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CHAPTER 3 ENGINE

M750L SERVICE MANUAL 18.0

CHAPTER 3 ENGINE PAGE 3-

3.11CRANKSHAFT AND BALANCE SHAFT

Order

Job name/ Part name

Q'ty

Remarks

Locknut M35x1.5

Apply Loctite 243(Blue)
Tightening torque:150N.m
Lock the crank balancer drive gear nut with a
center punch.

CAUTION:

the removed nut must be

replaced with a new one.

key

Flat key A4x20

Flat key A4x30

Cylindrical pin 5x8

Summary of Contents for HY740STL 2018

Page 1: ...ifferent types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts information and service General Inf...

Page 2: ...M750L ATV SERVICE MANUAL 18 0 M750L 18 0...

Page 3: ...ld use discretion as to how much disassembly is needed to correct any given condition All references to left and right side of the vehicle are from the operator s perspective when seated in a normal r...

Page 4: ...CONTENTS CHAPTER1 General Information CHAPTER2 Maintenance CHAPTER3 700 Engine CHAPTER4 Chassis CHAPTER5 Final Drive CHAPTER6 Brakes CHAPTER7 Electrical...

Page 5: ...contains 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 ATV Never s...

Page 6: ...ORMATION WARNING The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts info...

Page 7: ...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 and O...

Page 8: ...r 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 the connecto...

Page 9: ...SION 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 6214 0 621...

Page 10: ...CHAPTER 1 GENERALINFORMATION M750L SERVICE MANUAL 18 0 CHAPTER 1 GENERAL PAGE 1 5 1 2 V I N AND ENGINE SERIAL NUMBER...

Page 11: ...CHAPTER 1 GENERALINFORMATION M750L SERVICE MANUAL 18 0 CHAPTER 1 GENERAL PAGE 1 6...

Page 12: ...CHAPTER 1 GENERALINFORMATION M750L SERVICE MANUAL 18 0 CHAPTER 1 GENERAL PAGE 1 7 1 3 VEHICLE DIMENSIONS Note The on road equipments rear view mirror turn lights etc are not Standard Equipment for USA...

Page 13: ...CHAPTER 1 GENERALINFORMATION M750L SERVICE MANUAL 18 0 CHAPTER 1 GENERAL PAGE 1 8 NOTES...

Page 14: ...ions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts information and service 2 1 PERIODIC MAINTENANCE 2 2 FUEL SYSTE...

Page 15: ...ortant components are explained in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 16km h 10 mil...

Page 16: ...x Sediment Tube Daily D Headlamp Inspection Daily C apply dielectric grease to connector when replaced Tail lamp inspection Daily C apply dielectric grease to socket when replaced Air Filter Main Elem...

Page 17: ...f necessary Rear Axle and Bearings 50 hrs 6 months I L Front Suspension 50 hrs 6 months I L T if necessary Rear Suspension 50 hrs 6 months I T if necessary Spark Plug 100 hrs 12 months I R if necessar...

Page 18: ...very two years or 200 hours 3 Transmission Oil SEA 80W 90GL5 Add to proper level on dipstick Change annually or at 100 hours 4 Rear Gear case oil SEA 80W 90GL5 Add to proper level Change annually or a...

Page 19: ...joint Grease Locate fittings and grease Every 3 months or 50 hours 18 Front prop shaft yoke Grease Locate fittings and grease Every 3 months or 50 hours 19 Inner and outer CV Joints Grease M Grease in...

Page 20: ...rformed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately If you spill gasoline on...

Page 21: ...eakage Replace every two years 2 Be sure vent lines and drain lines are routed properly toward the ground and secured with cable ties CAUTION Make sure lines are not kinked or pinched NOTE On some mod...

Page 22: ...fuel system following cautions should be always followed for personal safety and to avoid system damages Disconnect negative cable at battery DO NOT smoke and place No SMOKING sign near work area Mak...

Page 23: ...e sure that the fuel tank surface at module mounting area is clean and free of surface defects Place the bolts on module cover and tighten the bolts gradually in star pattern sequence to apply equal c...

Page 24: ...g to rim at front and rear of rim Rear rim measurement A should be 1 16 to 1 8 1 5 to 3 mm more than front rim measurement B NOTE The steering post arm frog can be used as an indicator of whether the...

Page 25: ...rom a sealed container to avoid contamination to system Check brake system for fluid leaks Check brake for excessive travel or spongy feel Check friction pads for wear damage and looseness Check surfa...

Page 26: ...lay is correct and brake pedal travel is still excessive air may be trapped some where in the system Bleed the hydraulic brake system in a conventional manner following the procedure outlined in the B...

Page 27: ...Damping should be smooth throughout the range of travel Check all front suspension components for wear or damage Inspect from strut cartridges for leakage Shock spring preload can not be adjusted rep...

Page 28: ...ALLATION 1 With the transmission in gear and the parking Brake locked place the wheel in the correct Position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the t...

Page 29: ...uipment size and type and replace in pairs The use of non standard size or type tires may affect ATV handling and cause machine damage TIRE TREAD DEPTH Always replace tires when tread depth is worn to...

Page 30: ...on 8 11 LT SwingArmPivotLeft 14 19 RefertoSWING ARM ASSEMBLY INSTALLATION 4 2SWING ARM CHAPTER4A CHASSIS SwingArmPivotRight 120 165 ThreadedPivotNut forswingarm 120 165 NutM14X1 5AttachingFrontAbsorbe...

Page 31: ...CHAPTER 2 MAINTENANCE M750L SERVICE MANUA 18 0 CHAPTER 2 MAINTENANCE PAGE 2 18 NOTES...

Page 32: ...L INSPECTION 3 2 6 COOLANT LEVEL INSPECTION 3 3 CYLINDER HEAD COVER 3 4 CYLINDER HEAD 3 5 CAMSHAFT AND ROCKER ARMS 3 6 VALVES AND VALVE SPRINGS 3 7 CYLINDER AND PISTON 3 8 V BELT CLUTCH AND SECONDARY...

Page 33: ...ocker arm rocker arm shaft Rocker arm inside diameter Rocker shaft outside diameter Rocker arm to rocker arm shaft clearance 14 000 14 018 mm 13 981 13 991 mm 0 009 0 037 mm 14 05 mm 13 94 mm 0 08 Val...

Page 34: ...nder clearance Piston size D Measuring point H Piston pin bore inside diameter 0 03 0 062 mm 101 95 101 97 mm 10mm 23 002 23 008 mm 22 99 23 0 mm 0 15m m 101 87 23 03 mm 22 98 mm Piston pin outside di...

Page 35: ...0 1 0 34 mm 0 1 0 14 mm 0 04 0 10 mm 0 4 mm 0 2 mm 0 15 mm Item Standard Limit Radiator Type Width height thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Cooling fin...

Page 36: ...t M10 2 55 Loctite 243 Oil passage Bolt M10 2 20 Crankcase Stud M10 4 23 Oil filter block Bolt M20 1 36 Oil filter M18 1 20 Drain bolt Bolt M12 1 25 Cylinder head Nut M10 4 45 Timing check plug Plug M...

Page 37: ...TE Valve clearance adjustment should be made with the engine cool at room temperature When the valve clearance is to be measured or adjusted the piston must be at Top Dead Center T D C on the compress...

Page 38: ...e right crankcase cover when the piston is Top Dead Center TDC NOTE Check the slit c have EX on the cam chain sprocket and the up plane d of the cylinder head alignment When the piston is Top Dead Cen...

Page 39: ...g in Valve clearance is decreased Turning out Valve clearance is increased Hold the adjuster to prevent it from moving and tighten the locknut Measure the valve clearance If the clearance is incorrect...

Page 40: ...ltage When the engine is stopped the battery voltage should be greater than 12 volts 12V If the battery voltage is normal you may turn off the engine Wait several minutes and check again At the time p...

Page 41: ...TE Insufficient compression pressure will result in performance loss 1 Check Valve clearance Out of specification Adjust Refer to VALVE CLEARANCE ADJUSTMENT section 2 Start the engine and let it warm...

Page 42: ...et or Piston Repair Compression pressure at sea level Standard 1100 50 kPa 11 2 0 5Kg cm2 11 0 5 bar Measurement steps Crank the engine with the throttle wide open until reading on the compression gau...

Page 43: ...the clutch and ad ditives could cause clutch slippage Be sure no foreign material enters the crankcase 5 Start the engine and let it warm up for a few minutes 6 Turn off the engine NOTE Wait a few mi...

Page 44: ...h speeds more than specified when checking the pressure NOTE Wipe any spilled oil off the engine 3 2 6 COOLANT LEVEL INSPECTION Inspect Coolant level Coolant level should be between the maximum a and...

Page 45: ...rns Do not remove the radiator cap when the engine and radiator are hot Scalding hot fluid and steam may be blown out under pressure which could cause serious injury When the engine has cooled open th...

Page 46: ...Coolant is potentially harmful and should be handled with special care WARNING splashes in your eyes Thoroughly wash your eyes with water and consult a doctor If coolant splashes on your clothes Quick...

Page 47: ...CHAPTER 3 ENGINE M750L SERVICE MANUAL 18 0 CHAPTER 3 ENGINE PAGE 3 16 12 Stop the engine and inspect the level NOTE Wait a few minutes until the coolant settles before inspecting the coolant level...

Page 48: ...der head cover removal Remove the parts in order Water Pump 1 1 Drain Plug B 1 2 Composite gasket 4 3 Drain Plug A 1 4 Tubing Components 2 1 5 Bolt M6 16 4 6 Valve cover intake side 1 7 Valve cover ex...

Page 49: ...Valve cover intake side Valve cover exhaust side 4 Loosen Bolt NOTE Loosen the nuts in their proper loosening sequence number order Start by loosening each nut 1 2 turn until all are loose 5 Remove Bo...

Page 50: ...using a figure eight sanding paten NOTE Rotate the cylinder head cover several times for an even resurfacement CYLINDER HEAD COVER INSTALLATION 1 Install Dowel pins Cylinder head cover NOTE Apply the...

Page 51: ...CHAPTER 3 ENGINE M750L SERVICE MANUAL 18 0 CHAPTER 3 ENGINE PAGE 3 20 6 Install Composite gasket NEW Tubing Components 2 Composite gasket NEW Drain Plug B and Drain Plug A 7 Install Water Pump...

Page 52: ...parts in order Pipe A Exhause 1 Pipe B Exhause 1 Water Pump 1 Drain the coolant Air Cleaner 1 Cylinder head cover 1 Spark Plug cap 1 1 TB D46 Throttle Body Assembly D46 1 2 Bolt M8 25 2 3 Feed Hose A...

Page 53: ...moval procedure for installation CYLINDER HEAD REMOVAL 1 Align I mark a on the rotor with the stationary pointer b on the right crankcase cover NOTE If any special mark found contact the ATV manufactu...

Page 54: ...ankcase Remove the Tighten Bolt while holding the rotor mounting bolt with a wrench 5 Remove Cylinder head NOTE Loosen the nuts in their proper loosening sequence Start by loosening each nut 1 2 turn...

Page 55: ...cylinder head NEW Dowel Pin 14 16 Cylinder head NOTE Apply engine oil onto the nut threads Tighten the nuts in a crisscross pattern 2 Tighten Nuts cylinder head 3 Install Cam Chain Sprocket Timing ch...

Page 56: ...haft during installation of the cam shaft Dam age or improper valve timing will result While holding the camshaft temporarily tighten the bolts Remove the safety wire from the timing chain 4 Install S...

Page 57: ...ioner cap bolt Please in the thread place daub a little sealant 10 Install Split Washer d5 Decompression Centrifugal Shaft 11 Check Valve timing Out of alignment Adjust Repeat installing sequence 3 5...

Page 58: ...Remove the parts in order Cylinder Head Cover 1 1 Lock Rocker Arm Bolt 2 2 Washer d8 aluminum 2 3 Rocker Arm Shaft O Ring 9 8 2 4 2 4 Rocker Arm exhaust 1 5 Rocker Arm intake 1 Refer to ROCKER ARMS IN...

Page 59: ...Excessive wear Replace Inspect the surface condition of the rocker arm shafts Pitting scratches blue discoloration Replace or check lubrication Measure the inside diameter A of the rocker arm holes O...

Page 60: ...moval procedure for installation Rocker Arm Shaft O Ring 9 8 2 4 8 Install Rocker Arm intake Rocker Arm Shaft O Ring 9 8 2 4 NOTE Before installing the Rocker Arm Shaft O Ring 9 8 2 4 check the O Ring...

Page 61: ...discoloration Re place 2 Measure Cam lobes length a Out of specification Replace Cam lobes length Intake 33 945 34 045 mm Limit 33 745 mm Exhaust 33 547 33 647 mm Limit 33 35 mm 3 Inspect Cam shaft o...

Page 62: ...CHAPTER 3 ENGINE M750L SERVICE MANUAL 18 0 CHAPTER 3 ENGINE PAGE 3 31 3 Install Plate Locate Bolt 6 12 NOTE Apply Loctite 243 Blue to screw threads...

Page 63: ...Remove the parts in order Cylinder head 1 Refer to CYLINDER HEAD section Camshaft 1 Refer to CAMSHAFT section 1 Valve cotters 8 2 Spring retainer 4 3 Valve spring inner 4 4 Valve spring Outer 4 5 Val...

Page 64: ...compress so much as to avoid damage to the valve spring VALVE AND VALVE SPRINGS INSPECTION 1 Measure Valve stem diameter Out of specification Replace Valve stem diameter Intake 6 57 6 585mm Limit 6 5...

Page 65: ...ter Out of specification Replace Valve guide inside diameter Intake 6 6 6 615 mm Limit 6 63mm Exhaust 6 6 6 615 mm Limit 6 63 mm 7 Measure Stem to guide clearance Valve guide inside diameter Valve ste...

Page 66: ...nto the valve seat to make a clear pattern Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed If the valve seat is too wide too narrow or the...

Page 67: ...face and repeat the above steps NOTE Make sure to clean off all compound from the valve face and valve seat after every lapping operation Apply Mechanic s blueing dye Dykem b to the valve face Instal...

Page 68: ...outer Spring retainer NOTE Install the valve spring with the larger pitch a facing upwards bSmaller pitch 4 Instal Valve cotters NOTE Install the valve cotters while com pressing the valve spring with...

Page 69: ...on removal Remove the parts in order Cylinder head Refer to CYLINDER HEAD 1 Timing chain guide 1 section 2 Cylinder 1 3 Dowel pin 2 4 Cylinder gasket 1 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8...

Page 70: ...When removing the 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 Me...

Page 71: ...ance Cylinder bore Piston skirt 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 03 0 0...

Page 72: ...ston ring Top ring Limit 0 18mm 2nd ring 0 02 0 06mm Limit 0 15mm 2 Position 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 cyl...

Page 73: ...D when assembling When installing the spacer be careful so that the both edges are not overlapped Lubricate the pistons and piston rings liberally with engine oil 2 Install Piston Piston pin Piston pi...

Page 74: ...nder check that the gaps are so located D 2nd ring and lower side rail E upper side rail F 1ST ring and spacer 5 Lubricate Piston outer surface Piston ring Cylinder inner surface Engine oil 6 Install...

Page 75: ...LT CLUTCH AND SECONDARY PRIMARY SHEAVE COVER LEFT Order Job name Part name Q ty Remarks cover left removal Remove the parts in order 1 socket head cap screws m6x20 8 2 cvt big cover componets 1 3 out...

Page 76: ...ty Remarks V belt driven assy complete Remove the parts in order 1 primary sheave removal mounting bolt driving wheel 1 1 2 installation sleeve driving sheel 1 1 3 mounting bolt driven wheel 1 4 inst...

Page 77: ...the driving cluch puller remove the driving wheel DRIVEN ASSY AND V BELT REMOVAL 1 Remove Bolt driven assembly Plate washer Driven assembly V belt CLUTCH CARRIER INSPECTION 1 Inspect Scratches Glaze u...

Page 78: ...CHAPTER 3 ENGINE M750L SERVICE MANUAL 18 0 CHAPTER 3 ENGINE PAGE 3 47 sheave and secondary sheave 2 Measure V belt width Out of specification Replace V belt width 29 2mm Limit 27 6 mm...

Page 79: ...removal Drain the engine oil Remove the parts in order Refer to ENGINE OIL REPLACEMENT section 1 Couplers A C magneto lead 1 NOTE 2 Couplers Pick up coil lead 1 Disconnect the couplers 3 Magneto cover...

Page 80: ...er Job name Part name Q ty Remarks A C magneto and starter clutch removal Remove the parts in order 1 Rotor 1 Refer to A C MAGNETO ROTOR REMOVAL INSTALLATION section 2 Starter torque limiter 1 3 idle...

Page 81: ...2 Remove Rotor Woodruff key NOTE special tools and equipment flywheel puller Remove the rotor with the flywheel puller Screw the flywheel puller in the rotor Make sure the threaded connections of the...

Page 82: ...r teeth Starter torque limiter teeth Burrs chips roughness wear Replace 2 Check Starter clutch operation 1 Install the starter driven gear onto the starter clutch 2 Turn the starter driven gear by han...

Page 83: ...rter torque limiter holder A Starter torque limiter socket B Starter torque limiter slip torque Standard 41 2 62 8N m 4 2 6 4kgf m Starter driven gear bearing Inspect the starter driven gear bearing f...

Page 84: ...r Woodruff key NOTE Install the starter wheel gear then install the woodruff key Engine oil 3 Install Rotor Plain washer rotor Nut rotor NOTE Clean the tapered portion of the crankshaft and the rotor...

Page 85: ...he mating surface of the left crankcase 2 Oil road plug 1 3 Right crankcase 1 4 Engine mount bushing 4 5 Tubing components 1 1 6 Needle roller bearing baffle 4 7 O ring 8 8X1 9 2 Apply grease 8 Tubing...

Page 86: ...2U to left crankcase 28 Seal 1 29 Bearing 6004 2 30 Bearing 5206 1 31 Bearing 6205 3 32 Bearing 6204 1 33 Bearing 61805 1 34 Locating pin 10X16 2 35 Needle roller bearings NK20 16 2 36 Locating pin 8X...

Page 87: ...SHAFT Order Job name Part name Q ty Remarks 1 Locknut M35x1 5 1 Apply Loctite 243 Blue Tightening torque 150N m Lock the crank balancer drive gear nut with a center punch CAUTION the removed nut must...

Page 88: ...r 1 Align the punch mark as shown in the figure 12 Crank balancer driven gear B 1 13 Crank balancer driven gear A 1 CRANKSHAFT INSPECTION 1 Measure Crankshaft runout Out of specification Replace crank...

Page 89: ...HAPTER 3 ENGINE PAGE 3 58 3 Measure Crank width Out of specification Replace crankshaft Crank width 73 95 74 05 mm 4 Inspect Crankshaft sprocket Wear Damage Replace crankshaft Crankshaft journal Clogg...

Page 90: ...V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE section 1 Cvt small cover componets 1 2 Wash B small cover 1 3 Wash A small cover 1 4 Left cover 1 Apply bond to the mating surface of the left cover CAUTIO...

Page 91: ...y hand and check that it moves smoothly If it does not move smoothly Replace the oil pump assembly 2 Measure Tip clearance between the inner rotor and the outer rotor Side clearance between the outer...

Page 92: ...ply Loctite 243 Blue to the oil pump bolts 2 Install the new snap ring 2 Install Oil pump drive gear and chain NOTE 1 Install the oil pump drive gear with chain 2 The flange side of the oil pump drive...

Page 93: ...CHAPTER 3 ENGINE M750L SERVICE MANUAL 18 0 CHAPTER 3 ENGINE PAGE 3 62 3 13SHIFT SYSTEM...

Page 94: ...7 Parking stalls shift drum 1 Align the punch mark as shown in the figure 8 Gearshift cam stopper plate 1 9 In the car stalls plectrum 1 10 Gearshift fork shaft 1 11 Low reverse gearshift fork 1 12 Re...

Page 95: ...rking brake disc 1 6 Counter shaft 1 7 Parking switch plate 1 8 Washer 25 2 3 9 Ring 25 3 10 High driven gear 1 11 High gearshift dog 1 12 Vice shaft spline housing 2 13 Reverse driven gear 1 14 Gear...

Page 96: ...TER 3 ENGINE PAGE 3 65 15 Low reverse gearshift dog 1 16 Low driven gear 1 17 Intermediate gear 1 1 18 Counter shaft plug 1 19 Slotted head screws M5x14 4 Apply Loctite 243 Blue to screw threads and t...

Page 97: ...ob name Part name Q ty Remarks 1 Idler wheel 2 1 2 Drive bevel gear 1 3 Rear output shaft 1 4 Driven bevel gear 1 5 Bearing braket 1 6 locking nut M20x1 5 1 Tightening torque 100N m Lock the drive bev...

Page 98: ...e bearing 32NQ5419 1 14 Bearing braket rear output shaft 1 15 O ring 59 6x3 5 1 Apply grease 16 Shim optional 2 17 Bearing 5205 1 18 Washer 52 1 19 Seal 35x54x8 1 Apply grease 20 Stud bolts M8x38 2 Ap...

Page 99: ...st the tooth contact and backlash until they are both within specification If the correct tooth contact cannot be maintained when adjusting the backlash replace the rear output shaft drive and driven...

Page 100: ...der 11 Bearing seat front drive shaft order 3 Wire ring 21x1 3 order 6 Front drive shaft order 1 Sleeve front drive shaft order 4 1 Front drive shaft 1 2 Spline sets 1 3 Bearing braket front drive sha...

Page 101: ...coolant Remove the parts in order Refer to COOLANT REPLACEMENT section 1 Fan motor leads 1 2 Cool fan thermo switch leads 1 3 Inlet hose radiator 1 4 Outlet hose radiator 1 5 Pipe storage tank 1 6 Pip...

Page 102: ...urn replace the cooling fan assembly with a new one NOTE 1 When making this test it is not necessary to remove the cooling fan 2 The voltmeter is for making sure that the battery applies 12 V to the m...

Page 103: ...Connect the thermo switch 1 to a circuit tester and place it in the water A contained in a pan which is placed on the stove 4 Heat the water to raise its temperature slowly and read the column thermom...

Page 104: ...ER PUMP Order Job name Part name Q ty Remarks Water pump removal Remove the parts in order Drain the coolant Refer to COOLANT REPLACEMENT section 1 Hose water pump 1 2 Hose radiator 1 3 Bypass hose 1...

Page 105: ...ylinder head 1 2 Minor cycle conduit 1 3 Inlet hose radiator 1 4 Thermostatic holder 1 5 Thermostatic cover 1 6 Thermostatic valve 1 7 Thermostatic shell 1 Reverse the removal procedure for installati...

Page 106: ...sealed and its setting requires specialized work If its accuracy is in doubt replace A faulty unit could cause serious over heating or over cooling 2 Inspect Thermostatic cover Cracks damage Replace...

Page 107: ...oling parts removal Drain the engine oil Remove the parts in order Refer to ENGINE OIL LEVEL INSPECTION section 1 Oil cooling hose A 1 2 Oil cooling hose B 1 3 Oil filter 1 4 O ring 2 5 Oil filter mou...

Page 108: ...month thereafter Oil filter replacement at the above intervals should be done together with the engine oil change Engine oil change refer to ENGINE OIL LEVEL INSPECTION section 2 Inspect Oil cooling h...

Page 109: ...guide lines 3 18 2 11 Replacement Techniques 3 18 2 12Interchange ability 3 18 2 13Plugging 3 18 2 14Cleaning Procedure 3 18 3 Throttle Body As sembly with stepper motor 3 18 3 1 Description and Worki...

Page 110: ...Appearance Components of Fuel Module 3 18 8 3 Dimensions 3 18 8 4 Identification and Markings 3 18 8 5 Operating Conditions 3 18 8 6 Service Procedure 3 18 8 7 Fuel Module Diagnosis 3 18 8 8 Fuel Modu...

Page 111: ...e optimizing vehicle drivability for all operating conditions The ECU also provides diagnosis when system malfunctions occur 3 18 1 2 Appearance The MT05 ECU has a polyester header with an aluminum ba...

Page 112: ...Down mode The preparation involves storing important information into EEPROM Reset During reset all outputs shall be set to a predefined state The controller shall monitor itself for proper operation...

Page 113: ...lue color For low temperature applications Viton A black All other applications Injector to manifold Dimensions ID 9 61 mm OD 14 49 mm Cross section 2 44 mm Materials Viton A black or brown other appl...

Page 114: ...of the ability to comply with the flow tolerance requirements after exposure to the following temperature environments Also they will not experience unacceptable external leakage any type of physical...

Page 115: ...n fuel injectors to correct any malfunction Can damage injector DO NOT Replace the injector with other part number not recommended for this application Will severely affect the performance of the inje...

Page 116: ...The following procedure outlines standard Multec 3 and Multec 3 5 Fuel Injectors removal and replacement Warning The injector and all associated hardware may be extremely hot Shut off ignition Discon...

Page 117: ...ion Relieve the fuel pressure in the system and disconnect the fuel connection at the injector Plug the fuel feed line Injector cleaner with the specific ratio of the cleaner and gasoline to be mixed...

Page 118: ...e of throttle position sensor coupler stepper motor coupler and MAP MAT sensor coupler if this sensor is mounted on the throttle body Disconnect accelerator cable from throttle body Remove air cleaner...

Page 119: ...the by pass passage after removing bottom cover To ensure good idle stability DO NOT Use any dropped or impacted unit Internal damage may have occurred or emissions settings may have been upset DO NO...

Page 120: ...sure When installed at the minimum torque the sensor shall be capable of sealing engine coolant with a positive pressure of 206 8 kPa 30 psi at 135 C applied to the probe tip end of the sensor Extreme...

Page 121: ...mperature excursion to 125 C for 2 hours 3 18 5 4 Storage Environment Storage temperature 50 C to 150 C for an indefinite duration 3 18 5 5 Electrical Environment Typical Voltage The sensor circuit op...

Page 122: ...sured basing on 21 C Operating temperature range 260 850 C 3 18 6 4 Fuel Quality Requirements Pb 0 005g L P 0 0002g L S 0 04 weight proportion x MMT 0 0085g L Si 4ppm 3 18 7 Ignition Coil 3 18 7 1Desc...

Page 123: ...ary tower Use tools designed for secondary removal It is possible to damage a secondary lead in such a manner that creates an electrical path to outside the system permitting improper system operation...

Page 124: ...of the electrical components The electrical connections are not designed for repeated connection and disconnection DO Insure the low voltage connectors are entirely seated and the locking mechanism is...

Page 125: ...nter up the center electrode insulator Allow plug to cool down 4 If the spark plug threads have carbon scale deposits clean with wire brush taking care not to injure the electrode or the insulator tip...

Page 126: ...flow to generate the system pressure Pressure Regulator Pressure Regulator is a diaphragm type mechanical device Fuel flow from filter enters in the inlet of pressure regulator Pressure regulator regu...

Page 127: ...at high pressures when the engine is stopped loosening or disconnecting fuel line will cause dangerous spout of fuel Before loosening disconnecting fuel lines please follow the Fuel Pressure Relief P...

Page 128: ...on Disconnect negative cable at battery Disconnect fuel module wire coupler Drain the fuel in fuel tank thru fuel filler with help of hand pump siphon Collect the fuel in approved container for contam...

Page 129: ...of regulator assembly Make sure that 2 O rings one is bigger diameter the other is smaller diameter are assembled in pressure regulator Place the pressure regulator on module at regulator pod Push the...

Page 130: ...l tank Not intended function of fuel module DO NOT Use module mounting bolts for mounting other components Affects fuel module sealing DO NOT Damage fuel pump harness while servicing fuel module Damag...

Page 131: ...screen is unstable when first turned on disconnect it from the main lead and try again Make sure the DLC is always firmly inserted into the diagnostic socket Never test electrical signals that exceed...

Page 132: ...light for displaying all the information during testing Keyboard There are 5 keys one is reserved on the main unit for selecting and controlling test steps 3 18 9 1 3 Preparations Connection Find the...

Page 133: ...lear DTC Data Stream Status Stream and Record Data Op e r a t i o n s When the unit is powered up the screen will display the interface as below Here we take diagnostic function for demonstration Sele...

Page 134: ...rface to indicate Delphi 3 diagnostic connector should be used Press the screen will display engine information as below Press with accessing system fleeting on the screen then it will display as belo...

Page 135: ...is in front of it press the screen will display detailed information of the code as below 2 Clear DTC Select Clear DTC and press it will display as below 3 Data Stream Select Data Stream and press it...

Page 136: ...to confirm and continue to input the sequent numbers till all the 7 numbers were input When all the 7 numbers were set press the screen will display a message for confirmation of the Plate Number inpu...

Page 137: ...CHAPTER 3 ENGINE PAGE 3 106 Then Enter Year continues as below After that Enter Week follows as below Till now the date input was completed and it starts to record data press to stop recording Check m...

Page 138: ...ltage P0131 O2A 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 Circ...

Page 139: ...ifferent types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts information and service 4 1 A RM RE...

Page 140: ...ten the nuts only finger tighten at this time They will be tightened to the final torque after the front wheels are installed and the vehicle is on the ground WARNING DO NOT reuse old bolts Serious in...

Page 141: ...ing and collapse strut body 5 Remove two pinch bolts from strut body 6 Remove strut body 7 Install front shock cartridge until bottomed in strut casting 8 Install pinch bolts with clamp s Torque pinch...

Page 142: ...unting bracket 7 Using ball joint cup removal installation toolkit remove ball joint cup from strut housing Refer to photos at right Install puller guide 1 Thread bolt 2 with nut 3 onto bal joint stud...

Page 143: ...STEERING POST ASSEMBLY Note 1 Hand tighten the crown nut of the steering post 2 Align cotter pin hole 3 Install cotter pin Bend both ends of cotter pin around nut in opposite directions 4 Check steeri...

Page 144: ...CHAPTER 4A CHASSIS M750L SERVICE MANUAL 18 0 CHAPTER 4 CHASSIS PAGE 4 6 NOTES...

Page 145: ...and service 5 1 WHEEL HUB AND SPINDLE TORQUE TABLE 5 2 FRONT HUB DISASSEMBLY INSPECTION 5 3 FRONT HUB REMOVAL INSPECTION 4x4 ATV500 5 3 b FRONT HUB INSTALLATION 4X4 ATV500 5 4 FRONT HUB BEARING REPLA...

Page 146: ...ls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 2 Check bearings for side play by grasping tire wheel firmly and checking for...

Page 147: ...y by grasping the tire Wheel firmly and checking for movement Grasp The top and bottom of the tire The tire should rotate smoothly without binding or rough spots 3 Remove wheel nuts and wheel 4 Remove...

Page 148: ...ing or rough spots or side play 9 Install brake caliper using new bolts Tighten bolts to specified torque CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use...

Page 149: ...ear or damage Replace housing if damaged 5 5 FRONT DRIVE AXLE INNER AND OUTER CV JOINT REMAVAL INSPECTION 4X4 NOTE The outer CV joint cannot be disassembled or repaired if damage or faulty the drive a...

Page 150: ...p the in inner CV joint out from the front differential INSPECTION NOTE The boots are subjected to a lot of abuse if the vehicle is ridden in rough terrain If the boots are damage and left un repaired...

Page 151: ...the strut install the front hub and wheel 5 Install the ball joint on the A arm the steering tie rods the hubs and the wheels as described in this Chapter and Chapter 4 5 7 FRONT DRIVE AXLE DISASSEMB...

Page 152: ...alls from the bearing cage then remove the bearing race from the bearing cage 5 If any of the components of the bearing assembly are damaged replace the entire assembly as no replacement parts are ava...

Page 153: ...outboard boot was removed install a new boot onto the drive axle at this time NOTE Position the new boot bands with their tabs facing toward the rear of the vehicle 3 Install 2 new small boot bands on...

Page 154: ...the stopper ring Make sure it is seated correctly in the inboard joint groove 11 After the stopper ring is in place fill the inboard joint cavity behind the bearing assembly with additional molybdenum...

Page 155: ...down the tab on the boot band and secure the tab with the locking clip and tap them with a plastic hammer Make sure they are locked in place 18 If removed install the stopper ring and make sure it is...

Page 156: ...ng shaft nut than remove the nut 3 Remove the rear disc brake caliper 4 Remove the link RR Stabilizer 5 Remove the mounting bolt of rear shock absorber and upper and lower A arm Takedown the A arm com...

Page 157: ...rear hub 8 Remove oil seal 9 Remove the snap spring of the rear hub 10 Using bearing extractor to take down the hub bearing Notice when reassembling hub bearing that were removed and rear hub which a...

Page 158: ...6X22 H Bolt M8X25 I Bolt M6X40 J Oil seal 22X48X11 K Oil drain plug L Washer 12 M Diff 4WD cover N Electromagnetic valve O Bead flange P Input shaft Q Oil seal 35X62X7 R Housing cover S Housing 5 10 2...

Page 159: ...the input shaft with the bearing 6007 B 4 Remove the splined dog A then remove the housing cover B Remove the D52 lock snap ring C then remove the pinion with the bearing 6205 D 5 Remove the differen...

Page 160: ...cessive play between inner and outer race Inspect detent spring and finger spring for wear cracks relaxation Replace part with any defects IMPORTANT New seals should be installed after the transmissio...

Page 161: ...D with the D35 lock snap ring F install the bead flange G to the input shaft D Components A Diff lock cover B D8 lock snap ring C Diff fork pivot D Return spring 1 E Diff lock pawl spring F Return spr...

Page 162: ...ssy D with paper washer B locating pin C tighten the screws E torque bolts to 8ft lbs 12Nm Put the splined dog F into the housing cover install diff lock cover assy H with paper washer A locating pin...

Page 163: ...ointor A into the housing Install the electromagnetic valves B torque bolts to 40ft lbs 54Nm Install oil drain plug D and washer C torque bolt to 21ft lbs 28Nm Add 450 ml gear oil then install diff fi...

Page 164: ...ng cover 20 Bearing 6007 21 Bolt M8X15 22 Diff carrier cover 23 Bevel crownwheel 24 Washer 25 Bevel gear 26 Roll pin 27 Center pin 28 Bevel pinion washer 29 bevel pinion 30 Center spacer 31 Differenti...

Page 165: ...er Remove the lock nut using the special tool 7 Remove the pinion bearing assembly 5 11 2 REAR GEAR CASE ASSEMBLY 1 Drive the pinion gear assembly into the drive housing 2 Install a new lock nut and t...

Page 166: ...ve assembly and hold it Set a horizontal type dial indicator on the ring gear through the filler hole Turn the ring gear back and forth with the drive shaft to read backlash STANDARD 0 05 0 25mm SERVI...

Page 167: ...2 65 5 BOLT M8X28 6 BOLT M10X1 25X28 7 WASHER 35 5 8 O RING 20X3 9 NUT M16X1 5 10 OUTPUT AXLE RING REAR GEAR BOX 11 INPUT AXLE RING REAR GEAR BOX 12 LOCK NUT 13 SEAL 35X55X11 14 SEAL 38X85X8 15 SEAL 3...

Page 168: ...CHAPTER 5 FINAL DRIVE LH500ATV D SERVICE MANUAL 14 0 CHAPTER 5 FINAL DRIVE 5 24 NOTES...

Page 169: ...G PROCEDURE 6 5 FLUID REPLACEMENT BLEEDING PROCEDURE 6 6 HAND BRAKE MASTER CYLINDER REMOVAL INSPECTION INSTALLATION 6 7 FRONT PAD REMOVAL INSPECTION INSTALLATION 6 8 FRONT DISC INSPECTION REMOVAL REPL...

Page 170: ...7 4 242mm Brake Disc Thickness Variance Between Measurements 0 002 0 051m m Brake Disc Run out 0 005 0 12 7m m 6 2 TORQUE Item Torque ft lbs except where noted Torque Nm Front Caliper Mounting Bolts 1...

Page 171: ...pads both hydraulic and mechanical must be burnished to achieve full braking effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the brake pads...

Page 172: ...phragm from reservoir 3 Inspect vent slots in cover and remove any debris or blockage 4 If changing fluid remove old fluid from reservoir with a brake fluid pump or similar tool NOTE Do not remove bra...

Page 173: ...intain level in reservoir CAUTION Maintain at least 1 2 13mm of brake fluid in the reservoir to prevent air from entering the master cylinder 10 Tighten bleeder screw securely and remove bleeder hose...

Page 174: ...hed surfaces Do not allow brake fluid to come in contact with finished surfaces 3 Remove master cylinder from handlebars INSPECTION Inspect parking brake for wear If teeth or locking cam are worn repl...

Page 175: ...Severe injury m ay occur if machine tips or falls 2 Remove the front wheel 3 Remove caliper from mounting bracket 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with...

Page 176: ...ake system 5 Install the adjuster screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counter clockwise 6 Install reservoir cap Hand and or Foot Brake Master Cylinder s...

Page 177: ...contact the ATV manufacture via the agent for the parts and special instruction REMOVAL 1 Remove wheel remove caliper from the strut 2 Loosen and remove brake hose s to caliper Place a container unde...

Page 178: ...liper bore slowly with pads installed NOTE Brake fluid will be forced through compensating port into m aster cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from r...

Page 179: ...a flare nut wrench remove hose s Place a container to catch brake fluid draining from brake hose 3 Remove caliper 4 Remove brake pad as described above 5 Inspect surface of caliper for nicks scratches...

Page 180: ...l indicator Replace disc if worn beyond service limit Brake Disc Thickness New0 177 0 187 4 496 4 750mm Service Lim it 0 167 4 242 mm Brake Disc Thickness Variance Service Limit 0 002 0 051mm differen...

Page 181: ...13 6 13 FOOT BRAKE PEDAL FOR B TYPE ADJUSTING If the push rod joint is reinstalled adjust the push rod length so that the distance between the centers of the master cylinder lower mounting bolt hole a...

Page 182: ...CHAPTER 6 BRAKES M750L SERVICE MANUAL 18 0 CHAPTER 6 BRAKES PAGE 6 14 NOTES...

Page 183: ...7 3 IGNITION SYSTEM 7 4 CHARGING SYSTEM 7 5 ELECTRICS STARTING SYSTEM 7 6 COOLING SYSTEM 7 7 LIGHTING SYSTEM 7 8 GEAR POSITION INDICATOR SWITCH TEST 7 9 SPEEDOMETER SYSTEM 7 10 MAIN SWITCH AND HANDLE...

Page 184: ...CHAPTER 7 ELECTRICAL M750L SERVICE MANUAL 18 0 CHAPTER 10 ELECTRICAL 10 2...

Page 185: ...he headlight beam can be adjusted vertically all models and horizontally except the light on handlebar 2 Place the vehicle on a level surface with the headlight approximately 25 7 6m from a wall 3 Mea...

Page 186: ...Never add electrolyte after a battery has been in service NOTE New Battery must be fully charged before use 1 Remove vent plug from vent fitting 2 Fill battery with electrolyte to upper level marks on...

Page 187: ...be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test MF Maintenance Free battery does not require th...

Page 188: ...aulty Terminal 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 c...

Page 189: ...CHAPTER 7 ELECTRICAL M750L SERVICE MANUAL 18 0 CHAPTER 10 ELECTRICAL 10 7 LH700ATV EFI MODEL...

Page 190: ...rk plug cap resistance entire ignition system 6 Ignition coil 1 Fuse NO CONTINUITY Check switches Replace the fuse CONTINUITY 2 Battery INCORRECT Check the battery condition Refer to BATTERY INSPECTIO...

Page 191: ...nimum spark gap 6mm 0 24 in OUT OF SPECIFICATION OR NO SPARK Tester lead Spark plug side Tester lead High tension cord side 5 Resistive cable with Spark plug cap resistance Remover the spark plug cap...

Page 192: ...to the ignition coil Check if the primary coil has the specified resistance Primary coil resistance 0 58 0 058 20 Tester lead Connector side Right Tester lead Resistive cable side Remover the resisti...

Page 193: ...OUT OF SPECIFICATION Check the pickup coil has the specified resistance Primary coil resistance 168 252 20 Replace the pickup coil NO CONTINUITY MEETS SPECIFICATION 8 Main switch CHECK SWITCHES Repla...

Page 194: ...n series with the negative battery cable Check for current draw with the key off if the draw is excessive loads should be disconnected from the system one by one until the draw is eliminated Check com...

Page 195: ...Measure the battery terminal voltage start the engine and accelerate to about 5 000rpm check the terminal voltage Measured voltage terminal Voltage 0 2 2 5V up NOTE Use a fully changed battery MEETS...

Page 196: ...SERVICE MANUAL 18 0 CHAPTER 10 ELECTRICAL 10 14 MEETS SPECIFICATION 5 Wiring connection check the entire charging system for connections Refer to CIRCUIT DIAGRAM POOR CONNECTION correct CORRECT Repla...

Page 197: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 8 15 7 5 ELECTRICS STARTING SYSTEM DI AGRAM...

Page 198: ...ear brake switch 9 starter switch 10 wiring connection entire starting system 1 fuse refer to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BA...

Page 199: ...equivalent capacity as that of the battery lead or more otherwise it may burn This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity CONTINUITY Replace the...

Page 200: ...ch 7 Engine stop switch NO CONTINUITY Replace the handlebar switch 8 Front rear brake switch CHECKING SWITCHES NO CONTINUITY Replace the brake switch 9 Starter switch CHECKING SWITCHES NO CONTINUITY R...

Page 201: ...motor inspection 3 Relay 6 Thermo switch 7 Wiring connection entire cooling system 1 fuse CHECK SWITCHES NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTI...

Page 202: ...OT MOVE The wiring circuit from battery to fan motor is faulty Repair 6 Thermo switch Remove the thermo switch from the radiator Connect the pocket tester X1 to the thermo switch Immerse the thermo sw...

Page 203: ...APTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 8 21 7 Wring connection Check the connection of the entire cooling system Refer to CIRCUIT DIAGRAM UPPER CONNECTION Correc...

Page 204: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 8 22 7 7 LIGHTING SYSTEM...

Page 205: ...system 1 fuse refer to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section in CHAPTER 3 INCORRECT Clean battery terminal...

Page 206: ...am indicator light fail to come on 1 Blub and bulb socket CHECK SWITCHES NO CONTINUITY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC20V to the headlight and high beam indi...

Page 207: ...ket CHECK SWITCHES NO CONTINUITY Replace the bulb and or bulb socket CONTINUITY 2 Voltage Connect the pocket tester DC20V to the bulb socket connector Tester lead Black terminal Tester lead Green term...

Page 208: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 8 26 7 8 GEAR POSITION INDICATOR SWITCH TEST DI AGRAM...

Page 209: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 8 27...

Page 210: ...SPPED SENSOR Speed Sensor on the Transmission Out Put Shaft Operation Instructions of LCD Meter and Speed Sensor Main Technical Parameter Item Code Vol value Unit Operating voltage Vcc 5 20 V Operatin...

Page 211: ...WD indicator 8 Fuel gauge Indicator 2 Front diff lock 9 Gear position 3 Neutral indicator light 10 Engine working hour counter 4 High beam indicator light 11 km mile selector 5 Speedometer 12 Engine r...

Page 212: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 8 30 7 10 MAIN SWITCH AND HANDLE SWITCH HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL...

Page 213: ...m the fuel tank 2 Measure the resistance with an ohmmeter across the sensor terminal and its body 3 If the reference values are not indicated the sensor is faulty Resistan ce Sensor terminal its body...

Page 214: ...CAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 8 32 What displays on instrument while fuel sensor is in its upright position What displays on instrument while fuel sensor is in its ups...

Page 215: ...OCK SHIFT Fig 1 1 The rider shifts by the Switch on handlebar 2 The Switch gives signal to Controller 3 The controller gives power to the solenoid During this time the 4WD Diff lock indicator is not o...

Page 216: ...tion NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section in CHAPTER 3 INCORRECT Clean battery terminals Recharge or replace the battery 3 Main swit...

Page 217: ...Brown terminal Green Orange terminal INCORRECT Replace the controller 6 solenoid Disconnect the solenoid from the wire harness Connect the solenoid to the battery Battery lead Dark Brown terminal Batt...

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