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CHAPTER 3 ENGINE

ATV SERVICE MANUAL 2005/

version number 0501

CHAPTER 3 ENGINE PAGE. 3- 26

3.5VALVES AND VALVE SPRINGS

Order

Job name / Part name

Q ’ty

Remarks

1

2
3
4
5
6
7
8

Valves and valve springs removal
Cylinder head
Rocker arm , rocker arm shaft

Valve cotters

Spring 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 SHAFT AND
ROCKER ARMS" section.
Refer to "VALVES AND VALVE SPRINGS
REMOVAL/INSTALLATION" section.

Refer to "VALVES AND VALVE SPRINGS
INSTALLATION" section

Reverse the removal procedure for installation

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Summary of Contents for LH400CUV-2

Page 1: ...LH400CUV 2 SERVICE MANUAL ...

Page 2: ...y anyone without this knowledge are likely to render the vehicle unsafe and unfit for use Linhai Group is continually striving to improve all its models Modifications and sig 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 specifications are subject to change with...

Page 3: ...ng the vehicle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle NOTE A NOTE provides key information to make procedures easier or clearer CONTENTS CHAPTER1 General Information CHAPTER2 Maintenance CHAPTER3 Engine CHAPTER4 Chassis CHAPTER5 Final Drive CHAPTER6 Transmission CHAPTER7 Brakes CHAPTER8 Electrical ...

Page 4: ...tains 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 service when the engine is warm or hot Escaping steam from cooling system or hot oil from the machine can cause severe burns The engine must be cool before service Crate of the UTV and parts in the UTV ma...

Page 5: ... 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 CUV model for spare parts information and service 1 1 IMPORTANT INFORMATION 1 2 V I N AND ENGINE SERIAL NUMBER 1 3 VEHICLE DIMENSIONS ...

Page 6: ...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 rings when overhauling the engine All gasket surfaces oil seal lips and O rings must be cleaned 2 Properly oil all mating parts and bearings during reassembly Apply grease to the oil seal lips LOCK WASHERS PLATES AND COTTER PINS Replace all lock washer...

Page 7: ...here 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 connector as shown Never run an engine in an enclosed area Carbon monoxide exhaust gas is poisonous and can cause severe injury or death Always start engines outdoors Gasoline is extremely flammable and explosive under certain conditions Battery electrolyt...

Page 8: ...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 6214 3 281 1 094 0 3927 0 03927 mph mi ft yd in in Volume Capacity cc cm3 cc cm3 lit liter lit liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centi...

Page 9: ...SERVICE MANUAL 09 0 CHAPTER 1 GENERAL 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 stamped into left side of engine crankcase ...

Page 10: ...CHAPTER 1 GENERALINFORMATION CUV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 6 1 3 VEHICLE DIMENSIONS Note The on road equipments rear view mirror turn lights etc are not Standard Equipment for USA ...

Page 11: ...CHAPTER 1 GENERALINFORMATION CUV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 7 NOTES 12 ...

Page 12: ...even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 2 1 PERIODIC MAINTENANCE 2 2 THROTTLE PEDAL INSPECTION 2 3 CHOKE ADJUSTMETN 2 4 FUEL SYSTEM 2 5 TOE ALIGNMENT 2 6 BRAKING SYSTEM INSPECTION 2 7 SUSPENSION SPRING RPELOAD ADJUSTMENT 2 8 WHEELS 2 9 TIRE PRESSURE 3 0 FRAME NUTS BOLTS FASTENERS ...

Page 13: ...peed of approximately 16km h 10 miles per hour 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 Inspection may reveal the need for replacement parts Always use genuine parts available from your dealer Service and adjustments are critical If you are not familiar...

Page 14: ...ad wear 10 Monthly I Gear case Oil 10 Monthly C 150 annually R Engine Cylinder Head and Cylinder Base Fasteners 25 3 months I re torque required at first service only General Lubrication all fittings pivots cables etc 25 3 months L Engine Oil Level Daily I Engine Oil Change 30 hrs 3 months R Break in Service at 1 month Change oil more often in cold weather use Oil Filter 50 hrs 6 months I C Engine...

Page 15: ...onths I Adjust as needed DL Fuel System 100 hrs 12 months Check for leaks at tank cap lines fuel valve filter and carburetor Replace lines every 2 years DL Fuel Filter 100 hrs 12 months R Radiator 100 hrs 12 months I R Cooling System hoses 50 hrs 6 months I R if necessary Spark arrestor 10 hrs monthly C R if necessary DL Clutches drive and Driven 25 hrs 3 months I R R if necessary Engine mounts 25...

Page 16: ...lly or at 100 hours 4 Rear Gear case oil SEA 80W 90GL5 Add to proper level Change annually or at 100 hours 5 Front Gear case oil only for 4WD Model SEA 80W 90GL5 Add to proper level Change annually or at 100 hours 6 Steering system Grease Lubricate the pivoting and sliding parts Every 3 months or 50 hours 7 Tie rods Grease Grease Semi annually 8 Shift Linkages Grease Locate fittings and Grease Sem...

Page 17: ...CHAPTER 2 MAINTENANCE CUV SERVICE MANUA 09 0 CHAPTER 2 MAINTENANCE PAGE 2 6 ...

Page 18: ...not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal play periodically in accordance with 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 warm it up thoroughly 4 ...

Page 19: ...efueling is performed 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 your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are p...

Page 20: ...e replaced in accordance with the Periodic Maintenance Chart or whenever sediment is visible in the filter 1 Remove line clamps at both ends of the filter 2 Remove fuel lines from filer 3 Install new filter and calmps onto fuel lines with arrow pointed in direction of fuel flow 4 Install clamps on fuel line 5 Start engine and inspect for leaks 2 5 TOE ALIGNMENT METHOD STRAIGHTEDGE OR STRING Be sur...

Page 21: ... Use DOT 3 brake fluid NOTE Use new brake fluid or brake fluid from 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 surface condition of the disc BRAKE PAD INSPECTION Pads should be changed when friction material is worn to 3 64 1mm HOSE FITTING INSPECTION ...

Page 22: ...ever 2 Loosen the jam nut of the adjuster on the caliper 3 Turn the adjuster bolt CW clockwise by hand till the pad touch the brake disc turn the adjuster bolt CCW counterclockwise by 1 4 to one turn for 10 to 20mm free play at the end of the parking lever 4 Tighten the jam nuts securely against the adjusters 5 Make sure the rear wheels turns freely without dragging 6 Turn the adjustor the one on ...

Page 23: ...r suspension Damping should be smooth throughout the range of travel Check all rear suspension components for wear or damage Inspect shock for leakage Shock spring preload can be adjusted using the shock spanner wrench Always adjust both shock absorber spring preload to the same setting Uneven adjustment can cause poor handling and loss of stability Turn the adjuster 1 to increase or decrease the ...

Page 24: ...eel nuts to the proper Torque listed in the table On wheel nuts Make sure tapered end of nut goes into taper on wheel Wheel Nut Torque Specifications CAUTION If wheels are improperly installed it could affect Vehicle handling and tire wear 2 9 TIRE PRESSURE TIRE INSPECTION CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle Improper tire inflation ...

Page 25: ...se the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3mm or less 3 0 FRAME NUTS BOLTS FASTENERS Periodically inspect the tightness of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each cha...

Page 26: ...CHAPTER 2 MAINTENANCE CUV SERVICE MANUA 09 0 CHAPTER 2 MAINTENANCE PAGE 2 15 NOTES ...

Page 27: ... 3 2 2 IDLING SPEED ADJUSTMENT 3 2 3 SPARK PLUG INSPECTION 3 2 4 COMPRESSION PRESSURE 3 2 5 ENGINE OIL LEVEL INSPECTION 3 2 6 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 CLUTCH AND SECONDARY PRIMARY SHEAVE 3 8 A C MAGNETO AND STARTER CLUTCH 3 9 OIL PUMP 3 10 CRANKCASE AND CRANKSHAFT 3 11 COOLING SYSTEM 3 11...

Page 28: ...hain Cam chain type No of links DID 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 mm 11 95 mm Valve Valve seat Valve guide Valve clearance cold IN Valve dimensions EX 0 08 0 12 mm 0 16 0 20 mm A head diameter IN EX B face width IN EX C seat width I...

Page 29: ...3 mm 30 1 mm 31 6 mm 7 8 9 0 kg 37 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 17 991 18 000 mm 0 15m m 18 045 mm 17 975 mm Piston pin outside diameter Piston rings Top ring Type End gap installed Side clearance installed 2nd ring Type End gap i...

Page 30: ... width 22 6 mm 21 0 mm Carburetor Type I D mark Ventuly outside diameter Main jet M J Jet needle M A J Throttle valve size J N Pilot air jet Th V Needle jet P A J 1 Pilot outlet N J Pilot jet P O Bypass B P Pilot screw P S Valve seat size V S Starter jet 1 G S 1 Float height F H Engine idle speed Intake vacuum CVK CVK32 φ47 138 NPCA φ31 11 φ2 6 φ3 4 140 φ0 7X4 1 7 8 φ1 2 140 17 1 350 1 650 r m 30k...

Page 31: ...Radiator Type Width height thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Cooling fin with electric fan 360 246 68 mm 110 140kPa 1 1 1 4kg cm 2 1 1 1 4bar 2 L 0 35 L Thermostatic valve Valve opening temperature Valve full open temperature Valve full open lift 70 74 83 4 mm ...

Page 32: ...er neck supporting Oil pump Oil pump cover Drain plug Carburetor joint Carburetorjointandcarburetor Fuel pump Exhaust pipe assembly Crankcase left and right Drain bolt Oil filer Crankcase cover left Magnet cover _ _ _ Bolt Nut Bolt Bolt Nut Nut Bolt Bolt Bolt Bolt Bolt Bolt _ Bolt Bolt Screw Bolt Bolt Bolt Nut _ Nut Bolt Bolt Bolt Bolt _ M 6 M 8 M12 M 6 M 8 M 6 M 6 M16 M 6 M 6 M10 M 6 M8 M 6 M 6 M...

Page 33: ... pump Bolt M 6 2 12 1 2 Timing check plug P lug 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 assembly _ M36 1 90 9 0 Stator _ M 5 3 7 0 7 Pick up coil _ M 5 2 7 0 7 Starter motor Bolt M 6 2 10 1 0 Thermo switch _ M16 1 23 2 3 Thermo unit _ P t1 8 1 8 0 8 ...

Page 34: ...lug 4 Measure Valve clearance Out of specification 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 a on the rotor with the stationary pointer b on the crankcover 1 when the piston is Top Dead Center TDC Measure the valve clearance by using a feeler gauge 6 Adjust Valve clearance Adj...

Page 35: ...screw Crankcase cover 3 2 2 IDLING SPEED ADJUSTMENT 1 Start the engine and let it warm up for several minutes 2 Attach Inductive tachometer to the spark plug lead 3 Check Engine idling speed Out of specification Adjust Engine idling speed 1 350 1 650 r min 4 Adjust Engine idle speed Adjustment steps Turn the pilot screw until it is lightly seated Turn the pilot screw out by the specified number of...

Page 36: ...d in the spark plug wells to prevent it from falling into the cylinder 1 Check Spark plug type Incorrect Replace Standard spark plug DR8EA NGK 2 Inspect Electrode Wear damage Replace Insulator Abnormal color Replace Normal color is a medium to light tan color 3 Clean Spark plug with spark plug cleaner or w ire brush 4 Measure Spark plug gap with a wire gauge Out of specification Adjust gap Spark p...

Page 37: ...low away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder 5 Attach Compression gauge 6 Measure Compression pressure If it exceeds the maximum pressure allowed Inspect the cylinder head valve surfaces and piston crown for carbon deposits If it is below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again Follow the table...

Page 38: ...utes 2 Turn off the engine 3 Inspect Do not thread dipstick in Engine oil level Oil level should be between maximum and minimum marks Oil level is below the minimum mark Add oil up to the proper lever RECOMMENDED ENGINE OIL Refer to the chart for selection of the oils suited to the atmospheric temperature API STANDARD API SE or higher grade CAUTION Do not put in any chemical additives or use oils ...

Page 39: ... strainer O ring Drain the crankcase of its oil 4 Install O ring NEW Compression spring Oil strainer Drain plug Oil filer plug NOTE Check the drain plug O ring If damaged replace it with a new one 5 Fill Crankcase Oil quantity 1 4L 6 Check Engine oil level Refer to ENGINE OIL LEVEL INSPECTION section ENGINE OIL PRESSURE INSPECTION Inspection steps Slightly loosen the oil check bolt Start the engin...

Page 40: ...EVEL INSPECTION Inspect Coolant level Coolant level should be between the maximum a and minimum b marks Coolant level is below the LOWER level line Add soft water tap water up to the proper level CAUTION Hard water or salt water is harmful to engine parts Use only distilled water if soft water is not available If you use tap water make sure it is soft water 1 Start the engine and let it warm up fo...

Page 41: ... When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap Slowly rotate the cap counterclockwise toward the detent This allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it NOTE Remove the radiator cap after removing the drain bolt 4 Clean Radiator Fill soft...

Page 42: ... 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 Quickly wash it away with water and then with soap and water If coolant is swallowed Vomit immediately and see a physician CAUTION Hard water or salt water is harmful to engine parts Use only distilled water if soft water is not available If you ...

Page 43: ... the coolant slowly to the specified level 10 Install Radiator cap 11 Start the engine and let it warm up for several minutes 12 Stop the engine and inspect the level NOTE Wait a few minutes until the coolant settles before inspecting the coolant level 13 Install Remain parts 3 3CYLINDER HEAD ...

Page 44: ...or joint Joint O ring 1 1 2 1 1 1 1 2 Remove the parts in order Refer to CARBURETOR section 9 10 11 12 13 14 15 16 17 18 19 20 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 gasket Breather plate Cam sprocket Timing chain Cylinder head Cylinder head gasket Dowel pin 1 1 1 1 ...

Page 45: ...der head match mark d when the piston is at TDC on the compression 2 Loosen 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 falling into the crankcase Remove the bolt while holding the rotor mounting bolt with a wrench 5 Remove Cylinder head NOTE Loosen th...

Page 46: ...auge across the cylinder head Measure the warpage If the warpage is out of specification resurface the cylinder head Place a 400 600 grit wet abrasive pape on the surface 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 NEW Dowel pins Cylinder head NOTE App...

Page 47: ... sprocket with the stationary pointer d on the cylinder head Align the pin on the cam shaft with the 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 Remove the safety wire from the timing chain 4 Install Breather plate Plane washer 5 Install Timing ...

Page 48: ... alignment Adjust 8 Check Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJUSTMENT section 3 4CAMSHAFT AND ROCKER ARMS Order Job name Part name Q ty Remarks 1 Cam shaft and rocker arms removal Cylinder head Lock washer 1 Remove the parts in order Refer to CYLINDER HEAD section 2 Plate 1 Refer to ROCKER ARM AND ROCKER ...

Page 49: ...SHAFTRE MOVAL 1 Remove Rocker arm shaft intake Rocker arm shaft exhaust NOTE Attach a rocker arm shaft puller bolt and weight to the rocker arm shaft and slide out the shaft CAM SHAFT INSPECTION 1 Inspect Cam lobes Pitting Scratches Blue discoloration Re place 2 Measure Cam lobes length a and b Out of specification Replace Cam lobes length Intake a 36 545 36 645 mm Lim it 36 45 mm b 30 021 30 121 ...

Page 50: ...cessive 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 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 rocker arm sh...

Page 51: ...denum disulfide oil 4 Install Rocker arm Rocker arm shaft exhaust NOTE Exhaust Install the rocker arm shaft exhaust 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 not confuse the installation direction of rocker arm shaft Be sure to install the threaded ...

Page 52: ...rm rocker arm shaft Valve cotters Spring 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 SHAFT AND ROCKER ARMS section Refer to VALVES AND VALVE SPRINGS REMOVAL INSTALLATION section Refer to VALVES AND VALVE SPRINGS INSTALLATION section Reverse the removal ...

Page 53: ...ON Do not 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 5 975 5 990mm Limit 5 94mm Exhaust 5 960 5 975mm Limit 5 92mm 2 Measure Runout valve stem Out of specification Replace Runout limit 0 01 mm 3 Measure Free length valve spring Out of specification Replace Valve spr...

Page 54: ...eter Out of specification Replace Valve 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 Replace the valve guide Stem to guide clearance limit Intake 0 08 mm Exhaust 0 10 mm VALVE SEATS INSPECTION 1 Eliminate Carbon deposits from the valve face and val...

Page 55: ...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 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 valve face should be lapped Lapping steps Apply a coarse lapping com pound a to the valve face CAUTION Do no...

Page 56: ...g dye Dykem b to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve seat with c again VALVES AND VALVE SPRINGS INSTALLATION 1 Deburr Valve stem end Use an oilstone to smooth the stem end 2 Apply Molybdenum disulfide oil onto the valve stem and oil seal Molybdenum disulfide oil 3 Install V...

Page 57: ...AGE 3 31 4 Instal Valve cotters NOTE 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 CAUTION Do not hit so much as to damage the valve ...

Page 58: ...order Cylinder head Refer to CYLINDER HEAD 1 Joint 1 section 2 O ring 2 3 Timing 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 PISTON RINGS REMOVAL 9 Piston 1 section 10 Piston ring top 1 Refer to PISTON RINGS 11 Piston ring 2nd 1 PISTON AND CYLINDER ...

Page 59: ...o the crankcase cavity 2 Remove Top ring 2nd ring Oil ring NOTE 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 Measure the cylinder bore with a cylinder bore gauge Measure the cylinder bore in parallel to and a right angle to the crankshaft Then find...

Page 60: ... clearance 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 02 0 04mm 3 Measure Piston pin bore diameter Out of specification Replace Piston pin bore diameter 17 004 17 015mm Limit 17 045mm 4 Measure Piston pin outside diameter Out of specification Replace Pis...

Page 61: ...4 0 08m m Limit 0 12mm 2nd ring 0 03 0 07mm Limit 0 12mm 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 cylinder bore 1 5 0mm 3 Measure End gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of the oil ring If the oil ring rails show excessive gap replace all three rings End...

Page 62: ...nstall Piston Piston pin Piston pin clip NEW NOTE Apply engine oil to the piston pins The mark 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 from falling into the crankcase Make sure to install each piston in its respective cylinder 3 Install Gasket cylinder NEW Dowel pins...

Page 63: ...37 5 Lubricate Piston outer surface 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 guide exhaust side through the timing chain cavity ...

Page 64: ...E PAGE 3 38 3 7V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE CRANKCASE COVER LEFT Order Job name Part name Q ty Remarks Crankcase cover left removal Remove the parts in order 1 Crankcase cover left 1 2 1 3 Hose clamp B 1 4 Joint B 1 5 Air strainer B 1 6 Hose clamp A 1 7 Joint A 1 ...

Page 65: ...ame Q ty Remarks V belt clutch and secondary Remove the parts in order 1 primary sheave removal Nut Plain washer 1 1 Refer to PRIMARY SHEA VE 2 Primary fixed sheave 1 REMOVAL section 3 Nut 1 Refer to SECONDARY SHEAVE 4 Clutch housing 1 AND V BELT REMOVAL 5 Clutch assembly 1 section 6 V belt 1 Refer to SECONDARY SHEAVE 7 Primary sliding sheave 1 INSTALLATION section 8 Collar 1 9 Primary sheave cap ...

Page 66: ...VE Apply lightweight lithium soap base grease Order Job name Part name Q ty Remarks Secondary sheave disassembly Disassemble the parts in order 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 Secondary sliding sheave 1 8 O ring 2 Refer to SECONDARY S...

Page 67: ...with the rotor holder SECONDARY SHEAVE AND V BELT REMOVAL 1 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 clutch carrier yet NOTE Loosen the nut clutch carrier one turn using the locknut wrench while holding the clutch carrier with the rotor holder 3 R...

Page 68: ...CAUTION Use the spacer diameter 30mm thickness 2 3mm CLUTCH INSPECTION 1 Measure Clutch shoe thickness Scratches Glaze using coarse sandpaper Wear Damage Replace Clutch shoe thickness 3 0mm Limit 2 0mm NOTE After using the sandpaper clean off the polished particles Inspect the other clutch shoes Replace all three as a set V BELT INSPECTION 1 Inspect V belt Cracks Wear Scaling Chipping Replace Oil ...

Page 69: ... 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 PRIMARY SHEAVE ASSEMEBLY 1 Clean Primary sliding sheave face Primary fixed sheave face Collar Weight Primary sliding sheave cam face NOTE Remove any excess grease 2 Install Weight Collar NOTE Apply molybdenum disulfide gr...

Page 70: ...e grease nipple groove and oil seals Lightweight lithium soap base grease to the bearings oil seals and inner surface of the secondary 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 lithium soap base grease to the guide pin sliding groove and oil seal NEW 5 Inst...

Page 71: ... thickness 2 3mm 6 Install V belt Clutch assembly NOTE Install the V bet with clutch assembly to the primary sheave side CAUTION Never smear grease to the V belt secondary 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 clutch housing NOTE Tighten the nut ...

Page 72: ...of the secondary sheave and make the V belt tense 3 8A C MAGNETO AND STARTER CLUTCH MAGNETO COVER AND STATOR COIL Order Job name Part name Q ty Remarks Magneto cover and stator coil removal Drain the engine oil Remove the parts in order Refer to ENGINE OIL REPLACEMENT section NOTE Disconnect the couplers 1 Couplers A C magneto lead 2 2 Exhaust pipe 1 3 Exhaust pipe gasket 1 ...

Page 73: ...on number 0501 CHAPTER 3 ENGINE PAGE 3 47 4 Magneto cover 1 Reverse the removal procedure for installation 5 Gasket magneto cover 1 6 Dowel pins 2 7 Stator coil 1 8 Pick up coil 1 A C MAGNETO AND STARTER CLUTCH Order Job name Part name Q ty Remarks ...

Page 74: ...e nut rotor while holding the rotor with a sheave holder Do not allow sheave the holder touch to the projection on the rotor 2 Remove Rotor Woodruff key NOTE Remove the rotor using the flywheel puller Center the flywheel puller over the rotor Make sure after installing the holding bolts that the clearance between the flywheel puller and the rotor is the same everywhere If necessary one holding bol...

Page 75: ...place it When turning the starter wheel gear counter clockwise it should turn freely If not the starter clutch is faulty Replace it A C MAGNETO ROTOR INSTALLATION 1 Install Starter wheel gear Woodruff key NOTE Install the starter wheel gear then 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...

Page 76: ...CHAPTER 3 ENGINE ATV SERVICE MANUAL 2005 version number 0501 CHAPTER 3 ENGINE PAGE 3 50 3 9OIL PUMP Order Job name Part name Q ty Remarks ...

Page 77: ...emoval procedure for installation OIL PUMP INSPECTION 1 Inspect Drive gear oil pump Pump housing Pump housing cover Wear cracks damage Replace 2 Measure Tip clearance between the inner 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 assembly Tip cleara...

Page 78: ...CHAPTER 3 ENGINE ATV SERVICE MANUAL 2005 version number 0501 CHAPTER 3 ENGINE PAGE 3 52 3 10CRANKCASE AND CRANKSHAFT ...

Page 79: ...dary 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 CYLINDER AND PISTION section Refer to V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE section Refer to A C MAGNETO AND STARTER CLUTCH section Refer to OIL PUMP section Refer to WATER PUMP section Refer to ...

Page 80: ...or installation CRANKSHAFT REMOVAL 1 Remove Crankshaft assembly Timing chain NOTE Before removing the crankshaft assembly remove the timing chain from the crankshaft sprocket If the timing chain hooks to the crankshaft sprocket the crankshaft cannot be removed CRANKSHAFT INSPECTION 1 Measure Crankshaft runout Out of specification Replace crankshaft and or bearing NOTE Measure the crankshaft runout...

Page 81: ...amage Replace crankshaft Bearing Wear Crack Damage Replace crankshaft Pump drive gear Wear Damage Replace crankshaft 5 Inspect Crankshaft journal Clogged Blow out the journal with compressed air CRANKCASE INSTALLATION 1 Clean all the gasket mating surface and crankcase mating surface thoroughly 2 Apply Sealant onto the crankcase mating surfaces NOTE DO NOT ALLOW any sealant to come into contact wi...

Page 82: ...5 version number 0501 CHAPTER 3 ENGINE PAGE 3 56 Dowel pins Timing chain NOTE Install the timing chain not to be seen through the crankshaft hole a on the crankcase left 3 11COOLING SYSTEM 3 11 1RADIATOR Order Job name Part name Q ty Remarks ...

Page 83: ...spect Radiator Obstruction Blow out with compressed air through the rear of the radiator Flattened fins Repair or replace If flattened over the 20 of radiator fin repair or replace the radiator CAUTION Use only specified adhesive to repair the radiator 2 Inspect Radiator hoses Radiator pipes Cracks damage Replace 3 Measure Radiator cap opening pressure Radiator cap opens at a pressure below the sp...

Page 84: ...5 version number 0501 CHAPTER 3 ENGINE PAGE 3 58 and make sure there is no pressure drop 4 Inspect Fan motor assembly Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM 5 Inspect Pipes Cracks damage Replace 3 11 2WATER PUMP ...

Page 85: ...oval Remove the parts in order 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 PUMP INSTALLATION 4 Outlet hose radiator 1 section 5 Housing cover 1 6 Housing cover gasket 1 7 Water pump housing 1 1 ...

Page 86: ...ation NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant temperature and or level discoloration of coolant or milky transmission oil If necessary replace water pump as an assembly INSPECTION 1 Inspect Impeller shaft Wear damage Replace Fur deposits Clean 2 Inspect Impeller shaft gear Wear damage Replace 3 Inspect Mechanical sea...

Page 87: ...smear any oils or grease on the ring side of the mechanical seal 3 Inspect Mechanical sea slip ring side Inspect the slip ring side of the mechanical seal and the impeller for level installation Incorrect level Reinstall 4 Install Impeller shaft Circ lip NEW Installation steps Apply a small amount of grease to the impeller shaft tip Install the impeller shaft while turning it Use care so that the ...

Page 88: ...APTER 3 ENGINE ATV SERVICE MANUAL 2005 version number 0501 CHAPTER 3 ENGINE PAGE 3 62 7 Install Shaft Align the slot on the impeller shaft with the projection on the shaft when installing 3 11 3THERMOSTAT ...

Page 89: ...removal procedure for installation INSTALLATION 1 Inspect Thermostatic valve Valve does not open at 70 74 Replace Inspection steps Suspend the thermostatic valve in a vessel Place a reliable thermometer in water Observe 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 speci...

Page 90: ...CHAPTER 3 ENGINE PAGE 3 64 Thermostatic valve Thermostatic cover 3 12CARBURETOR 1 Remove Fuel hose 2 Remove Manual enriching starter rope 3 Remove Nut Throttle cable 4 Lossen Bolt Bolt 5 Remove Carburetor assy 6 Remove Cover 7 Remove Diaphragm spring Piston valve ...

Page 91: ...RVICE MANUAL 2005 version number 0501 CHAPTER 3 ENGINE PAGE 3 65 8 Inspect Jet needle Wear Replace Piston valve Wear Replace 9 Remove Float chamber Float Needle valve 10 Inspect Needle valve Wear Replace 11 Remove Idling jet ...

Page 92: ...CHAPTER 3 ENGINE ATV SERVICE MANUAL 2005 version number 0501 CHAPTER 3 ENGINE PAGE 3 66 12 Remove Pilot jet 13 Remove Main jet 14 Remove Main nozzle 15 Remove Mixture adjusting screw ...

Page 93: ...CE MANUAL 2005 version number 0501 CHAPTER 3 ENGINE PAGE 3 67 16 Remove Nut Throttle valve mounting arm Torsion bar spring Gasket 17 Remove Screws Throttle valve mounting bracket 18 Reverse the removal procedure for installation ...

Page 94: ...CHAPTER 3 ENGINE ATV SERVICE MANUAL 2005 version number 0501 CHAPTER 3 ENGINE PAGE 3 68 NOTES ...

Page 95: ...CHAPTER 3 ENGINE ATV SERVICE MANUAL 2005 version number 0501 CHAPTER 3 ENGINE PAGE 3 69 ...

Page 96: ...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 REAR A ARM REPLACEMENT 4 3 REAR STABILIZER BAR REMOVAL INSTALLATION 4 4 FRONT STRUT REPLACEMENT 4 5 FRONT STRUT BALL JOINT REPLACEMENT 4 6 BOX REMOVAL INSTALLATION 4 7 STEERING ASSEMBLY REMOVAL INSTALLATION ...

Page 97: ...mbly onto vehicle frame Install new bolts and new nuts NOTE Tighten 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 DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 7 Attach A arm to strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm I...

Page 98: ...CHAPTER 4 CHASSIS CUV SERVICE MANUAL 09 0 CHAPTER 4 CHASSIS PAGE 4 3 Upon A arm installation completion test vehicle at low speeds before putting into regular service 4 2 REAR A ARM REPLACEMENT ...

Page 99: ...e and safely support vehicle with weight removed from the rear wheel s 2 Remove the wheel nuts and wheel NOTE To ease the removal of the spindle bolt remove the hub cap and loosen the spindle bolts before removing the wheel 3 Remove the hub cap cotter pin spindle bolt and washer ...

Page 100: ... off of the axle 6 Remove the bolt that secures the shock and coil to the lower A arm 7 Loosen two bolts that secure the A arm to frame by alternating each about 1 3 of the way until A arm can be removed Perform this procedure on the upper A arm 8 Examine the A arm bushing and A arm shaft Replace if worn Discard hardware 9 Remove the bottom stabilizer bar nut 10 Loosen two bolts that secure the A ...

Page 101: ...NOT reuse old bolts Serious injury 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 32 ft lbs 44 Nm 15 Install the stabilizer and tighten nut to 40 ft lbs 56 Nm 16 Re install wheel and caliper Upon A arm installation completion test vehicle at low speeds bef...

Page 102: ...ar 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 stabilizer from the fram 6 Inspect the stabilizer bar Inspect the bushings and replace if needed 7 Inspect the stabilizer joint and replace if needed 8 Reverse the procedure for installation Torque the stabilizer bolts to 23 ft l...

Page 103: ...3 Remove upper strut pivot assembly 4 Remove coil spring 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 bolts to 15ft lbs 21Nm 9 Reassemble spring and top pivot assembly Be sure all parts are installed properly and ...

Page 104: ...rom ball joint stud 6 Remove screws and ball joint mounting 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 as shown Hold bolt 2 and turn nut 3 clockwise until ball joint is removed from strut housing 8 To install new ball joint cup Insert new ball joint...

Page 105: ...the rest of the removal process The box is not as stable with the hinge pin removed 7 With the hinge pins removed remov the box from the frame Two people maybe needed to remove the bed from the frame CAUTION Use caution when removing the box It is recommended to have two people to carefully remove the box from the frame Box Installationg 1 Place the box onto the frame Align the hinges of the box w...

Page 106: ...eel cover and the steering wheel 2 With the steering wheel holder nut removed remove the steering wheel holder 3 Remove the steering column bolts 4 Remove the upper of the steering column 5 Remove the cotter pins and the tie rod end bolts both sides 6 With the cover bolts removed remove the steering assy and the lower of the steering column 7 Reverse the procedure for installation ...

Page 107: ...CHAPTER 4 CHASSIS CUV SERVICE MANUAL 09 0 CHAPTER 4 CHASSIS PAGE 4 12 NOTES ...

Page 108: ...ION 4X4 5 7 FRONT DRIVE AXLE INSTALLATION 4X4 5 8 FRONT DRIVE AXLE DISASSEMBLY INSPECTION 4X4 5 9 FRONT DRIVE AXLE ASSEMBLY 4X4 5 10 REAR HUB EXPLODED VIEW 5 11 REAR HUB AND KNUCKLE REMOVAL INSPECTION 5 12 REAR HUB AND KNUCKLE INSTALLATION 5 13 REAR DRIVE SHAFT REMOVAL 5 14 REAR DRIVE SHAFT INSTALLATION 5 15 REAR GEARCASE EXPLODED VIEW 5 16 REAR GEARCASE DISASSEMBLY 5 17 REAR GEARCASE ASSEMBLY 5 1...

Page 109: ...N 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 VIEW 5 3 FRONT HUB REMOVAL INSPECTION 1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before b...

Page 110: ...r 7 Rotate each bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion or roughness is evident 5 4 FRONT HUB INSTALLATION 1 Inspect the hubstrut bearing surface for wear or damage 2 Apply grease to drive axle spindle 3 Install spindle through the backside of the hubstrut Install the hub onto the spindle 4 Install spindle nut and tighten to 101 ft lbs ...

Page 111: ...REPLACEMENT 1 Remove outer snap ring 2 Form the back side tap on the outer bearing race with a drift punch in the reliefs as shown 3 Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support 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 ...

Page 112: ...Circlip 8 Bearing 9 Stopper ring 10 Inboard boot NOTE Always order and replace 6 and 8 together REMOVAL 1 Place the vehicle on level ground and set the parking brake Block the rear wheels so the vehicle will not roll in either direction 2 Remove the front wheels steering tie rods disconnect the A arm on the ball joint end as described in this Chapter and Chapter 4 CAUTION To avoid damage to the fr...

Page 113: ...in a circular motion and also a reciprocate for inner one and check the drive shaft joints for excessive wear or play 3 This inner CV joint inboard pivot joint can be serviced if there is wear or play The outer CV joint outboard pivot joint cannot be serviced if worn or damage and if necessary the drive shaft assembly must be replaced 5 7 FRONT DRIVE AXLE INSTALLATION 4X4 CAUTION To avoid damage t...

Page 114: ...oard joint 3 Wipe out all of the molybdenum disulfide grease within the inboard joint cavity 4 Remove the stopper ring from the inboard joint 5 Remove the inner CV joint 6 Remove the circlip and slide off the bearing assembly Be careful not to drop any of the steel balls from the bearing cage 7 Slide the inner CV off the drive axle and discard the boot band A it cannot be reused 8 If the outboard ...

Page 115: ...ary 8 Inspect the snap ring groove on the inboard joint for wear or damage 9 Inspect the splines on the inner CV joint for wear or damage 10 Check the stopper ring in the end of the inboard joint Make sure it seats in the groove correctly if damage the ring must be replaced See right picture 11 Inspect the exterior of the inner CV joint for cracks or damage replace if necessary Check the movement ...

Page 116: ...ing race and install the race into the bearing case Align the steel ball receptacles in both parts b Install the steel balls into their receptacles in the bearing case c Pack the bearing assembly with molybdenum disulfide grease This will help hold the steel balls in place 6 Position the bearing assembly with the small end of the bearing going on first and install the bearing onto the drive axle 7...

Page 117: ... the tab on the boot band and secure the tab with the locking clips and tap them with a plastic hammer Make sure they are locked in place 15 Install the large boot bands onto each boot CAUTION It is critical to avoid undue stress on the rubber boots after the drive axle is installed and the vehicle is run Don t twist the boot and always set the both ends in designed position 16 Secure all large bo...

Page 118: ...e to hang the caliper to prevent possible damage to the brake line 5 Remove hub cap cotter pin front spindle nut and washer 6 Remove the upper and lower control arm bolts 7 Slide the rear hub and knuckle from the rear drive axle 8 Inspect the rear hub and knuckle assembly by hand for smoothness and side to side movement replace as needed 5 12 REAR HUB AND KNUCKLE INSTALLATION 1 Start the rear hub ...

Page 119: ...AR HUB AND KNUCKLE REMOVAL section 2 Slide the rear drive axle out of the knuckle by pulling the hub and knuckle assembly outward and down 3 Pull the rear drive axle straight out 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 INSTALLATION 1 Install a new...

Page 120: ... rear drive axle into the knuckle 4 Lift knuckle into place and install bolt to upper and lower control arm Torque bolt to 44 ft lbs 60 Nm 5 Install the washer and the spindle retainer nut 6 Install the wheel and wheel nuts Torque wheel nuts to 59 ft lbs 66 Nm 7 Lower the vehicle Torque the spindle retaining nut to 101 ft lbs 137 Nm Install a new cotter key and the hub cap 8 Install brake caliper ...

Page 121: ... O RING 160X2 65 5 BOLT M8X28 6 BOLT M10X1 25X28 7 WASHER 31 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 30X55X11 14 SEAL 38X85X8 15 SEAL 38X80X8 16 BEARING 15NQ2815 17 OIL SCREEN CAP 18 O RING 19 WASHER 20 OIL PLUG 21 TUBE REAR GEAR BOX BREATHER 22 BEARING 6306 23 BEARING 6006 24 BEARING ...

Page 122: ...all a new lock nut and tighten it using the special tool 3 Stake the lock into the case groove 4 Coat a new O ring with grease and install it onto the pinion gear shaft 5 Apply grease to the lips of new oil seals Install the inner oil seal into the drive housing until it is flush with the stepped edge 6 Install the outer oil seal into the drive housing until with the drive housing outer surface 7 ...

Page 123: ...that the bearing is not installed squarely or the case is deformed 10 Inspect the bearings and case 11 If the backlash is excessive replace the ring gear right shim with a thinner one 12 If the backlash is small replace the ring gear right shim with a thicker one 13 Backlash is changed by about 0 06mm when thickness of the spacer is changed by 0 12mm 5 19 FRONT GEARCASE SLIP LIMIT TORQUE TEST 4X4 ...

Page 124: ... recommended to replace the FRONT DIFFRENTIAL as an assembly when out of specification 5 20 FRONT GEARCASE DISASSEMBLY INSPECTION 4X4 1 Drain and properly dispose of used oil 2 Remove bolts gasket and shift motor 3 Remove bolts and diff case cover 4 Remove pins gear and selector rail ...

Page 125: ... CUV SERVICE MANUAL 09 0 CHAPTER 5 FINAL DRIVE 5 18 5 Remove selector fork splined dog and input shaft 6 Remove bearing and seal 7 Remove gear screws pinion shaft retainer plate and pinion shaft 8 Remove seal from the case ...

Page 126: ...CHAPTER 5 FINAL DRIVE CUV SERVICE MANUAL 09 0 CHAPTER 5 FINAL DRIVE 5 19 9 Remove bolts left cover and differential Differential 10 Remove seal from left cover ...

Page 127: ...ng and finger spring for wear cracks relaxation Replace part with any defects CAUTION New seals should be installed after the transmission is completely assembled 5 21 FRONT GEARCASE ASSEMBLY 4X4 1 Install pinion shaft with bearing 2 Install retainer plate with flat side toward bearing and torque screws Apply LoctiteTM 243 Blue to screw threads and torque screws to 8ft lbs 12Nm 3 Install gear 4 In...

Page 128: ...cTiteTM 518 to mating surfaces reinstall cover and torque bolts 8ft lbs 12Nm 8 Reinstall gasket and shift motor and torque bolts 2ft lbs 3Nm 9 Install differential into case Apply LocTiteTM 518 to mating surfaces reinstall left cover and torque bolts 14ft lbs 20Nm 10 Install new seals ...

Page 129: ...T DIFFRENTIAL DISASSEMBLY INSPECTION 4X4 1 Remove bolts and bevel crownwheel 2 Remove bolts and differential cap A 3 Remove spring seat springs outer single clutch plate differential plat outer double clutch plate bevel gear and gear axle washer 4 Remove bolts and differential cap B ...

Page 130: ... pinion washers bevel pinions and center spacer from differential housing 8 Clean all components and inspect for wear Inspect gears for wear cracks chips or broken teeth Inspect inner and outer splines on the spider gears and friction plates replace if edges are rounded Inspect casting for crack Inspect axletree for smooth operation check for excessive play between inner and outer race Inspect dis...

Page 131: ...rs bevel pinions and center spacer into differential housing 2 Install bevel gear gear axle washer outer double clutch plate differential plate outer single clutch plate springs spring seat 3 Install differential cap A 4 Check the preload clearance Clearance 1 2 1 5mm Out of specification change spring seat spring replace clutch plate as necessary ...

Page 132: ...w threads and torque bolts to 24ft lbs 32Nm 6 Install bevel gear gear axle washer outer double clutch plate differential plate outer single clutch plate springs spring seat 7 Install differential cap B 8 Check the preload clearance Clearance 1 2 1 5mm Out of specification change spring seat spring replace clutch plate as necessary ...

Page 133: ... torque bolts to 16ft lbs 22Nm CAUTION Slip limit torque relate to the preload clearance on the differential and affect the Steering Effort heavy steering Always field test the CUV carefully and thoroughly after front gearcase and differential service for vehicle maneuvers and operation 5 24 FRONT GEARCASE EXPLODED VIEW ...

Page 134: ... 5 FINAL DRIVE 5 27 5 25 REAR FRONT PROP SHAFT REMOVAL Using roll pin remover remove the roll pin from prop shaft Slide the prop shaft back and away from the gear case The rear gearcase must be disassembly from the frame before the rear prop shaft removal ...

Page 135: ...CHAPTER 5 FINAL DRIVE CUV SERVICE MANUAL 09 0 CHAPTER 5 FINAL DRIVE 5 28 NOTES ...

Page 136: ...st same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 6 1 GEAR SHIFTER REMOVAL 6 2 GEAR SHIFTER DISASSEMBLY 6 3 GEAR SHIFTER ASSEM BLY 6 4 GEAR SHIFTER INSTALL ATION 6 5 SHIFT LINKAGE ADJUSTMENT 6 6 ENGINE ANDTRANSMISSION REMOVAL 6 7 ENGINE AND TRANSMSSION INSTALL ATION 6 8 TRANSMISSION DISASSEMBLY 6 9 TRANSMISSION ASSEMBLY 6 10 TROUBLE SHOOTING ...

Page 137: ...gear selector out of mounting bracket and away from frame 6 2 SHIFTER DISASSEMBLY CAUTION Wear eye protection during this procedure Read each step completely before proceeding Essential parts maybe lost or damaged if you do not heed this caution 1 Clamp shifter housing lightly in a soft jawed vice Using a cross pattern loosen each of the four screw s holding the cover to the shifter housing Loosen...

Page 138: ... replaced in the proper channels 7 Inspect O rings for damage Replace if any damage is found 8 Flush housing with parts washer fluid or penetrating oil to remove all moisture 9 Dry all parts and remove any corrosion with a wire brush 6 3 SHIFTER ASSEMBLY 1 Grease and insert slides into shifter housing taking care not to cut or tear O ring in the process NOTE The LH slide has two short notches and ...

Page 139: ...g out of desired range NOTE When adjusting linkage always adjust both linkage rods The adjustment of one rod can prevent proper adjustment of the other rod Remove necessary components to gain access to shift linkage rod ends 1 Inspect shift linkage tie rod ends and pivot bushings and replace if worn or damaged Lubricate the tie rod ends with a light aerosol lubricant or grease 2 Loosen all rod end...

Page 140: ...se again one half of the revolutions counted in Step 8 10 Tighten the rod end jam nuts securely while holding the rod end The jam nuts must be tightened with both front and rear rod ends parallel to each other If jam nuts are properly tightened the rod should rotate freely 1 4 turn without binding 11 Repeat steps 7 10 for the High Reverse rod 6 6 ENGINE AND TRANSMISSION REMOVAL 1 Remove seat side ...

Page 141: ...s between the engine and transmission and left them on the transmission See picture 2 brackets between the engine and transmission 8 Remove right and left side engine mount bolts and remove engine from engine stay 9 Remove front drive shaft 4WD see chapter 5 10 Remove lower left bracket rear bracket and right mount bolts M10x1 25x70 11 Remove transmission from frame and remove drive shaft ...

Page 142: ...t remove the fasteners to re position the transmission by tightening the fasteners in different order Transmission Mounting Bolts Torque 25 ft lbs 35 Nm 4 Drive in a new roll pin 5 Position Engine in frame Install all brackets loosely install new fasteners but not tighten fasteners 6 Make sure those spacers are in correct position 7 Link engine and transmission together with engine mount jig cente...

Page 143: ...itches IMPORTANT The gear position indicator switches must be removed prior to disassembly 3 Remove the transmission cover bolts 4 Carefully remove the cover with a soft face hammer tap on the cover bosses 5 Remove bearing and helical gear 6 Remove input shaft reverse shaft and both shift fork shafts as an assembly 7 Remove pinion shaft retainer plate and pinion shaft ...

Page 144: ...wear 12 Inspect engagement dogs of gears and replace if edges are rounded 13 Inspect gear teeth for wear cracks chips or broken teeth 14 Remove seals from transmission case IMPORTANT New seals should be installed after the transmission is completely assembled 15 Inspect bearings for smooth operation Check for excessive play between inner and outer race 6 9 TRANSMISSION ASSEMBLY 1 Install sprocket ...

Page 145: ...dry and shafts are fully seated in the transmission case Apply silicon glue to mating surfaces 5 Reinstall cover and torque bolts in a crisscross pattern in 3 steps to 14 ft lbs 20 Nm 6 Install new front only for 4X4 and rear output shaft seals 7 Install pinion shaft with bearing 8 Install retainer plate with flat side toward bearing 9 Apply LoctiteTM 242 Blue to screw threads and torque screws to...

Page 146: ... shaft and gear assembly along with sprocket and chain 13 Prior to reinstalling the cover make sure the mating cover surfaces are clean and dry and shafts are fully seated in transmission case Apply silicon to mating surfaces 14 Reinstall main cover and torque bolts in a cross pattern in 3 step to 14 ft lbs 20Nm 15 Install new input shaft seal 16 Install drain plug with a new sealing washer Torque...

Page 147: ...on components Check the following items when transmission locked Gear shifter malfunction Selector lever end come out from slides notches engage the Hi and Lo Gear at the same time NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting linkage rods from transmission bell cranks Manually select each gear range at t...

Page 148: ...CHAPTER 6 TRANSMISSION CUV SERVICE MANUAL 07 0 CHAPTER 6 TRANSMISSION PAGE 6 13 2X4 TRANSMISSION EXPLODED VIEW ...

Page 149: ...CHAPTER 6 TRANSMISSION CUV SERVICE MANUAL 07 0 CHAPTER 6 TRANSMISSION PAGE 6 14 4X4 TRANSMISSION EXPLODED VIEW ...

Page 150: ...CHAPTER 6 TRANSMISSION CUV SERVICE MANUAL 07 0 CHAPTER 6 TRANSMISSION PAGE 6 15 NOTES ...

Page 151: ...mation 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 8 PARKING BRAKE REAR CALIPER REMOVAL INSTALL 7 9 FRONT PAD INSPECTION REMOVAL REPLACEMENT 7 10 FRONT DISC INSPECTION REMOVAL REPLACEMENT 7 11 FRONT CALIPER REMOVAL INSPECTION INSTALLATION 7 12 REAR BR...

Page 152: ...sc Thickness 0 177 0 187 4 496 4 750m m 0 167 4 242mm 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 noted Torque Nm Front Caliper Mounting Bolts 18 0 25 Rear Caliper Mounting Bolts 18 0 25 Front Brake Disc 18 0 25 Rear Brake Disc 18 0 25 Park Brake Mouting Bolts 18 0 25 Banjo Bolt 15 0 21 7 3 BRAKE SYSTE...

Page 153: ...king 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 accelerate the CUV to 50 km h 30 mph and to brake to a stop 2 Using hi gear accelerate to 50 km h 30 mph then compress brake lever pedal to decelerate to 0 8km h 5 mph 3 Repeat procedure on each brake sys...

Page 154: ...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 maintain pedal pressure and open bleeder screw Close bleeder screw and release foot pedal NOTE Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder 8 Repeat p...

Page 155: ...servoir 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 1 3cm 14 Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion Replace hose if w ear or abrasion is found 7 6 PARKING BRAKE AND BRAKE LINE INSPECTION 1 Inspect the spring o...

Page 156: ...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 Adjustment 1 Place the vehicle in neutral on a flat level surface 2 Carefully lift the rear of the vehicle off the ground and stabilize on jack stands 3 Loosen the jam nut A on the rear caliper adjustme...

Page 157: ...bolts from 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 Installation 1 Install the park brake assembly into place Tighten the two bolts in increments for proper installation 2 Torque the two bolts to 18 ft lbs 24 Nm 3 Test the park brake for proper fu...

Page 158: ...liper piston into caliper bore slowly 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 excess fluid from reservoir as required 5 Push mounting bracket inward and slip outer brake pad past edge Remove inner pad INSPECTION Measure the thickness of the pad...

Page 159: ...til stationary pad contacts disc then back off 1 2 turn counter 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 nuts 8 It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise...

Page 160: ... soften the bolt locking agent 2 Remove bolts and disc 3 Clean 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 CALIPER REMOVAL INSPECTION INSTALLATION CAUTION The caliper is a non serviceable Component it must be replaced as an assembly NOTE If any spe...

Page 161: ... and slowly increase speed to 30 mph Gradually apply brakes to stop 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 Elevate and support rear of CUV safely CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove the rear wheel 3 R...

Page 162: ...p the brake lever until pressure has been built up Maintain at least 1 2 13 mm of 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 caliper is a non serviceable Component it must be replaced as an assembly NOTE If any special service needed contact the CU...

Page 163: ...ing action before putting into service Inspect for fluid leaks 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 NOTE If new brake pads are installed it is recommended that a burnishing procedure be performed after installation of new brake pads to exte...

Page 164: ...Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 0 005 0 127 mm REMOVAL REPLACEMENT 1 Removal wheel hub and caliper 2 Remove bolts and disc from the flange 3 Clean mating surface of disc and hub 4 Install new disc on flange Tighten to specified Rear Brake Disc Mounting Bolt Torque 18 ft lbs 25 Nm CAUTION Always use new brake disc mounting bolts ...

Page 165: ...CHAPTER 7 BRAKES CUV SERVICE MANUAL 09 0 CHAPTER 7 BRAKES PAGE 7 15 NOTES ...

Page 166: ... 8 3 IGNITION SYSTEM 8 4 CHARGING SYSTEM 8 5 ELECTRICS STARTING SYSTEM 8 6 COOLING SYSTEM 8 7 LIGHTING SYSTEM 8 8 REVERSE LIMIT SYSTEM 8 9 GEAR POSITION INDICATOR SWITCH TEST 8 10 SPEEDOMETER SYSTEM 8 11 MAIN SWITCH AND HANDLE SWITCH 8 12 FUEL GAUGE FUEL LEVEL SENSOR 8 13 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT 8 14 WIRING DIAGRAM ...

Page 167: ...ly except the light on handlebar 2 Place the vehicle on a level surface with the headlight approximately 25 7 6m from a wall 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 4 Start the engine and turn the headlight switch to high beam 5 Observe headlight aim The most intense part of the headlight beam should be aimed 2 51mm below ...

Page 168: ... 8 3 TAILLIGHT BRAKELIGHT LAMP REPLACEMENT 1 From the rear of the taillight remove two screws holding lens cover in place and remove lens cover 2 Remove lamp and replace it with recommended lamp 3 Reinstall the lens cover removed in step 1 4 Test the taillight brake light ...

Page 169: ...ery 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 case 3 Set battery aside and allow it to cool and stabilize for 30 minutes 4 Add electrolyte to bring level back to upper level mark on case NOTE This is the last time that electrolyte should be ...

Page 170: ...y should 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 the Specific Gravity Test and Refill Open Circuit Voltage Test Battery voltage should be checked with a digital multitester Readings of 12 6 or less require further battery testing and charging...

Page 171: ...al 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 coding in connectors etc Faulty ignition coil winding measure resistance of primary and secondary Worn magneto RH end crankshaft bearings Sheared flywheel key Flywheel loose or damaged Trigger coil air gap t...

Page 172: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL PAGE 8 7 CIRCUIT DIAGRAM ...

Page 173: ...Spark 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 INSPECTION Clean battery terminals Recharge or replace the battery CORRECT Standard spark plug DR8EA NGK 3 Spark plug OUT OF SPECIFICATION Check the spark plug condition Check the spark plug type Check the ...

Page 174: ...inimum spark gap 6mm 0 24 in OUT OF SPECIFICATION OR NO SPARK Tester lead Spark plug side Tester lead High tension cord side 5 Spark plug cap resistance Remover the spark plug cap Connect the pocket tester ΩX1 k to the spark plug cap NOTE When removing the spark plug cap do not pull the spark plug cap from high tension cord Remove Turning counterclockwise Connect Turning clockwise Check the high t...

Page 175: ...ness Connect the pocket tester 1 to the ignition coil Check if the primary coil has the specified resistance Primary coil resistance 3 6 4 8Ω 20 Tester lead Spark plug lead Tester lead Pink Terminal Connect the pocket tester Ω 1k to the ignition coil Check the secondary has the specified resistance Secondary coil resistance 10 7 14 5 KΩ 20 OUT OF SPECIFICATION BOTH MEET SPECIFICATION Replace the i...

Page 176: ...T OF SPECIFICATION Check the pickup coil has the specified resistance Primary coil resistance 168 252Ω 20 Replace the pickup coil NO CONTINUITY MEETS SPECIFICATION 8 Main switch CHECK SWITCHES Replace the main switch CONTINIUTY NO CONTINUITY 9 Engine stop switch for USA model Replace the handlebar switch CONTINIUTY POOR CONNECTIONS 10 Wiring connection Check the connection of the entire ignition s...

Page 177: ...th 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 the draw is excessive loads should be disconnected from the system one by one until the draw is eliminated Check component wiring as well as the component for partial shorts to ground to eliminate the draw Current draw key ...

Page 178: ...INCORRECT 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 terminal Tester lead Battery terminal 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...

Page 179: ... tester ΩX1 to the stator coil Tester lead yellow terminal Tester lead yellow terminal Measure the stator coil resistance Stator coil resistance 0 5 0 8Ω 20 OUT OF SPECITICATION Replace the stator coil MEETS SPECIFICATION 5 Wiring connection check the entire charging system for connections Refer to CIRCUIT DIAGRAM POOR CONNECTION correct CORRECT Replace the rectifier regulator ...

Page 180: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 15 8 5 ELECTRICS STARTING SYSTEM DI AGRAM ...

Page 181: ...rear 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 BATTERY INSPECTION section in CHAPTER 3 INCORRECT Clean battery terminals Recharge or replace the battery 3 Starter motor Connect the battery positive terminal and starter motor cable using a jumper le...

Page 182: ... must have the 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 starter replay 5 Starting circuit cut off relay Disconnect the starting circuit cut off relay coupler from the wireharness Connect the pocket tester Ωx1 and battery 12V to the starting...

Page 183: ...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 Replace the handlebar switch 10 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM POOR CONNECTION Correct ...

Page 184: ...ANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 19 8 6 COOLING SYSTEM IF THE FAN MOTOR FAILS TO TURN Procedure Check 1 Fuse Main Fan 2 Battery 4 Fan motor inspection 3 Main switch 5 Thermo switch 6 Wiring connection entire cooling system ...

Page 185: ...itch CHECK SWITCHES NO CONTINUITY Replace the main switch 4 Fan motor inspection 1 Connect the battery to the fan motor Battery lead Green Blue terminal Battery lead Green ground Check the fan motor operation DOES NOT MOVE Replace fan motor 5 Fan motor inspection 2 Turn the main switch to off Remove the thermo switch lead from thermo switch Connect jumper lead to thermo switch leads Turn the main ...

Page 186: ...mperatures while heating the coolant with the temperature gauge WARNING Handle the thermo switch with special care Never subject it to strong shocks or allow it to be dropped Should it be dropped it must be replaced Do not touch the thermo switch to the bottom of the heated vessel 88 3 Thermo switch ON 80 Thermo switch OFF OUT OF SPECIFICATION Replace the thermo switch Wring connection Check the c...

Page 187: ...ill keep rising The heat alarm unit operates the moment the temperature reaches 115 5 with the buzzer sounding and the signal flashing Stop the engine now to have the circuit fixed Procedure Check 1 Fuse Main Fan 4 Thermo unit 2 Battery 5 Voltage 3 Main switch 6 Wiring connection entire cooling system 1 fuse CHECKING SWITCHES NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Ref...

Page 188: ...m of the heated vessel Coolant temperature Resistance OUT OF SPECIFICATION Replace the thermo unit 80 47 5 56 8Ω 100 26 2 29 3Ω MEETS SPECIFICATION 8 Voltage Connect the pocket tester DC20V to the Temperature gauge couple Tester lead Green Blue terminal Tester lead Green ground Turn the main switch to on Check for voltage 12V on the temperature gauge lead OUT OF SPECIFICATION The wiring circuit fr...

Page 189: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 24 8 7 LIGHTING SYSTEM FOR USA MODEL ...

Page 190: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 25 FOR EUROPE MODEL ...

Page 191: ...fer 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 terminals Recharge or replace the battery 3 Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 4 Light switch CHECK SWITCHES NO CONTINUITY Replace the right handlebar switch 5 Dimmer sw CHECK SWITCHES NO CONTINU...

Page 192: ...S NO CONTINUITY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC20V to the headlight and high beam indicator light couplers A When the dimmer switch is on low beam B When dimmer switch is on high beam Headlight Tester lead White or Blue lead Tester negative lead Green lead Turn the main switch to on Turn the light switch to on position Turn the dimmer switch to low beam o...

Page 193: ...or bulb socket CONTINUITY 2 Voltage Connect the pocket tester DC20V to the bulb socket connector Tester lead Black terminal Tester lead Green terminal Turn the main switch to on Turn the lights switch to on pilot position Check the voltage 12V on the bulb socket connector OUT OF SPECIFICATION The wiring circuit from main switch to bulb connector of faulty Repair This circuit is not faulty ...

Page 194: ...SE LIMIT SYSTEM The limit set for the speed limiter by the manufacturer is 13 15 km h which can be reset in accordance with the user s practice Turning the adjusting bolt clockwise is to increase the speed while counterclockwise decrease it NOTE This limit can be released by the override switch ...

Page 195: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 30 8 9 GEAR POSITION INDICATOR SWITCH TEST Switch table ...

Page 196: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 31 Switch schematic ...

Page 197: ...ain 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 output Voh Vcc 1 V Operating distance D 1mm D 2 5mm mm C The following is the graphic illustration for sensor installation Wire 1 red is positive and wire 2 black negative Wire 3 yellow works as the one to output signals Note Always screw i...

Page 198: ...Shaft Operation Instructions of LCD Meter and Speed Sensor Main Technical Parameter Item Code Vol value Unit Operating voltage Vcc 5 20 V Operating current Icc 15 mA Operating distance D 1mm D 8mm mm The following is the graphic illustration for sensor installation 1 OIL SEAL 4 THE COVER 2 DOWEL PIN 5 THE HALL SENSOR 3 MAGNET ...

Page 199: ...al indicator light 7 Engine rpm meter 2 High beam indicator light 8 9 The odometer 3 Turn indicator light 10 Engine working hour counter 4 Reverse indicator light 11 2WD 4WD indicator 5 Speedometer A km mile selector 6 Coolant temperature meter B hour distance selector 12 Fuel gauge Indicator ...

Page 200: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 35 8 11 MAIN SWITCH AND HANDLE SWITCH ...

Page 201: ...n Install a new seal rubber onto the fuel level sensor Install the retainer plate onto the sensor by aligning the tab with the grove Install the sensor into the fuel tank while aligning the grove in the plate with the boss on the fuel tank Install and tighten the bolts securely Install the removed parts in the reverse order of removal Fuel Gauge Fuel level Sensor Inspection Move the float to the b...

Page 202: ...ould come on If the fuel gauge does not function properly check the fuel level sensor If the fuel level sensor is OK replace the LCD Meter Fuel level Sensor Inspection Disconnect the fuel level sensor 2p Green connector and connect the ohmmeter to the sensor side connector terminals Measure the fuel level sensor resistance with the float at the top FULL And bottom RESERVE positions FLOAT POSITION ...

Page 203: ...hen to the Controller Controller lights the 4WD indicator 5 If the Splined Dog is not in right position 4WD won t engage this information will be given to the Sensor by the Magneto on the Selector Plate and then to the Controller The controller will try to drive the Shift Motor several times in 1 min During this time the 4WD indicator is not on this requires the rider to back or move ride the ATV ...

Page 204: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 39 Fig 2 Fig 3 Page from owner s manual ...

Page 205: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 40 Fig 4 ...

Page 206: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 41 8 14 WIRING DIAGR ...

Page 207: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 42 ...

Page 208: ...CHAPTER 8 ELECTRICAL CUV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 43 NOTES ...

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