned process Notice The fork system is ensured in the neutral speed position The tightening force moment for the plug cover is 50Nm The ti...

Page 136: ...al tool The bearing is ensured in position Fig 227 Dismantlement and Installation of Input Shaft Oil Seal Dismantlement When the oil seal is removed the transmission assembly is not broken down The oi...

Page 137: ...changed the installation position of relative shaft must be readjusted Adjustment of Output Shaft and Differential Assembly Adjustment of Output Shaft The distance B1 from the big plane of output sha...

Page 138: ...of the assembly bearing outer ring to the contact surface of clutch housing is measured The bearing hole depth A2 of output power assembly on the transmission case is also measured To Calculate the In...

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