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Liangzi Power UTV1000-3 Maintenance Manual Download Page 33

3.ENGINE 

 

3-

     

3 

Remove the air filter and mounting bracket. 

 

 

 

 

 

 

 

 

 

 

 

 

Unscrew  the  exhaust  clamp  securing  front  the 

exhaust pipe to “Y” exhaust pipe. 

 

 

 

 

 

 

 

Unscrew the front exhaust pipe nuts. 

Unplug the connector of oxygen sensor 

Move  the  front  exhaust  pipe  forward  then 

remove it. 

 

 

 

 

 

 

Unscrew  the  “Y”  exhaust  pipe  nuts  from  rear 

cylinder. 

Unplug the connector of oxygen sensor 

Remove the “Y” exhaust pipe and put it as shown. 

Remove the engine upper support bracket. 

 

 

 

 

 

 

 

Bracket 

Support 

bracket 

Summary of Contents for UTV1000-3

Page 1: ...UTV1000 3 4 Maintenance Manual Shandong Liangzi Power Co Ltd Any copy or without written permission or authorization is prohibited to use the manual version 1 May 2017 All rights reserved...

Page 2: ...sed to show the basic principles of operation and work procedures They may not represent the actual vehicle exactly in detail Manufacturer reserves the right of no prior notice on product improvement...

Page 3: ...see the doctor Keep cooling liquid far away from children 5 Wear proper working suit boots and hat If necessary please wear long sleeve working suit and gloves for operation 6 Gasoline is highly infla...

Page 4: ...urer shall be outward 20 In cleaning and drying bearing please keep bearing support still Before installation please carry out lubrication with oil or lubricating oil 21 Please correct install elastic...

Page 5: ...5500RPM Idle speed 1650rpm Lubrication Type Wet tank lubrication oil filters can be changed Oil pressure 0 07 0 25MPa at 1250rpm Type of oil SAE10W 50 SJ Oil quantity 2200mL Replacement of capacity 20...

Page 6: ...Crankshaft deflection Service limit 0 07mm Crankshaft pin diameter New 41 986 to 42 010mm Service limit 41 967mm Connecting rod big end radial clearance Service limit 0 09mm Connecting rod small end d...

Page 7: ...k absorber travel 120mm Rear shock absorber Coil spring oil damper Rear shock absorber travel 135mm Drive train Front differential Shaft driven single auto lock differential Front differential ratio 3...

Page 8: ...allation location Specifications mm Torque N m kgf m Fastening bolt of engine M10 70 7 1 Fastening nut of suspension arm M12 80 8 2 Bolt of rear shock absorber M12 80 8 2 Bolt of front shock absorber...

Page 9: ...gneto flywheel bolt M16 150 15 3 Magneto stator bolt M6 12 5 1 3 One way bolt M8 30 3 1 Engine oil drain plug M12 20 2 0 Gearbox oil drain plug M12 20 2 0 Decompression valve plug M22 20 2 0 Cylinder...

Page 10: ......

Page 11: ...riod of time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a dealer as they require special tools and technical skills In case of complicated...

Page 12: ...air if necessary O O O O Wheel bearings Check bearing assemblies for looseness or damage Replace if damaged O O O O Front and rear Suspension Check operation and for leakage Correct if necessary O O S...

Page 13: ...crease in power output and an increase in fuel consumption never remove or modify any component in the air filter housing The engine management system is calibrated to operate specifically with these...

Page 14: ...ENTER TDC on the compression stroke Remove left and right seats gear shift handle and engine shield Remove spark plug cable and spark plug of both cylinders Remove the valve cover of both cylinders 1...

Page 15: ...lel to cylinder head base If not use Allen key to turn crankshaft 360 1 Printed marks on camshaft timing gear 2 Cylinder head base Insert the feeler gauge between the valve stem end and adjusting scre...

Page 16: ...e Until marks on magneto flywheel 1 and magneto cover are aligned 1 Mark 1 on magneto flywheel 2 Notch on magneto cover 3 Location of crankshaft position sensor At TDC ignition the printed marks on th...

Page 17: ...nut 6 Feeler gauge Valve clearance adjuster locknut 12N m CAUTION Install the valve cover of both cylinders spark plug cable and spark plug of both cylinders the plug screw and O ring of magneto cover...

Page 18: ...oves smoothly without sticking and snaps back automatically when it is released Check to see that the gas pedal operates correctly It must operate smoothly and fully spring back to the idle position w...

Page 19: ...ld 6 Remove dipstick and wipe clean stem 7 Fully screw in dipstick to check oil level 8 Remove dipstick and read oil level Oil level must be between minimum 2 and maximum 1 marks on dipstick 9 There i...

Page 20: ...tic drain plug from metal shavings and residue 12 Install a new gasket ring on drain plug Torque drain plug to 20 N m 13 Remove oil filter screws oil filter cover and oil filter 1 Oil filter screw 2 O...

Page 21: ...rain plug to 20 N m 9 Pour the specified oil GL 4 90 about 420mL by syringe through the oil level check plug hole until the oil over flows 10 Tighten the oil level check plug to 20 N m FRONT DIFFERENT...

Page 22: ...reducer case and then drain oil completely by removing the drain plug Tighten the drain plug to 20 N m Pour the specified oil GL 4 90 about 220mL by syringe through the oil level check plug hole until...

Page 23: ...then place a load of 75kg on the seat Measure the distance A and B of the front wheels and calculate the difference Toe in B A 5mm A front of front wheel B rear of front wheel Out of range of toe in A...

Page 24: ...cle inspected by an authorized dealer Brake fluid level Check the brake fluid level by observing the lower limit line on the brake fluid reservoir When the brake fluid level is below the lower edge of...

Page 25: ...lways replenish the system with the premixed coolant or with 50 antifreeze and 50 water Do not use tap water straight antifreeze or straight water in the system Tap water contains minerals and impurit...

Page 26: ...cap Partially unscrew coolant drain plug located below water pump housing When coolant is drained completely remove cooling drain plug completely and install a new gasket ring Screw the coolant drain...

Page 27: ...ne When engine has completely cooled down recheck coolant level in radiator and coolant tank Top up if necessary WHEELS Lift wheels up at horizontal position and ensure no load to each wheel Shake whe...

Page 28: ...rd cylinder pressure 0 9 1 2Mpa Too low cylinder pressure may cause the following Excessive wear to cylinder Wear to piston or piston ring Blockage of piston ring in groove Close valve seat Damage to...

Page 29: ...ing values Remove oil pressure gauge and adapter hose Installation oil pressure switch to 12 N m and the oil pressure switch wire connector Install engine shield gear shift handle globe and left and r...

Page 30: ......

Page 31: ...e the vehicle on level surface when diagnosing an engine problem NOTE For a better understanding the many illustrations are taken with engine out of vehicle To perform the following instructions it is...

Page 32: ...MOVAL To avoid potential burns let engine and exhaust system cool down before performing any servicing Place vehicle on a work station that will have access to an engine lifting hoist Then start with...

Page 33: ...ipe Unscrew the front exhaust pipe nuts Unplug the connector of oxygen sensor Move the front exhaust pipe forward then remove it Unscrew the Y exhaust pipe nuts from rear cylinder Unplug the connector...

Page 34: ...nector B Remove the spark plug cables Remove the ignition coil connector A of rear cylinder Remove the ignition coil connector B of front cylinder Unplug the trigger coil connector C Unplug the magnet...

Page 35: ...e the gear shifting indication wire Remove the adiabatic plate of starter motor and the power supply cable K Unscrew the bolt and clamp remove the CVT inlet and outlet pipes Unscrew bolt to remove the...

Page 36: ...ensor connector M Remove the throttle cable N Unscrew the lock nuts to remove the parking brake cable Unscrew the mounting bolts to remove the parking brake bracket Remove the outlet engine coolant ho...

Page 37: ...ar engine mounting bolt Remove the mounting plate of right seat Remove the mounting plate of left seat Remove the front engine mounting bolt Lift the engine to clear mounting brackets Turn engine 90 f...

Page 38: ...3 ENGINE 3 8 LUBRICATION SYSTEM COMPONENTS...

Page 39: ...NE LUBRICATION CIRCUIT 1 Camshaft bearings 2 Oil pressure switch 3 Oil filter 4 Oil pressure regulator valve 5 Oil strainer 6 Oil pump 7 Crankshaft main bearings 8 Crankshaft support bearing 9 Connect...

Page 40: ...r high oil consumption refer to HIGH OIL CONSUMPTION in the TROUBLESHOOT ING subsection Check for engine oil leaks For leak indicator hole refer to COOLING SYSYTEM INSPECTION in the PERIODIC MINTENANC...

Page 41: ...ooler Removal Refer to the PERIODIC MAINTENCE PROCEDURES subsection to Drain engine oil Drain engine coolant Remove oil cooler retaining screws 1 Retaining screws 2 Oil cooler Place rags or towels und...

Page 42: ...e oil pressure switch Use a multimeter to check the resistance between as shown OPS CONNECTO R ENGINE NOT RUNNING ENGINE RUNNING PIN RESISTANCE 4 Engine ground Close to 0 normally reaches Infinite ope...

Page 43: ...free length SPRING FREE LENGTH NEW NOMINAL 39mm 1535in SERVICE LIMIT 37 mm 1457in NOTE Replace worn or damaged components Clean bore and thread in the magneto housing from metal shavings and other con...

Page 44: ...ks scratches or other damages Check for scratches in crankcase between outer rotor and oil pump bore If so replace damaged parts Check oil pump cover for damages and for surface straightness with a st...

Page 45: ...ance of the oil pump as shown OIL PUMP MEASUREMENT A OIL PUMP COVER MEASUREMENT B Subtract measurement B from measurement A to obtain axial clearance OIL PUMP AXIAL CLEARANCE SERVICE LIMIT 0 2 mm 0079...

Page 46: ...and injure your eyes Check engine oil strainer for cracks or other damage Replace if damaged Oil Strainer Installation The installation is the reverse of the removal procedure OIL STRAINER RETAINING...

Page 47: ...3 ENGINE 3 17 MAGNETO SYSTEM...

Page 48: ...Inspection and Cleaning Check magneto cover for cracks or other damage Replace if necessary NOTE Clean all metal components in a nonferrous metal cleaner Use LOCTITE CHISEL GAS KET REMOVER P N413 708...

Page 49: ...ier 2 Check resistance between YELLOW wires REQUIED TOOL FLUKE115 MULTIMETER TERMINAL RESISTANCE 20 C 68 F 1 and2 0 15 0 30 1 and3 2 and3 TYPICAL 3 If any reading is out of specification replace stato...

Page 50: ...plug connectors properly Stator Removal Remove MAGENTO COVER See procedure in this subsection Remove screws securing the wire holding strip Remove stator retaining screws then the stator 1 Holding str...

Page 51: ...Remove screw and washer securing rotor to crankshaft Remove rotor REQUIRED TOOL MAGNET0 PULLER CRANKSHAFT PROTECTOR NOTE Use grease to place protector on crank shaft end prior to screw on the magneto...

Page 52: ...nkshaft The woodruff key and the keyway must be aligned Rotate starter double gear counterclockwise to align intermediate gear teeth with sprag clutch gear 1 Starter double gear 2 Sprag clutch gear 3...

Page 53: ...on For installation reverse the removal procedure Pay attention to the following details Apply LOCTITE648 GREEN P N413 711 400 on threads of sprag clutch housing screws Install screws but do not torqu...

Page 54: ...arter drive gears are located on the engine MAG side behind the magneto cover Starter Drive Gear Removal Remove MAGENTO COVER See procedure in this subsection Remove location pins starter double gear...

Page 55: ...sure 4 Disconnect fuel injectors electrical connectors 5 Remove plenum adapter elbow 6 Remove intake manifold from engine SOME PARTS REMOVED FOR CLARITY 1 Intake manifold 2 Remove retaining screws x4...

Page 56: ...VALVE COVER in this subsection Refer to TIMING CHAIN subsection and remove the following parts Timing chain tensioner Camshaft timing gear Remove the camshaft retaining plate 1 Camshaft retaining plat...

Page 57: ...r signs of wear Measure camshaft journal using a micrometer A Camshaft lobe exhaust valves B Camshaft lobe intake valves C Camshaft journal timing chain side D Camshaft journal spark plug side CAMSHAF...

Page 58: ...E PRODURES subsection NOTE Before removing cylinder head blow out remaining coolant by air pressure During cylinder head removal the remaining coolant in cylinder head could overflow into the engine a...

Page 59: ...iming chain side 3 Oil supply to camshaft bearing journal spark plug side Cylinder Head Camshaft Bearing Inspection Measure camshaft bearing in cylinder head A Cam shaft bearing timing chain side B Ca...

Page 60: ...HEAD SCREW IDENTIFICATION engine Location no 1 M10 159 Location no 2 M6 105 Tighten M10 cylinder head screws FIRST as per following specifications TIGHTENCE SEQUENCE M10 CYLINDER HEAD SCREWS M10 CYLIN...

Page 61: ...l when unlocking valves Components could fly away because of the strong spring preload LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE Remove valve cotters 1 Valve spring compressor clamp...

Page 62: ...be properly engaged in valve stem grooves 1 Position of the valve spring 2 Valve cotter After spring is installed ensure it is properly locked by tapping on valve stem end with a soft hammer so that v...

Page 63: ...INTAKE VALVE NEW 4 966mm to4 980 mm 1955in to 1961 in SERVICE LIMIT 4 930mm 1941 in Valve Face and Seat 1 Valve seat 2 Exhaust valve contaminated area 3 Valve face contact surface to valve seat Check...

Page 64: ...a few times NOTICE An improperly locked valve spring wi1l cause engine damage VALVE GUIDES Valve Guide Inspection Always replace valve stem seals whenever valve guides are removed Measure valve guide...

Page 65: ...in Apply some lapping compound to valve face and work valve on its seat with a lapping tool 1 Valve seat 2 Valve face contact surface to valve seat 3 Turn valve while pushing against cylinder head A V...

Page 66: ...and compare NOTE Take the same measuring points like described in CYLINDER TAPER above A Perpendicular to crankshaft axis B Parallel to crankshaft axis CYLINDER OUT 0F ROUND NEW MAXIMUM 0 015mm 0006in...

Page 67: ...fer to following procedures in this subsection to remove Cylinder head Cylinder Place a rag under piston and in the area of timing chain compartment WARNING Piston circlips are spring loaded Remove on...

Page 68: ...1 Use the micrometer to set the cylinder bore gauge 2 Dial bore gauge TYPICAL 1 Indicator set to 0 zero Position the dial bore gauge20 mm 787 in above cylinder base measuring perpendicularly 90 to pis...

Page 69: ...20 020 mm 7878in to 7882in SERVICE LIMIT 20 050 mm 7894in Replace connecting rod if diameter of connecting rod sma1l end is out of specifications Refer to BOTTOM END subsection for removal procedure C...

Page 70: ...e of cylinder 2 Use the piston appropriate circlip installer to assemble the NEW piston circlip as per following procedure NOTICE Always replace disassembled piston circlip s by NEW ones Place a rag o...

Page 71: ...OWER COMPRESSION RING NEW 0 20 mm to 0 40mm 008in to 016in SERVICE LIMIT 0 70 mm 028 in OIL SCRAPER RING NEW 0 20 mm to 0 70mm 008in to 028in SERVICE LIMIT 1 00 mm 039in To measure the ring end gap pl...

Page 72: ...second rings are not interchanged Check that rings rotate smoothly after installation Space the piston ring end gaps120 apart and do not align the gaps with the piston pin bore or the thrust side axis...

Page 73: ...camshaft timing gear refer to CYLINDER AND HEAD magneto cover and rotor refer to MAGNETO SYSTEM timing chain guide and lower timing chain guide 1 Timing chain 2 Timing chain guide 3 Lower timing chain...

Page 74: ...hain condition for wear and teeth condition If chain is excessively worn or damaged replace it as a set camshaft timing gear and timing chain Timing chain installation Installation is the same for bot...

Page 75: ...3 ENGINE 3 47 ENGINE DRIVE SHAFT CRANKCASE AND PTO COVER...

Page 76: ...3 ENGINE 3 48 CRANKSHAFT...

Page 77: ...3 ENGINE 3 49...

Page 78: ...aring cover and its O ring 1 Bearing cover screws 2 O ring 3 Bearing cover gearbox side Front Bearing Cover Removal Remove the bearing cover at the front of the engine NOTICE Check ends of the circlip...

Page 79: ...nd the first torquing should be done within10 minutes it is suggested to have all you need on hand to save time Use a plexiglass plate and apply some sealant on it Use a soft rubber roller50mm 75mm 2i...

Page 80: ...sleeve between propeller shaft and front engine drive shaft 3 Remove the front bearing cover refer to ENGINE DRIVE SHAFT REMOVAL INSTALLATION in this subsection 4 Remove drive shaft seal from bearing...

Page 81: ...PTO COVER OIL SEAL To replace oil seal it is not necessary to remove engine from vehicle PTO Oil Seal Removal Refer to CONTINUOUSLY VARLABLE TRAINSMISSION CVT subsection to remove the following parts...

Page 82: ...rive pulley Driven pulley CVT air guide Disconnect vent hose Remove PTO cover screws and pull PTO cover 1 PTO cover 2 PTO cover screws 3 Vent hose nipple PTO Cover Inspection Check the PTO cover for c...

Page 83: ...LAIN BEARING TOOL PLAIN BEARING REMOVER UNSTALLER The PTO cover has to be supported from below with suitable support with straight surface in order to prevent damage of the sealing surface 1 PTO cover...

Page 84: ...R SCREW Tightening sequence 10N m 1 N m 89lbf in 9lbf in DRIVEGEARS Drive Gears Location The engine is equipped with a breather gear which prevents engine oil coming out through the breathing system i...

Page 85: ...e breather gear assembly if necessary Drive Gears Installation The installation is essentially the reverse of the removal procedure Adequately oil the ball bearing of the breather gear CRANK CASE Cran...

Page 86: ...mp housing 11 Refer to LUBRICATION SYSTEM subsection to remove following parts Oil filter Oil cooler Oil pump drive gear NOTE Oil pump removal from crankcase is not necessary but recommended to see co...

Page 87: ...iameter and compare to PTO MAG main journa1 diameters of crankshaft refer to CRANKSHAFT Replace if the measurements are out of specification 1 Plain Bearing 2 Oil bore A Measure plain bearing inside d...

Page 88: ...d plain bearings in place during installation The O ring will disappear in the groove of the plain bearing remover installer Mark position of plain bearing oil bore on plain bearing remover installer...

Page 89: ...MP GEARS in the COOLING SYSTEM subsection Tightening sequence for screws on crankcase is as per following illustration TIGHTENCE SEQUENCE CRANKCASE SCREWS Tightening torque M6 10N m 1N m 89lbf in 9lbf...

Page 90: ...piston no 2 is at TDC 1 Allen key14 mm When rear piston is at TDC marks on magneto flywheel 2 and on the magneto cover are aligned 1 Mark 2 on magneto flywheel 2 Notch on magneto cover 3 Crankshaft po...

Page 91: ...02in SERVICE LIMIT 0 600 mm 024in If play is out of specification replace crankcase and or crankshaft Connecting Rod Big End Axial Play Using a feeler gauge measure distance between butting face of c...

Page 92: ...nitia11y Carry out the tightening procedure described in CRANKSHAFT ASSEMBLY in this subsection A Connecting rod big end plain bearing CONNECTING ROD BIG END RADIAL ENGINES SERVICE LIMIT 42 100mm 1 65...

Page 93: ...n 1 Micrometer 2 Crankshaft journal PTO support bearing CRANKSHAFT JOURNAL DIAMETER PTO COVER BEARING NEW 34 004mm to34 020 mm 1 3387ln to1 3394in SERVICE LIMIT 33 998 mm 1 3385in CRANKSHAFT RADIAL PL...

Page 94: ...re not reusable Thread screws in the connecting rods then tighten as per fo11owing procedure NOTICE Strictly adhere following instructions Do not apply any thread locker The running direction of the b...

Page 95: ...rankshaft Installation For installation of crankshaft in crankcase reverse the removal procedure Pay attention to the fol_ lowing details Do not mix up the connecting rods of cylinders1 and2 during in...

Page 96: ...ese pulleys have metric threads Do not SAE threads puller Always tighten puller by hand to ensure that the drive pulley has the same type of threads prior to fully tightening DRIVE BELT Removal Remove...

Page 97: ...lley rear 4 Rotation direction The maximum drive belt life span is obtained when the drive belt has the proper rotation direction Install it so that the arrow printed on belt is pointing towards front...

Page 98: ...ne way clutch bearing for excessive play and smooth operation Replace one way clutch if necessary Installation For installation reverse the removal procedure Pay attention to the following details Do...

Page 99: ...e driven pulley is blocked unscrew the driven pulley screw 1 Driven pulley 2 Thrust washer 3 Driven pulley screw Inspection Driven pulley should be inspected annually for wear or damages Check sliding...

Page 100: ...Always place washer at the time of driven pulley installation When the driven pulley is blocked torque screw to 60N m CVT AIR GUIDE Removal Remove CVT cover Drive belt Drive pulley Driven pulley Unscr...

Page 101: ...3 ENGINE 3 73 GEARBOX...

Page 102: ...R see procedure in this subsection Unscrew the four 4 nuts that attach the gearbox to the engine LH SIDE OF ENGINE 1 Nut M8 RH SIDE OF ENGINE 1 Nut M8 Pull gearbox to separate it from engine Gearbox D...

Page 103: ...sher Insert a flat screwdriver in the slot of index lever Turn screwdriver clockwise and remove index washer 1 Index lever 2 Index washer 3 Shaft drum Remove the index lever with washer step ring and...

Page 104: ...ift drum 1 Shaft fork shaft 2 Shaft fork 3 Shaft drum Remove main shaft assembly with shift fork 1 Main shaft assembly 2 Shift fork Remove shifting sleeve HIGH range gear and shift fork 1 Shifting sle...

Page 105: ...1 Snap ring 2 Shifting sleeve LOW REVERSE range gear 3 Snap ring 4 Free pinion REVERSE range gear 5 Needle bearing 6 Main shaft assembly Gearbox Right Cover Remove ACTUATOR and GBPS GEARBOX POSITION S...

Page 106: ...3 Intermediate gear 4 Dowel pin Remove shift fork shaft Disengage shift forks from shift drum 1 Shift fork shaft 2 Shift fork 3 Shift drum Remove shift drum and thrust washer 1 Shift drum 2 Thrust wa...

Page 107: ...ox Bearings If necessary heat housing up to100 C 212 F before removing ball bearings NOTICE Always support gearbox housings properly when ball bearings are removed Housing damages may occur if this pr...

Page 108: ...rbox components Gear teeth damage Worn or scoured bearing surfaces Rounded engagement dogs and slots Worn shift fork engagement groove Worn splines on shafts and shifting sleeves Bearings Check if bal...

Page 109: ...IDTH 0F SHIFT FORK ENGAGEMENT GROOVE NEW 5 30 mm to5 40 mm 209in to 213in SERVICE LIMIT 5 50mm 217in Shafts Check bearing pin of reverse intermediate gear for wear 1 Bearing pin A Outer diameter Check...

Page 110: ...reverse range gear shift fork 2 Track for the high range gear shift fork 3 Springs Shift Forks Check both shift forks for visible damage wear or bent shift fork claws Check engagement rollers for wear...

Page 111: ...lines for wear or other damages Check if the output shaft bearings turn freely and smoothly Replace oil seal if brittle hard or damaged 4 4 Coupling Sleeve Check splines of coupling sleeve for wear or...

Page 112: ...ten the bolts to the specified torque Installation location Specifications mm Torque N m kgf m Mounting nut of engine M10 70 7 1 Nut of exhaust pipe M8 30 3 1 Bolt of front propeller shaft flange M8 4...

Page 113: ...oil of fins is blocked or damaged Correct curved fins Use water and compressed air to clean soil If damaged area reaches 20 please replace radiator 3 Pump overhauling can be carried out before dismant...

Page 114: ...k indicator hole if there is oil or coolant NOTE Flowing coolant indicates a defective rotary seal Oil indicates a defective inner oil seal If either seal is leaking both seals must be replaced at sam...

Page 115: ...gasket Thermostat installation For installation reverse the removal procedure pay attention to the following details Install the thermostat cover then torque screws to 10N m Check coolant level in ra...

Page 116: ...ove the radiator water inlet hose A and top mounting bolt on the right side Remove the connector of temperature controller on the radiator and the radiator water outlet hose B Remove the fill hose C a...

Page 117: ...l Fill up the radiator Check for any coolant leakage from radiator and hoses COOLANT TANK The coolant expands as the temperature up to 100 110 and pressure rise in the system If the limiting system wo...

Page 118: ...ing system Remove radiator outlet hose from water pump housing Remove screws retaining water pump housing 1 Screws 2 Water pump housing 3 Sealing ring Pull water pump housing to remove it Water pump h...

Page 119: ...te of the removal procedure Be careful not damage impeller wings during installation WATER PUMP SHAFT AND SEALS Shaft Seal removal NOTE It is not required to split crankcase to replace the water pump...

Page 120: ...lling in crankcase 1 Thrust water here CAUTION If thrust washer is not on water pump shaft use a magnet to retrieve it inside crankcase Using appropriate pliers remove and discard the retaining ring s...

Page 121: ...e Inspection Inspect water pump gear for wear and damage on the snap mechanism to the needle pin Replace if damaged Shaft Seal installation For installation reverse the removal procedure However pay a...

Page 122: ...andle with oil seal pusher Slide water pump shaft with the new rotary seal into crankcase To properly install water pump shaft with rotary seal use the rotary seal installer Use a plastic hammer and d...

Page 123: ...pump shaft with rotary seal must rotate freely Carefully push in water pump gear while turning to mesh with the inner drive gear 1 Water pump gear 2 Inner drive gear Tighten Screws of the water pump h...

Page 124: ...ture Resistance 50 216 264 60 148 180 80 74 6 90 6 90 53 5 66 5 100 40 6 48 6 In case of exceeding effective range of sensor please replace it Sensor installation Screw sensor with 16N m Fill in cooli...

Page 125: ...t allow fuel to spill on hot engine parts and or electrical connectors Never use a hose pincher on injection system high pressure hoses Replace any damage or deteriorated fuel lines When the repair is...

Page 126: ...sure regulator Check fuel injector and the fuel pressure regulator for leaks If it is not leaking then replace fuel pump module If no leakage start engine and observe fuel pressure The fuel pressure s...

Page 127: ...ntion to the following Install a new gasket Pay attention to pump orientation Tighten retaining screws as per illustrated sequence Install hose properly on OUT nipples and harness FUEL SENSOR The leve...

Page 128: ...lation Install fuel sensor to fuel tank Connect connector and hose Turn on fuel supply switch and check whether functions of fuel meter is normal or not Fuel leakage is not allowed FUEL TANK Fuel tank...

Page 129: ...here are no leaks Fuel pump installation For installation reverse the removal process but pay attention to the following Install a new gasket Pay attention to pump orientation Tighten retaining screws...

Page 130: ......

Page 131: ...ont wheel nut Raise the front of vehicle support it securely on jack stands Remove the right front wheel and the ball joint of tie rod from the steering knuckle Remove propeller shaft bolts on front d...

Page 132: ...n Specifications mm Torque N m kgf m Bolt of front propeller shaft flange M8 40 4 1 Bolt of front propeller shaft flange M10 80 8 2 FRONT WHEEL HUB Removal Raise the front of vehicle support it secure...

Page 133: ...with a cotter pin hole Install a new cotter pin and the wheel cap Fold one pin of cotter pin over drive shaft end FRONT DRIVE SHAFT Removal Remove the appropriate wheel hub Remove the guard plate of b...

Page 134: ...aft in differential and pull joint a little to make sure that the stop ring is locked in differential side gear groove Insert the other end of drive shaft in the knuckle and install the knuckle to the...

Page 135: ...eck that the joint of rubber case fits tightly Installation The installation is the reverse of the removal procedure Pay attention to refill the oil GL 4 90 Ensure tighten the bolts to the specified t...

Page 136: ...Check wheel hub for cracks or other damages Check inner splines and wheel rim bolts for wear or other damages If any damage is detected on wheel hub replace it with a new one Installation The installa...

Page 137: ...e splines on plunging joint are worn a check of differential inner splines should be done Check the ring at the end of drive shaft If wear is apparent replace the wear ring Check if the bearing in knu...

Page 138: ...rear differential side Remove the rear propeller shaft Inspection Inspect the propeller shaft for wear or damage If any defects are found replace the propeller shaft with new one Check if U joint move...

Page 139: ...rain oil completely by removing the drain plug Raise rear of vehicle support it securely on jack stands and remove rear wheels On both sides remove the drive shafts Remove propeller shaft bolts on rea...

Page 140: ...80 8 2 TIRES AND WHEELS When the tires are replaced never install a bias tire with a redial tire such a combination could create handling and or stability problems Dot mix tires of different size and...

Page 141: ...roperly seated If this is so deflate the tire completely and unseat the tire bead on bosh sides Then coat the bead with clean water and re seat the tire Adjust the tire pressure to specification The s...

Page 142: ......

Page 143: ...X 7 3 STEERING ALIGNMENT 7 4 STEERING WHEEL Inspect the steering wheel for distortion or damage If any damage is found replace the steering wheel with a new one Removal Remove the small cover of steer...

Page 144: ...rod for smooth movement If there are any abnormalities replace the steering rod with a new one Removal Remove the steering wheel Remove the mounting bolt A of the air spring Unscrew the fixing bolt B...

Page 145: ...ith a new one Removal Remove the steering wheel and rod Remove the upper cover of engine hood and the cover of battery box Disconnect connectors of the relay and battery Remove the battery Remove the...

Page 146: ...ecification set the front wheels in the straight position then place a load of 75kg on the seat Measure the distance A and B of the front wheels and calculate the difference Toe in B A 5mm A front of...

Page 147: ...spensions simultaneously Before overhauling front suspension system please ensure stable support of vehicle REMOVALAND DISASSEMBLY Loosen wheel nut of the appropriate Install a jack stand under the fr...

Page 148: ...eme end of either stroke A gurgling noise after completing one full compression and extension stroke Replace shock if any these conditions are found Knuckle Inspect the knuckle for damage If any damag...

Page 149: ...sion arm from side to side There should be no noticeable loose Replace bushing if necessary Move suspension arm up and down There should be no noticeable loose Replace bushing if necessary Check ball...

Page 150: ...d hub remove steering knuckle from ball cage tie rod INSPECTION Shock absorber Inspect the shock absorber for oil leakage or damage inspect the bushing for wear or damage If any damage are found repla...

Page 151: ...arm from side to side There should be no noticeable loose Replace bushing if necessary Move suspension arm up and down There should be no noticeable loose Replace bushing if necessary Upper Suspensio...

Page 152: ...8 SUSPENSION SYSTEM 8 6...

Page 153: ...container completely and keep it away from children When replenishing brake fluid take care not to get dust into fluid When washing brake components use new brake fluid Never use cleaning solvent A c...

Page 154: ...pedal fully squeezed Loosen the air bleeder valve for about quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake pedal Then close the bleeder va...

Page 155: ...brake disc 3 5mm Minimum thickness of rear brake disc 3 0mm Measure the warpage using the dial gauge If the warpage exceeds the service limit replace the brake disc with a new one Maximum warpage of b...

Page 156: ...inder and piston with clean brake fluid Clean slide pins with brake cleaner and a rag Inspection If boots are deteriorated or hard replace with new ones Check caliper cylinder for scratches rust or ot...

Page 157: ...eck if the hoses are crushed or damaged Any deformation can restrict the proper flow of fluid and cause braking problems Check hoses for cracking scrapes This damage can cause hose failure under press...

Page 158: ...ove left and right seats gear shift handle Remove engine shield Detach parking brake cable from pulley as follows Ensure parking brake is released Unscrew nut securing parking brake cable on parking b...

Page 159: ...ng brake cable Pull the parking brake lever up to engage the parking brake To release the unit press button on front end of parking lever then push the parking lever to the bottom The free play is 15...

Page 160: ......

Page 161: ...or wearing dirty gloves As a result hot spots and glass deformation may be caused with damage to bulb as well Pay attention to the following in replacing bulb Do not replace bulb when it is on Turn o...

Page 162: ...rator core whether it is insulated Install multimeter 1 10 Resistance of generator coil 0 9 1 5 color yellow Insulation resistance yellow grounding wire No load performance of the generator Z Start th...

Page 163: ...timeter Z If the resistance is not within the range of specified values replace the regulator rectifier NOTE If the probe is not connected and the multimeter reading is lower than 1 4V replace the mul...

Page 164: ...10 ELECTRICAL SYSTEM 10 4 STARTING SYSTEM Starter motor Brush Z Check the brush on the brush holder whether it is worn abnormal cracked or not smooth Worn cracked or not smooth Replace...

Page 165: ...Armature coil Z Test the connection between each wire and the armature coil with the multimeter Z If they are not connected replace the armature shaft Oil seal Z Check the oil seal lip for damage or l...

Page 166: ...starter relay The multimeter is set to 1x10 Starter relay coil resistance 3 5 Auxiliary starter relay Z Apply 12V voltage between the positive and negative terminals of the starter relay Test the conn...

Page 167: ...wire NOTE Z Make sure the battery voltage 12V The ignition coil wires are connected Z When using multimeter and the peak voltage adapter please refer to the user manual Z Move the gear to the neutral...

Page 168: ...coil is in good condition Resistance of ignition coil Primary winding 0 1 1 5 terminal ground Secondary coil 12 22K terminal spark plug cap Peak voltage of coupling coil Z Check the peak voltage of t...

Page 169: ...4V Z If the voltage is lower than the standard value replace coupling coil Resistance of coupling coil The multimeter is put at 1x100 step Resistance of coupling coil 120 130 Z If the resistance is n...

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Page 171: ...starter drive Symptom STARTER TURNS BUT STARTER DRIVE DOES NOT MESH WITH RING GEAR 1 Refer to starting system Symptom STARTER KEEPS RUNNING 1 Refer to starting system COOLING SYSTEM Symptom HIGH ENGIN...

Page 172: ...per ring 11 Check intermediate gear s behind of PTO cover Worn out and or broken gear s is are causing less coolant supply Replace worn out and or broken gear s refer to bottom end 12 Check if water p...

Page 173: ...inder and head Piston rings are broken low compression Replace piston rings refer to cylinder and head Valve stem seal damaged and or sealing lip is hard and or brittle Replace all valve stem seals 2...

Page 174: ...oil leaks Leakage of oil water mixture from indicator bore means damaged water pump seal ring and rotary seal Replace sealing ring rotary seal and change oil oil filter and or coolant refer to lubric...

Page 175: ...ew with recommended torque refer to MAGNETO SYSTEM GEARBOX Symptom UNUSUAL GEARBOX NOISE AND OR VIBRATION 1 Check oil level in gearbox Oil leakage from gearbox Replace damaged gasket s and or oil seal...

Page 176: ...rt s refer to CONTINUOUSLY VARBRIABLE TRANSMISSION CVT Check if friction washer at one way clutch is worn Replace friction washer refer to CONTINUOUSLY VARBRIABLE TRANSMISSION CVT 4 Check transmission...

Page 177: ...3 Check drive driven pulley sliding sheave for free axial movement Sliding sheave is stuck Replace damaged part s 4 Check condition of drive driven pulley spring Drive pulley spring tension is too sm...

Page 178: ...earing s do es not move freely Replace damaged part s and lubricate inside of one way clutch Spring sleeve s inside one way clutch is are worn out Replace both sleeves and springs and lubricate inside...

Page 179: ...pulley One way clutch does not operate properly Clean system and or replace damaged part s 2 Check driven pulley spring tension Driven pulley spring tension is too weak or broken Replace Driven pulle...

Page 180: ...wrong spark plug gap Readjust gap and clean spark plugs or replace 3 Check for fuel on spark plugs Flooded engine spark plugs wet when removed Activate engine drowned mode and crank engine with rags...

Page 181: ...ve part s refer to LEAK TEST 5 Verify spark plug condition Defective improperly set worn out fouled Identify source of problem and correct Replace 6 Check fuel level in fuel tank and fuel pressure Low...

Page 182: ...d cylinder surface for grooves Poor oil quality Use recommended oil Contamination through engine intake Replace defective part s and use new air filter 8 Check crankshaft rocker arms movement Oil pump...

Page 183: ...compression Worn piston s and or piston ring s Replace defective part s 6 Check fuel pressure Low fuel pressure Perform fuel pressure test refer to FUEL SYSTEM 7 Check air intake system Air filter is...

Page 184: ...Coolant temperature sensor is existing short circuit to ground P0118 Coolant temperature sensor is existing short circuit to power supply or disconnecting P0122 Throttle position sensor is existing sh...

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