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CHAPTER 3 ENGINE

BUCK 450 SERVICE MANUAL 20.0

3.12

Fuel Injection System

3.12.1  ECU
3.12.1.1 Description & Working Principle
3.12.1.2 Appearance
3.12.1.3 Handling – Don’ts & Do’s
3.12.1.4 Installation requirements
3.12.1.5 Power Requirements
3.12.1.6 Temperature Requirements
3.12.1.7 Maintenance service and Repair

3.12.2    Injector
3.12.2.1 Appearance
3.12.2.2 Temperature Requirements
3.12.2.3 Fuel Contamination
3.12.2.4 Injector Installation
3.12.2.5 Replacement Techniques
3.12.2.6 Interchange ability

3.12.3    Throttle  Body Assembly
3.12.3.1 Description and Working Principle
3.12.3.2Throttle Body Removal
3.12.3.3 Cleaning Procedure
3.12.3.4 Throttle Body Installation

3.12.4  Engine Coolant Temperature Sensor
3.12.4.1 Description and Working Principle
3.12.4.2Installation Requirements

3.12.5 Oxygen Sensor
3.12.5.1 Description and Working Principle
3.12.5.2 Technical Parameters
3.12.5.3 Fuel Quality Requirements

3.12.6  Ignition Coil
3.12.6.1 Description and Working Principle
3.12.6.2 Installation requirements
3.12.6.3 DOs a nd DONTs

3.12.7    Fuel Pump
3.12.7.1 Description and Working Principle
3.12.7.2 Operating Conditions
3.12.7.3 Service Procedure
3.12.7.4 Fuel Pump Removal
3.12.7.5Fuel Pump Installation
3.12.7.6Fuel Pressure Relief Procedure

CHAPTER 3 ENGINE PAGE. 3- 64

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Summary of Contents for ARCHON 400

Page 1: ...SERVICE MANUAL ARCHON 400...

Page 2: ...ig nificant changes in specifications or procedures will be forwarded to all authorized Linhai dealers and will appear in future editions of this manual where applicable NOTE Designs and specification...

Page 3: ...CONTENTS CHAPTER1 General Information CHAPTER2 Maintenance CHAPTER3 Engine CHAPTER4 Chassis CHAPTER5 Final Drive CHAPTER6 Transmission CHAPTER7 Brakes CHAPTER8 Electrical...

Page 4: ...ains sulfuric acid Serious burns can result from contact with skin eyes or clothing Always keep alert and wear protection Exhaust system components are very hot during and after use of UTV Never servi...

Page 5: ...GENERAL INFORMATION The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each UTV model for spare parts i...

Page 6: ...cements Use recommended oil and grease for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality GASKETS OIL SEALS AND O RINGS 1 Replace all gaskets seals...

Page 7: ...lick together 7 Check for continuity with a tester NOTE If there is no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness Use the tester on...

Page 8: ...CONVERSION TABLE METRIC TO IMP Known Multiplier Result Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb In lb ft lb In lb Weight kg g 2 205 0 03527 lb oz Distance km h km m m cm mm 0 621...

Page 9: ...ICE MANUAL 20 0 CHAPTER 1 GENERAL INFORMATION PAGE 1 5 1 2 V I N AND ENGINE SERIAL NUMBER The vehicle identification number 1 is stamped into the front of the frame tube The engine serial number 1 is...

Page 10: ...CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 1 GENERAL INFORMATION PAGE 1 6 1 3 VEHICLE DIMENSIONS...

Page 11: ...CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 1 GENERAL INFORMATION PAGE 1 7 NOTES...

Page 12: ...ve almost same appearance Always refer to Parts Manual of each UTV model for spare parts information and service 2 1 PERIODIC MAINTENANCE 2 2 THROTTLE PEDAL INSPECTION 2 3 FUEL SYSTEM 2 4 TOE ALIGNMEN...

Page 13: ...ed Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust or replace parts as necessary NOTE Inspectio...

Page 14: ...se Oil 100 hrs Monthly Check monthly and change annually Front Gear case Oil 100 hrs Monthly Check monthly and change annually Engine Cylinder Head and Cylinder Base Fasteners 25 hrs 3 months Inspect...

Page 15: ...sion 50 hrs 6 months Inspect lubricate tighten fasteners Rear Suspension 50 hrs 6 months Inspect tighten fasteners Spark Plug 100 hrs 12 months Inspect replace if necessary D Ignition Timing 100 hrs 1...

Page 16: ...k Check level daily 2 Brake Fluid DOT 3 Only Add to proper level above the minimum level mark and replenish if necessary As require change every two years or 200 hours 3 Transmission Oil SAE GL 4 85W...

Page 17: ...te fitting and Grease Semi annually 12 Front Rear A arm pivot Shaft Grease Locate fitting on pivot shaft and grease with grease gun Every 3 months or 50 hours 13 Throttle Cable Grease M Grease inspect...

Page 18: ...ith the Periodic Maintenance Chart and adjust the play if necessary THROTTLE FREEPLAY INSPECTION 1 Apply the parking brake 2 Put the gear shift lever in the N Neutral position 3 Start the engine and w...

Page 19: ...it run in an enclosed area Fuel powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Never drain the float bowl when the engine is hot Severe burns...

Page 20: ...ends must screw in same and enough threads length 2 5 BRAKING SYSTEM INSPECTION The following checks are recommended to keep the braking system in good operating condition Service life of braking syst...

Page 21: ...ked for proper operation The mechanical brake must be maintained to be full functional 1 With the engine off apply the parking brake lever and attempt to move the UTV 2 If the rear wheels are locked i...

Page 22: ...Always do the procedure 1 to 8 when necessary 2 6 SUSPENSION SPRING RPELOAD ADJUSTMENT Operator weight and vehicle loading affect suspen sion spring preload requirements Adjust if necessary FRONT SUSP...

Page 23: ...e the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION 1 With the transmission in gear and the parking Brake loc...

Page 24: ...cause machine damage especially in 4X4 model TIRE TREAD DEPTH Always replace tires when tread depth is worn to 1 8 3mm or less Operating an UTV with worn tires will increase the possibility of the veh...

Page 25: ...CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20 0 NOTES CHAPTER 2 MAINTENANCE PAGE 2 14...

Page 26: ...3 COMPRESSION PRESSURE 3 2 4 ENGINE OIL LEVEL INSPECTION 3 2 5 COOLANT LEVEL INSPECTION 3 3 CYLINDER HEAD 3 4 CAMSHAFT AND ROCKER ARMS 3 5 VALVES AND VALVE SPRINGS 3 6 CYLINDER AND PISTON 3 7 V BELT C...

Page 27: ...SC A 0404ASDH 108 Rocker arm rocker armshaft Rocker arm inside diameter Rocker shaft outside diameter Rocker arm to rocker arm shaft clearance 12 000 12 018 mm 11 981 11 991 mm 0 009 0 012 mm 12 03 m...

Page 28: ...22 42 83 kg 36 1 mm 35 0 mm 2 5 1 7mm 2 5 1 7mm Piston Piston to cylinder clearance Piston size D Measuring point H Piston pin bore inside diameter 0 02 0 049mm 79 965 79 980 mm 5mm 18 004 18 015 mm 1...

Page 29: ...6 mm 21 0 mm Oil pump Type Tip clearance Side clearance Housing and rotor clearance Trochoid type 0 1 0 34 mm 0 013 0 036 mm 0 04 0 09 mm 0 4 mm 0 15 mm 0 15 mm Item Standard Limit Radiator Type Widt...

Page 30: ...alve cover Filer neck supporting Oil pump Oil pump cover Drain plug Exhaust pipe assembly Crankcase left and right Drain bolt Oil filer Crankcase cover left Magnet cover _ _ Bolt Nut Bolt Bolt Nut Nut...

Page 31: ...1 2 Timing check plug Plug M16 1 8 0 8 One way clutch _ M 8 3 30 3 0 Clutch housing Bolt M14 1 60 6 0 Grease stopper Primary sheave _ M 4 4 3 0 3 Primary fixed sheave _ M14 1 60 6 0 Clutch carrier as...

Page 32: ...cification Adjust Valve clearance cold Intake valve 0 08 0 12m m Exhaust valve 0 13 0 16mm Measurement steps Rotate the primary fixed sheave counterclockwise to align the slit aE A on the rotor with t...

Page 33: ...rew Crankcase cover 3 2 2 SPARK PLUG INSPECTION 1 Remove Spark plug cap Spark plug CAUTION Before removing the spark plug use compressed air to blow away any dirt accumulated in the spark plug wells t...

Page 34: ...ASUREMENT NOTE Insufficient compression pressure will result in performance loss 1 Check Valve clearance Out of specification Adjust Refer to CALCE CLEARANCE ADJUSTMENT section 2 Start the engine and...

Page 35: ...plied into cylinder Reading Diagnosis Higher than without oil Worn or damaged pistons Same as without oil Possible defective ring s valves cylinder head gasket or Piston Repair Compression pressure at...

Page 36: ...grade CAUTION Do not put in any chemical additives or use oils with a grade of CD or higher Be sure not to use oils labeled ENERGY CONSERVING I or higher Engine oil also lubricates the clutch and add...

Page 37: ...loosen the oil check bolt Start the engine and keep it idling until the oil begins to seep from the oil check bolt If no oil comes out after one minute turn the engine off so it will not seize Check...

Page 38: ...ew minutes until the coolant settles before inspecting the coolant level COOLANTRE PLACE MENT 1 Remove Front cover of UTV plastic body work Seat 2 Remove Hose reservoir tank Drain the reservoir tank o...

Page 39: ...n Hose 7 Connect Hose reservoir tank 8 Fill Radiator to specified level Fill the coolant slowly until the coolant comes out from the head hose Reservoir tank to maximum level A aE A Recommended coolan...

Page 40: ...o coolant splashes onto painted surfaces If it does wash them immediately with water Do not mix different types of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines 9 Tig...

Page 41: ...CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20 0 3 3 CYLINDER HEAD CHAPTER 3 ENGINE PAGE 3 16...

Page 42: ...e Injector seat Joint O ring Crankcase cover Plug O ring Cam sprocket cover O ring Valve cover intake side O ring Valve cover exhaust side O ring Timing chain tensioner assembly Timing chain tensioner...

Page 43: ...n Bolt 3 Remove Timing chain tensioner assembly Timing chain tensioner gasket 4 Remove Breather plate Cam sprocket Timing chain NOTE Fasten a safety w ire to the timing chain to prevent it from fallin...

Page 44: ...urface plate and resurface the head using a figure eight sanding patten NOTE Rotate the cylinder head several times for an even resurfacement CYINDER HEAD INSTALLATION 1 Install Gasket cylinder head N...

Page 45: ...slot in the cam sprocket CAUTION Do not turn the crankshaft during installation of the cam shaft Dam age or improper valve timing will result While holding the camshaft temporarily tighten the bolts...

Page 46: ...50 SERVICE MANUAL 20 0 6 Tighten Bolt cam sprocket 7 Check Valve timing Out of alignment Adjust 8 Check Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJUSTMENT section CHAP...

Page 47: ...1 Remove the parts in order Refer to CYLINDER HEAD section 2 Plate 1 Refer to ROCKER ARM AND ROCKER 3 Rocker arm shaft intake 1 SHAFT REMOVAL AND INSTALLATION section 4 Rocker arm shaft exhaust 1 5 R...

Page 48: ...place 2 Measure Cam lobes length A aE A and A bE Out of specification Replace Cam lobes length Intake A aE A 36 545 36 645 mm Lim it 36 45 mm A bE A 30 021 30 121 mm Lim it 29 92 mm Exhaust A aE A 36...

Page 49: ...les Out of specification Replace Inside diameter rocker arm 12 000 12 018mm Lim it 12 030 mm Measure the outside diameter B of the rocker arm shafts Out of specification Replace Outside diameter rocke...

Page 50: ...haust completely pushed in 5 Install Rocker arm Rocker arm shaft intake NOTE Intake Insert the guide shaft 8 mm into the stud bolt hole in the cylinder head to the rocker arm shaft intake CAUTION Do n...

Page 51: ...pring retainer Valve spring inner Valve spring Outer Valve intake Valve exhaust Valve guide Spring seat 4 2 2 2 1 1 2 2 Remove the parts in order Refer to CYLINDER HEAD section Refer to ROCKER ARM SHA...

Page 52: ...id damage to the valve spring VALVE AND VALVE SPRINGS INSPECTION 1 Measure Valve stem diameter Out of specification Replace Valve stem diameter Intake 5 975 5 990mm Limit 5 94mm Exhaust 5 960 5 975mm...

Page 53: ...lve guide inside diameter Intake 6 000 6 012 mm Limit 6 05mm Exhaust 6 000 6 012 mm Limit 6 05 mm 7 Measure Stem to guide clearance Valve guide inside diameter Valve stem diameter Out of specification...

Page 54: ...e valve seat is too wide too narrow or the seat is not centered the valve seat must be replaced 4 Lap Valve face Valve seat NOTE After replacing the valve seat valve and valve guide the valve seat and...

Page 55: ...the valve guide and onto the valve seat to make a clear pattern Measure the valve seat with A cE A again VALVES AND VALVE SPRINGS INSTALLATION 1 Deburr Valve stem end Use an oilstone to smooth the st...

Page 56: ...Install the valve cotters while com pressing the valve spring with a valve spring compressor and attachment 5 Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood CAUT...

Page 57: ...chain guide exhaust side 1 Refer to PISTON RINGS 4 Cylinder 1 PISTON AND CYLINDER INSTALLATION section 5 Dowel pin 2 6 Cylinder gasket 1 7 Piston pin circlip 2 Refer to PISTON AND 8 Piston pin 1 PISTO...

Page 58: ...piston ring open the end gap of the ring by fingers and push up the other side of the ring CYLINDER INSPECTION 1 Measure Cylinder bore Out of specification Rebore or replace NOTE Measure the cylinder...

Page 59: ...kirt diameter Refer to CYLINDER section for cylinder bore measurement Out of specification Replace the piston and piston rings as a set Piston to cylinder clearance 0 02 0 04mm 3 Measure Piston pin bo...

Page 60: ...tion Piston ring into the cylinder NOTE Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore A 1E A 5 0mm 3 Measure End gap Out of specification Replace N...

Page 61: ...iston pins The mark A aE A on the piston must face the exhaust side of the cylinder Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip fr...

Page 62: ...Piston ring Cylinder inner surface Engine oil 6 Install Cylinder NOTE Install the cylinder with one hand while com pressing the piston rings with the other hand Pass the timing chain and timing chain...

Page 63: ...LEFT Order Job name Part name Q ty Remarks Crankcase cover left removal Remove the parts in order 1 Crankcase cover left 1 2 Front cover 1 3 Hose clamp B 1 4 Joint B 1 5 Air strainer B 1 6 Hose clamp...

Page 64: ...condary primary sheave removal Remove the parts in order 1 Nut Plain washer 1 1 2 Primary fixed sheave 1 3 Nut 1 4 Clutch housing 1 5 Clutch assembly 1 6 V belt 1 7 Primary sliding sheave 1 8 Collar 1...

Page 65: ...er 1 Nut 1 2 Clutch carrier 1 Refer to SECONDARY SHEAVE 3 Clutch shoe spring 3 DISASSEMBLY section 4 Compression spring 1 5 Spring seat 1 Refer to SECONDARY SHEAVE 6 Guide pin 4 INSTALLATION section 7...

Page 66: ...Remove Nut secondary sheave Clutch housing NOTE Loosen the nut secondary sheave while holding the clutch housing with the sheave holder 2 Remove Nut clutch carrier CAUTION Do not remove the nut clutc...

Page 67: ...CLUTCH INSPECTION 1 Measure Clutch shoe thickness Scratches Glaze using coarse sandpaper Wear Damage Replace Clutch shoe thickness 5 5mm Limit 4 0mm NOTE After using the sandpaper clean off the polis...

Page 68: ...VE INSPECTION 1 Inspect Secondary fixed sheave smooth operation Secondary sliding sheave smooth operation 2 Inspect Torque cam groove Wear Damage Replace 3 Inspect Guide pin Wear Damage Replace PRIMAR...

Page 69: ...econdary fixed sheave 2 Install Secondary sliding sheave NOTE Install the secondary sliding sheave using the oil seal guide to the secondary fixed sheave 3 Install Guide pin 4 Apply Lightweight lithiu...

Page 70: ...ary sheave and clutch 7 Install Nut clutch carrier NOTE Tighten the nut clutch carrier using the locknut wrench while holding the clutch carrier with the rotor holder 8 Install Clutch housing Nut clut...

Page 71: ...ator coil removal Drain the engine oil Remove the parts in order Refer to ENGINE OIL REPLACEMENT section NOTE Disconnect the couplers Reverse the removal procedure for installation 1 Couplers A C magn...

Page 72: ...gneto and starter clutch removal Rotor Shaft idle gear Idler gear Starter one way clutch assembly Woodruff key Starter wheel gear 1 1 1 1 1 1 Remove the parts in order Refer to A C MAGNETO ROTOR REMOV...

Page 73: ...turned out slightly to adjust the flywheel puller s position CAUTION Cover the crankshaft end with the box wrench for protection STARTER DRIVE GEAR INSPECTION 1 Inspect Starter idle gear teeth Starter...

Page 74: ...install the woodruff key 2 Install Plain washer Rotor NOTE Clean the tapered portion of the crankshaft and the rotor hub When installing the magneto rotor make sure the woodruff key is properly seated...

Page 75: ...pump removal Remove the parts in order A C magneto Refer to A C MAGNETO AND STARTER 1 Cover 1 CLUTCH section 2 Pump driven gear 1 3 Dowel pin 1 4 Oil pump assembly 1 5 Gasket 1 6 Impeller shaft gear...

Page 76: ...ner rotor and the outer rotor Side clearance between the outer rotor and the pump housing Housing and rotor clearance between the pump housing and the rotors Out of specification Replace the oil pump...

Page 77: ...ndary primary sheave A C magneto and starter clutch Oil pump Water pump Rear wheel Bolt O ring 1 1 Remove the parts in the order Refer to ENGINE REMOVAL section Refer to CYLINDER HEAD section Refer to...

Page 78: ...me Q ty Remarks 3 4 5 6 7 8 9 10 11 Timing chain Crankcase right Dowel pin Crankshaft assembly Balancer assembly Crankcase left Timing chain guide intake Bracket shift Oil seal 1 1 2 1 1 1 1 1 1 Rever...

Page 79: ...nkshaft cannot be removed CRANKSHAFT INSPECTION 1 Measure Crankshaft runout Out of specification Replace crankshaft and or bearing NOTE Measure the crankshaft runout with the crankshaft assembly runni...

Page 80: ...ut the journal with compressed air BALANCER INSPECTION Inspect Balancer driven gear Wear Damage Replace balancer CRANKCASE INSTALLATION 1 Clean all the gasket mating surface and crankcase mating surfa...

Page 81: ...ty Remarks Radiator removal Drain the coolant Remove the parts in order Refer to COOLANT REPLACEMENT section 1 Fan motor leads 1 2 Thermo switch leads 1 3 Outlet hose radiator 1 4 Inlet hose radiator...

Page 82: ...adiator pipes Cracks damage Replace 3 Measure Radiator cap opening pressure Radiator cap opens at a pressure below the specified pressure Replace Radiator cap opening pressure 110 140kPa 1 1 1 4kg cm2...

Page 83: ...der Drain the coolant Refer to COOLANT REPLACEMENT section A C magneto Refer to A C MAGNETO AND STARTER CLUTCH section 1 lmpeller shaft gear 1 2 Dowel pin plain washer 1 1 3 Shaft 1 Refer to WATER PUM...

Page 84: ...K 450 SERVICE MANUAL 20 0 Order Job name Part name Q ty Remarks 8 9 10 Impeller shaft O ring O ring 1 1 1 Refer to WATER PUMPINSTALLATION section Reverse the removal procedure for installation CHAPTER...

Page 85: ...ur deposits Clean 2 Inspect Impeller shaft gear Wear damage Replace 3 Inspect Mechanical seal Damage worn wear Replace WATER PUMP INSTALLATION 1 Install Mechanical seal NEW Installation steps Apply th...

Page 86: ...ps Apply a small amount of grease to the impeller shaft tip Install the impeller shaft while turning it Use care so that the oil seal is not damaged or the spring does not slip off its position NOTE A...

Page 87: ...at removal Drain the coolant Remove the parts in order Refer to COOLANT REPLACEMENT section 1 Clip 1 2 Hose 1 3 Hose clamp 1 4 Inlet hose radiator 1 5 Thermostatic cover 1 Refer to THERMOSTAT INSTALLA...

Page 88: ...the thermometer while continually stirring the water Thermostatic valve Vessel Thermometer Water A CLOSE B OPEN NOTE The thermostatic valve is sealed and its setting requires specialized work If its...

Page 89: ...Description and Working Principle 3 12 3 2Throttle Body Removal 3 12 3 3 Cleaning Procedure 3 12 3 4 Throttle Body Installation 3 12 4 Engine Coolant Temperature Sensor 3 12 4 1 Description and Workin...

Page 90: ...ANUAL 20 0 3 12 7 7 Fuel Leakage Check Procedure 3 12 8 Motor Scanner for MT05 EMS 3 12 8 1 Precautions 3 12 8 2 Configurations 3 12 8 3 Preparations Connection 3 12 8 4 Functions 3 12 8 5 MT05 ECU Ma...

Page 91: ...pipe or Engine when removed High temperature might reduce the life of the ECU and also can damage the ECU DO NOT Place the ECU close to or pour water oil or any other liquids ECU is susceptible to wa...

Page 92: ...vive with no permanent damage Battery and or Ignition voltage 13V DC for 1 minute But the fuse will fuse 3 12 1 6 Operating Temperature The controller shall operate in the ambient temperature from 20...

Page 93: ...me Operating Temperature Range some performance degradation 40 to 150 3 12 2 3 Fuel Contamination The injector fuel inlet filter protects the fuel injector from initial build fuel contamination as wel...

Page 94: ...ns of damage Even minor defects in the seal ring can lead to leakage Take extra care in installing seal ring over flange of injector inlet Carefully installing the harness connector will prevent termi...

Page 95: ...pressure Remove the retaining clip from the fuel injector Remove the fuel line connection from the injector Carefully clean debris from the interface surfaces Do not damage seal mating surfaces Remove...

Page 96: ...ttle Body Assembly 3 12 3 1 Description and Working Principle The Throttle Body Assembly is an interactive system comprised of the following subsystems the main casting body bearing system shaft and v...

Page 97: ...h that are present Do not let the bye pass holes be blocked by dirt or foreign particles 3 12 3 4 Throttle Body Installation Reverse the procedure for installation noting the following Adjust accelera...

Page 98: ...tioned above 3 12 5 Oxygen Sensor 3 12 5 1 Description and Working Principle This sensor is a device for monitoring the residual oxygen in the exhaust of an internal combustion engine It is the feedba...

Page 99: ...tes an electrical path to outside the system permitting improper system operation misfire or even possible personal injury if arcing occurs DO NOT Use parts that have been dropped or display physical...

Page 100: ...nd the power applied unwanted secondary output might occur possibly resulting in injury damage the ignition component and test equipment DO Take care when working around the ignition system The high v...

Page 101: ...clear of moving parts belts fan etc must be protected from or kept at least 125 mm away from radiant heat source exceeding 400 F must be protected from environmental damage dirt splash oils fluids et...

Page 102: ...ltage Too narrow of a gap could affect idle stability A flat gauge can t accurately measure the spark plug on used plugs DO When replacing spark plugs with new ones always use equivalent plugs with sa...

Page 103: ...regulator regulates the fuel pressure at a set pressure by releasing the excessive fuel flow to fuel tank 3 12 7 2 Operating Conditions Fuel Pump needs to be mounted on Fuel Tank Top according to the...

Page 104: ...cing make sure that the fuel hoses and clamps are connected according to the hose fitment instructions given in vehicle instruction manual After servicing please follow the Fuel Leakage Check Procedur...

Page 105: ...oints 2 Check Fuel Pump 3 Check Pressure Regulator 1 Clogged Filter 2 Kink Blockage in Fuel Hoses 3 Check Regulator 3 12 7 4 Fuel Pump Removal Relieve fuel pressure in fuel lines referring to the Fuel...

Page 106: ...Procedure to check any leakage before the engine is started 3 12 7 6 Fuel Pressure Relief Procedure Caution This work must not be done when engine is hot After making sure that engine is cold relieve...

Page 107: ...med by the person who is driving the car This unit should be used and stored in the following conditions Ambient temperature 0 50 Relative humidity 90 Note This instruction is only applicable to Delph...

Page 108: ...be used to diagnose Delphi Engine Management System with functions Read DTC Clear DTC Data Stream Status Stream and Record Data Operations When the unit is powered up the screen will display the inter...

Page 109: ...t Press with accessing system fleeting on the screen then it will display as right Available functions are as follows Read DTC Clear DTC Data Stream Status Stream Record Data Press or key to select fu...

Page 110: ...ight 3 Data Stream Select Data Stream and press it will display as right Press or key for page up down to view more Press key to exit 4 Status Stream Select Status Stream and press the interface will...

Page 111: ...Circuit Low Voltage P0132 O2A Circuit High Voltage P0031 O2A Heater Circuit High Voltage P0032 O2A Heater Circuit Low Voltage P0201 Injector 1 Circuit Malfunction P0202 Injector 2 Circuit Malfunction...

Page 112: ...CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20 0 NOTES CHAPTER 3 ENGINE PAGE 3 87...

Page 113: ...versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 4 1 FRONT A ARM REPLACEMENT 4 2 RE...

Page 114: ...rt Lh 17 Screw M5X10 18 Grease Fitting M6 19 Front Shock Absorber Assy 20 Bolt M10X1 25X57 21 Arm Upper Frt Lh Assy 22 Arm Lwr Frt Lh Assy 23 Carrier Bearing Wheel Lh Assy 1 Elevate and safely support...

Page 115: ...cle is on the ground DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 10 Attach A arm to strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If...

Page 116: ...16 Arm Lwr Rear Lh 17 Plug 18 Shaft Rear Lwr Arm 19 Cover Arm Lwr Rear Lh 20 Screw M5X10 21 Rear Shock Absorber Assy 22 Bolt M10X1 25X62 5 23 Bolt M10X1 25X57 24 Stabilizer Bar 25 Ball Pin Lh 26 Ball...

Page 117: ...move the spindle nut and washer Remove the hub assy by sliding it off of the shaft 5 Loosen two bolts that secure the rear knuckle to the A arm Remove the rear knuckle assembly by sliding it off of th...

Page 118: ...njury or death could result if fasteners come loose during operation 13 Attach A arm to rear knuckle Tighten upper and lower bolts to 44 ft lbs 60 Nm 14 Install the shock and tighten shock bolt to 44...

Page 119: ...ss to the stabilizer bar each side 3 Remove the stabilizer bar nut from the lower A arm each side 4 Remove the two bolts that secure the stabilizer bar to the main frame each side 5 Remove the stabili...

Page 120: ...during the rest of the removal process The box is not as stable with the hinge pin removed 6 With the hinge pins removed remove the box from the frame Two people maybe needed to remove the bed from th...

Page 121: ...20 Shoulder Bolt M10 1 25 30 21 Bushing For Adjustable Steering Wheel 22 Nut M10 23 Shaft Steering 24 Adjustment Cylinder 25 Shoulder Bolt M8 1 25 30 26 Washer 6 27 Bolt M6X12 1 With the steering whe...

Page 122: ...CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20 0 CHAPTER 4 CHASSIS PAGE 4 10 NOTES...

Page 123: ...REMOVAL INSPECTION 5 4 FRONT HUB INSTALLATION 5 5 FRONT HUB BEARING REPLACEMENT 5 6 FRONT DRIVE AXLE REMOVAL INSPECTION 5 7 FRONT DRIVE AXLE INSTALLATION 5 8 FRONT DRIVE AXLE DISASSEMBLY INSPECTION 5...

Page 124: ...ION Locking nuts and bolts with pre applied locking agent should be replaced if removed The self locking properties of the nut or bolt are reduced or destroyed during removal 5 2 FRONT HUB EXPLODED VI...

Page 125: ...isture dirt or corrosion or roughness is evident 5 4 FRONT HUB INSTALLATION 1 Inspect the hub strut bearing surface for wear or damage 2 Apply grease to drive axle spindle 3 Install spindle through th...

Page 126: ...pport casting on outer edges so bearing can be removed 4 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bear...

Page 127: ...er and Chapter 4 CAUTION To avoid damage to the front gearcase oil seal hold the front drive shaft horizontal and straight out from the front differential during removal 3 Hold the drive shaft straigh...

Page 128: ...ront differential 2 Push the drive shaft straight into the front differential and push it in all the way until it bottoms out If necessary carefully tap on the outer end of the drive shaft with a rubb...

Page 129: ...be reused b Slide the outboard boot off the drive axle and discard the boot band A it cannot be reused 9 Inspect the drive axle as described in this chapter INNER CV JOINT INSPECTION 1 Clean the beari...

Page 130: ...er end splines and the front hub cotter pin hole for wear or damage If any of these areas are worn or damaged replace the drive axle Check the movement of the joint NOTE Inner CV joint must be replace...

Page 131: ...mbly Work the grease in between the balls the race and the case Make sure all voids are filled with grease 9 Apply a liberal amount of molybdenum disulfide grease to the inner surfaces of the inboard...

Page 132: ...e stopper ring and make sure it is seated correctly in the drive axle groove 18 Apply molybdenum disulfide grease to the end splines 5 10 REAR HUB EXPLODED VIEW 5 11 REAR HUB AND KNUCKLE REMOVAL INSPE...

Page 133: ...b and knuckle assembly onto the drive shaft 2 Align the bottom of knuckle and lower control arm Secure with the lower control arm bolt 3 With the driveshaft placed in the knuckle align the knuckle wit...

Page 134: ...of the frame Use short sharp jerks to free the circlip from the gearcase The circlip holds the axle in the gearcase 4 Inspect the axle splines and CV boots for any damage 5 14 REAR DRIVE SHAFT INSTAL...

Page 135: ...d install bolt to upper and lower control arm Torque bolt to 45 ft lbs 60 Nm 5 Install the washer and the new spindle nut 6 Lower the vehicle Torque the spindle retaining nut to 103 ft lbs 140 Nm 7 Kn...

Page 136: ...CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20 0 CHAPTER 5 FINAL DRIVE 5 14 5 15 REAR GEARCASE EXPLODED VIEW REAR GEARCASE EXPLODED VIEW...

Page 137: ...PLER REAR AXLE 4 7 BOLT M18x1 5 1 31 WASHER 12 5 30 4 1 8 OIL SEAL30x60x15 1 32 NUT M12 1 25 1 9 BEARING 6008 1 10 ADJUST SHIM48x40 3 AR 11 HEXAGON HEAD BOLT 1 12 WASHER 1 13 DRIVEN BEVEL GEAR ASSEMBL...

Page 138: ...igh pressure water jet 1 Remove the oil drain plug A and let the oil drain from the gearbox Important Clean the plug carefully Replace the sealing washer B before it s assembled Fig 1 Fig 1 Fig 2 2 Re...

Page 139: ...ner L with the special tool Remove the bearing M and the oil seal P from the bevel gear bearing housing N Fig 4 Fig 4 2 Remove the six bolts M8 25 Q and the two bolts M10 1 25 25 R Remove the ring gea...

Page 140: ...st shim Y from the bevel gear comp driven X Fig 7 Fig 7 5 Remove the O ring Z the oil seal 65 90 9 a and the bearing b from the ring gear bearing housing T Fig 8 Fig 8 5 17 REAR GEAR CASE ASSEMBLY Imp...

Page 141: ...ar comp driven E in the bore of bearing A Mount the adjust shim F in the other neck of the bevel gear comp driven E Fig 2 Fig 2 3 Mount the needle bearing H and the needle bearing into the suited hole...

Page 142: ...rear gear case G together Fig 6 Fig 6 7 Tighten the six bolts M8 25 Q to a torque of 20 25N m Tighten the two bolts M10 1 25 25 P to a torque of 35 40N m 8 Mount the axle sleeve U of the inner outer...

Page 143: ...shaft neck of the bevel gear bearing housing Z Make the rear gear case G and the bevel gear bearing housing Z together Fig 11 Fig 11 12 Apply some Loctite 242 threadlocker on screw thread Tighten the...

Page 144: ...22 Fig 13 14 Mount the oil seal 65 90 9 j in the ring gear bearing housing C on the right Fig 14 Fig 14 15 Mount the oil seal k in the ring gear bearing housing G on the left Make the O ring m on the...

Page 145: ...CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20 0 CHAPTER 5 FINAL DRIVE 5 23 5 18 FRONT GEARCASE EXPLODED VIEW FRONT GEARCASE EXPLODED VIEW...

Page 146: ...Vent Pipe 1 10 Oil Seal 24 38 8 2 35 O Ring 81 2 1 9 1 11 Fill Plug 1 36 Gear Motor 1 12 O Ring 30 5 3 1 37 Screw M8 20 4 13 Drain Bolt 1 38 Pin Shaft 1 14 Washer 10 1 39 Shift Fork 1 15 Front Axle Bo...

Page 147: ...36 is protected if mounted Never clean the gearbox with a high pressure water jet Fig 0 Fig 0 1 Remove the DRAIN BOLT NO 13 and let the oil drain from the gearbox Important Clean the plug carefully an...

Page 148: ...ove the OIL SEAL NO 5 and repalce with a new seal Fig 5 Fig 5 6 Remove the four SCREW NO 37 Fig 6 Fig 6 7 Remove the GEAR MOTOR NO 36 Fig 7 Fig 7 8 Remove the six bolts M8 X L28 NO 29 Fig 8 Fig 8 9 Re...

Page 149: ...eth NOTE The DIFFERENTIAL GEAR ASSY A is NOT intended to be disassembled as it requires special tooling in order to properly reassemble If there is any damage to the gear bearings or others the assemb...

Page 150: ...38 SHIFT FORK NO 39 Fig 14 Fig 14 14 Remove the DRIVE CLUTCH NO 23 Fig 15 Fig 15 15 Inspect the bearing NO 26 If the bearing was damaged remove the RETAINER NO 25 first and then remove the bearing NO...

Page 151: ...ecial tool Fig 19 Fig 19 20 Remove the DRIVE PINION GEAR B Fig 20 Fig 20 NOTE The DIFFERENTIAL GEAR ASSY A AND THE DRIVE PINION GEAR B MUST BE REPLACED SIMULTANEOUSLY NOT SEPARAT 5 20 FRONT GEARCASE A...

Page 152: ...5 30 2 Mount the retainer 62 NO 25 Fig 2 Fig 2 3 Mount the drive clutch NO 23 Fig3 Fig 3 4 Mount the pin shaft NO 38 and the shift fork NO 39 Fig 4 Fig 4 5 Install the screw NO 30 and washer NO 29 th...

Page 153: ...E 5 31 Fig 6 7 Install the DIFFERENTIAL GEAR ASSY A into the carrier housing Fig 7 Fig 7 8 Install the DRIVE PINION GEAR B and install the BEARING RETAINER NO 6 with special tool Fig 8 Fig 8 9 Install...

Page 154: ...l the bolts NO 29 that secure the cover to the housing Torque the bolts in a criss cross pattern to 20 25Nm Fig 11 Fig 11 12 Mount the gear motor A Important Before assemble the gear motor NO 36 make...

Page 155: ...ER 5 FINAL DRIVE 5 33 14 Mount the coupler NO 4 Fig 14 Fig 14 15 Mount the O ring NO 3 Fig 15 Fig 15 16 Apply some Loctite 263 thread locker on screw thread mount the nut NO 3 tighten it to a torque o...

Page 156: ...CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20 0 CHAPTER 5 FINAL DRIVE 5 34 NOTES...

Page 157: ...me parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 6 1 GEAR SHIFTER REMOVAL 6 2 SHIFTER DISASSEMBLY 6 3 SHIFTER INSTALLATION 6...

Page 158: ...20 0 CHAPTER 6 TRANSMISSION PAGE 6 2 6 1 GEAR SHIFTER REMOVAL 1 Remove parts that interfere with access to shift selector seat cover etc 2 Disconnect the two linkage rods from transmission slides 3 Re...

Page 159: ...CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 6 TRANSMISSION PAGE 6 3 4 Remove the screw from the shifter 5 Remove the three bolts from the frame 6 Remove shift support assembly...

Page 160: ...SMISSION PAGE 6 4 6 2 SHIFTER DISASSEMBLY Disassemble the gear shift mechanism as shown NOTE Pay attention to the falling springs and steel balls 6 3 SHIFTER INSTALL ATION The assembly process is the...

Page 161: ...erosol lubricant or grease 2 Loosen all rod end adjuster jam nuts 3 Note orientation of tie rod end studs with stud up or down Remove both rod end studs from transmission bell cranks 4 Be sure idle sp...

Page 162: ...feed and return hoses refer to Engine chapters 3 Remove throttle cable wire connected to carburetor 4 Disconnect engine from wiring harness completely 5 Disconnect gear position indicator switches 6 R...

Page 163: ...bolt M10X1 25X120 and right mount bolt M10x1 25x70 11 Remove engine and transmission from engine mount bracket 6 6 ENGINE AND TRANSMISSION INSTALLATION 1 Reverse the procedure of chapter 6 5 ENGINE AN...

Page 164: ...on shaft retainer plate and pinion shaft 8 Remove front drive output housing cover screws Carefully remove the cover with a soft face hammer tap on the cover bosses 9 Note position of shim washers and...

Page 165: ...ocket on front output shaft with sprocket step side inward as shown only for 4X4 2 Assemble front only for 4X4 and rear output shafts 3 a 4X4 Install front and rear output shafts with chain as an asse...

Page 166: ...ble shafts with chain and shift forks 11 Carefully install high reverse shaft assembly and gear cluster as a unit into their respective bearing case areas Tap with a soft face hammer to seat shaft ass...

Page 167: ...eed adjustment Transmission oil type quality Driven clutch CVT deflection Loose fasteners on rod ends Loose fasteners on gear shift box Worn rod ends clevis pins or pivot arm bushings Linkage rod adju...

Page 168: ...CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 6 TRANSMISSION PAGE 6 12 4X4 TRANSMISSION EXPLODED VIEW...

Page 169: ...CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 6 TRANSMISSION PAGE 6 13 NOTES...

Page 170: ...rmation 7 1 SPECIFICATIONS 7 2 TORQUE 7 3 BRAKE SYSTEM SERVICE NOTES 7 4 BURNISHING PROCEDURE 7 5 BRAKE BLEEDING FLUID CHANGE 7 6 PARKING BRAKE AND BRAKE LINE INSPECTION 7 7 PARKING BRAKE ADJUSTMENT 7...

Page 171: ...Brake Disc Thickness 0 291 0 299 7 4 7 6mm 0 281 7 146mm Brake Disc Thickness Variance Between Measurements 0 002 0 051mm Brake Disc Run out 0 005 0 127mm 7 2 TORQUE Item Torque ft lbs except where no...

Page 172: ...raking effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the brake pads use the following procedure 1 Choose an area large enough to safely ac...

Page 173: ...n clear hose to the fitting and place the other end in a clean container Be sure the hose fits tightly on the fitting 6 Slowly pump foot pedal until pressure builds and holds 7 Hold brake pedal on to...

Page 174: ...reservoir cover 13 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve should be no less than 1 2 13m...

Page 175: ...vehicle should not roll while parked 3 If the vehicle moves adjustment is necessary 4 Adjust the parking brake where the cable attaches to the lever assembly on the rear brake caliper Parking Brake A...

Page 176: ...the bracket and lift park brake assembly out 2 Measure the thickness of the caliper parking brake pads Replace pads if worn beyond the service limit Service Limit 0 3 64 1 mm Park Brake Caliper Insta...

Page 177: ...ly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove e...

Page 178: ...er clockwise 6 Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install wheels and torque wheel nut...

Page 179: ...lean mating surface of disc and hub 4 Install new disc on hub and tighten to specified CAUTION Always use new brake disc mounting bolts Front Brake Disc Mounting Bolt Torque 18 ft lbs 25 Nm 7 11 FRONT...

Page 180: ...p machine Repeat procedure 10 times 7 12 REAR BRAKE PAD REMOVAL INSPECTION INSTALLATION NOTE The brake pads should be replaced as a set REMOVAL 1 Remove the cargobox CAUTION Use care when remove the c...

Page 181: ...brake fluid in the reservoir to prevent air from entering the brake system 5 Install wheels burnishing procedure should be performed 7 13 REAR CALIPER REMOVAL INSPECTION INSTALLATION CAUTION The cali...

Page 182: ...and firm brakes Make sure the brake is not dragging when lever is released If the brake drags recheck assembly and installation 11 Install the rear wheel and wheel nuts Carefully lower the vehicle NOT...

Page 183: ...ifications Brake Disc Runout Service Limit 0 005 0 127 mm REMOVAL REPLACEMENT 1 Remove the cargobox 2 Remove calipers 3 Remove bolts and disc from the flange 4 Clean mating surface of disc 5 Install n...

Page 184: ...CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20 0 CHAPTER 7 BRAKES PAGE 7 15 NOTES...

Page 185: ...CE 8 2 BATTERY 8 3 IGNITION SYSTEM 8 4 CHARGING SYSTEM 8 5 ELECTRICS STARTING SYSTEM 8 6 COOLING SYSTEM 8 7 LIGHTING SYSTEM 8 8 GEAR POSITION INDICATOR SWITCH TEST 8 9 SPEEDOMETER SYSTEM 8 10 MAIN SWI...

Page 186: ...light beam can be adjusted vertically 2 Place the vehicle on a level surface with the headlight approximately 9 8 3m from a wall 3 Measure the distance from the floor to the center of the headlight an...

Page 187: ...PAGE 8 3 TAILLIGHT BRAKELIGHT LAMP REPLACEMENT 1 Pull the Taillight plug off the wire harness remove the screw 2 Turn and remove the lamp base or Remove bulb and replace it with recommended bulb 3 Rei...

Page 188: ...ol water and seek immediate medical attention Battery Maintenance 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If...

Page 189: ...he storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perf...

Page 190: ...erminal board or connections wet corroded Poor ignition coil ground e g coil mount loose or corroded Faulty stator measure resistance of all ignition related windings Incorrect wiring inspect color co...

Page 191: ...system 5 Spark plug cap resistance 6 Ignition coil 1 Fuse NO CONTINUITY Check switches Replace the fuse CONTINUITY 2 Battery INCORRECT Clean battery terminals Recharge or replace the battery Check the...

Page 192: ...ion system is not faulty Minimum spark gap 0 6mm 0 24 in OUT OF SPECIFICATION OR NO SPARK 5 Resistive cable with Spark plug cap resistance Tester lead Spark plug side Tester lead High tension cord sid...

Page 193: ...tester 1 to the ignition coil Check if the primary coil has the specified resistance Primary coil resistance 0 58 0 058 20 Tester lead Right Terminal Tester lead Left Terminal Remover the resistive c...

Page 194: ...coil coupler Tester lead BI Terminal Tester lead G Terminal Check the pickup coil has the specified resistance Primary coil resistance 120 160 20 OUT OF SPECIFICATION Replace the pickup coil 8 Main sw...

Page 195: ...tery cable or ammeter with the engine running Damage will occur to light bulbs and speed limiter Connect an ammeter in series with the negative battery cable Check for current draw with the key off if...

Page 196: ...ORRECT Clean battery terminals Recharge or replace the battery 3 Charging voltage Connect the engine tachometer to the spark plug lead Connect the pocket tester DC20V to the battery Test lead Battery...

Page 197: ...ester X1 to the stator coil Tester lead yellow terminal Tester lead yellow terminal Measure the stator coil resistance Stator coil resistance 0 3 1 1 20 OUT OF SPECITICATION Replace the stator coil ME...

Page 198: ...TRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 14 8 5 ELECTRICS STARTING SYSTEM DIAGRAM TROUBLESHOOTING THE STARTER MOTOR OPERATES WHEN THE BRAKE SWITCH IS ON IF THE STARTER MOTOR FAI...

Page 199: ...attery 3 Starter motor Connect the battery positive terminal and starter motor cable using a jumper lead Check the starter motor operation DOES NOT MOVE Repair or replace the starter motor 4 Starter r...

Page 200: ...NDUCTION CONTINUITY Replace the starter replay 4 Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 1 Brake switch CHECKING SWITCHES NO CONTINUITY Replace the brake switch 7 Starter swit...

Page 201: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 17 8 6 COOLING SYSTEM...

Page 202: ...ystem 1 Fuse CHECK SWITCHES NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section INCORRECT Clean battery terminals Recharge or replace the battery 3...

Page 203: ...the thermo switch from the radiator Connect the pocket tester X1 to the thermo switch Immerse the thermo switch in the water Check the thermo switch for continuity NOTE Measure temperatures while hea...

Page 204: ...EAT ALARM UNIT WORKING When the main switch is turned on the temperature of the engine begins to go up As it comes to 88 3 the thermostat is connected and the fan starts to work cooling the coolant if...

Page 205: ...or allow it to be dropped Should it be dropped it must be replaced Do not touch the thermo unit to the bottom of the heated vessel Coolant temperature Resistance 80 47 5 56 8 100 26 2 29 3 OUT OF SPEC...

Page 206: ...450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 22 6 Wiring connection check the connections of the entire cooling system Refer to CIRCUIT DIAGRAM POOR CONNECTION CORRECT Replace the temperature...

Page 207: ...tem 1 fuse refer to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section INCORRECT Clean battery terminals Recharge or rep...

Page 208: ...am light and direction indicator light couplers A When the High low beam switch is on high beam High beam light Tester lead Blue lead Tester negative lead Green lead B When the High low beam switch on...

Page 209: ...ITY NO CONTINUITY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC20V to the taillight couplers 2 1 position light Tester lead Black terminal Tester lead Green terminal Turn...

Page 210: ...CTRICAL PAGE 8 26 8 8 GEAR POSITION INDICATOR SWITCH TEST Switch table This sensor is used to provide the gear position signal for meter display When the gearbox is in one gear position there is conti...

Page 211: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 27 Switch schematic...

Page 212: ...tio of black metal gear or gear rack B Main Technical Parameter for sensor Item Code Vol value Unit Operating voltage Vcc 5 20 V Operating current Icc 15 mA Low voltage output Vol 0 4 V Hight voltage...

Page 213: ...dicator 11 Km Mile Selector 3 High Beam Indicator Light 12 Gear Position Indicator 4 Parking Brake Indicate Lamp 13 2WD 4WD Indicator 5 Safety Belt Lamp 14 Front Differential Lock Indicator 6 Turn Rig...

Page 214: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 30 8 10 MAIN SWITCH AND HANDLE SWITCH Optional...

Page 215: ...e fuel sensor attached to fuel tank Hold fuel sensor in an upright position after removing it It is normal if indicator shows E otherwise circuitry connection fuel sensor or instrument should be inspe...

Page 216: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 32 Fuel sensor resistance range FLOAT POSITION RESISTANCE 20 68 F TOP FULL 16 BOTTOM RESERVE 100...

Page 217: ...OF THE ELECTRIC 4WD SHIFT 1 The rider shifts 2WD to 4WD by the Switch on panel 2 When shift 2WD 4WD or Diff Lock the mechanics in the front gear box maybe still engaged disengaged the mechanics would...

Page 218: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 34 8 13 WIRING DIAGRAM...

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