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Linhai T-Boss 550, Service Manual

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CHAPTER  7  ELECTRICAL                         

                          T-Boss550  SERVICE  MANUAL  20.0 

CHAPTER  7  ELECTRICAL  PAGE.7- 

6 

 

IF THE IGNITION SYSTEM FAILS TO OPERATE 

 

Procedure 

Check: 
1. Fuse (Main) 

6. Ignition coil 

2. Battery 

7.Pickup coil resistance   

3. Spark plug 

8.Main switch   

4. lgnition spark gap 

9.Wiring connection 

5. Spark plug cap resistance 

 

(entire ignition system) 

 
 
 
 
 
 
 
 

 

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:  DPR7EA  9  / 
NGK 

3.Spark plug 

 

 

OUT OF SPECIFICATION 

  Check  the  spark  plug 

condition.   

  Check  the  spark  plug 

type. 

 Check the spark plug gap. 

 

 

Repair or replace the spark plug 

 

 

 

 

Spark  plug  gap:  0.8

～

0.9mm 

 

 

 

 

 

Summary of Contents for T-Boss 550

Page 1: ...SERVICE MANUAL T Boss 550...

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

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

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

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

Page 6: ...ts 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...

Page 7: ...Dealing with stains rust moisture etc on the connector 1 Disconnect Connector 2 Dry each terminal with an air blower 3 Connect and disconnect the connector two or three 4 Pull the lead to check that i...

Page 8: ...t oil from the machine can cause severe burns The engine must be cool before service Crate of the UTV and parts in the UTV maybe have sharp edge always pay attention and wear protection CONVERSION TAB...

Page 9: ...SERVICE MANUAL 20 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 rear right of the frame tube The engine serial number is stam...

Page 10: ...CHAPTER 1 GENERALINFORMATION T Boss550 SERVICE MANUAL 20 0 CHAPTER 1 GENERAL PAGE 1 6 1 3 VEHICLE DIMENSIONS...

Page 11: ...CHAPTER 1 GENERALINFORMATION T Boss550 SERVICE MANUAL 20 0 CHAPTER 1 GENERAL PAGE 1 7 NOTES...

Page 12: ...le even some parts have almost same appearance Always refer to Parts Manual of each UTV model for spare parts information and service 2 1 PERIODIC MAINTENANCE 2 2 THROTTLE PEDAL INSPECTION 2 3 CHOKE A...

Page 13: ...le speed 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 adj...

Page 14: ...onthly 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 cable...

Page 15: ...lter Replace lines every 2 years DL Fuel Filter 100 12 months R Radiator 100 12 months I R Cooling System hoses 50 6 months I R if necessary Spark arrestor 10 monthly C R if necessary DL Clutches driv...

Page 16: ...ication Change annually or at 100 hours 4 Front Gear case oil SAE GL 4 85W 90 See 16 MAI NTENANCE Front Gear Case Lubrication Change annually or at 100 hours 5 Steering system Grease Lubricate the piv...

Page 17: ...3 Accelerator pedal and brake pedal Grease Grease inspect Monthly or 20 hours LUBRICATION RECOMMENDATIONS NOTE 1 More often under severe use such as wet or dusty conditions 2 Grease Light weight lithi...

Page 18: ...brake 2 Put the gear shift lever in the N Neutral position 3 Start the engine and warm it up thoroughly 4 Measure the distance the throttle pedal moves before the engine begins to pick up speed Free...

Page 19: ...sed area Fuel powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Never drain the float bowl when the engine is hot Severe burns may result FUEL LI...

Page 20: ...same and enough threads length 2 6 BRAKING SYSTEM INSPECTION The following checks are recommended to keep the braking system in good operating condition Service life of braking system components depen...

Page 21: ...rake has been adjusted at the factory the brake should be checked for proper operation The mechanical brake must be maintained to be full functional 1 With the engine off apply the parking brake lever...

Page 22: ...turn the adjuster nut directly But the adjust range is limited Always do the procedure 1 to 8 when necessary 2 7 SUSPENSION SPRING RPELOAD ADJUSTMENT Operator weight and vehicle loading affect suspen...

Page 23: ...he vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION 1 With the transmission in gear and the parking Brake locked place the w...

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

Page 25: ...CHAPTER 2 MAINTENANCE T Boss550 SERVICE MANUAL 20 0 CHAPTER 2 MAINTENANCE PAGE 2 14 NOTES...

Page 26: ...ENGINE PAGE 3 1 CHAPTER 3 ENGINE 500 cc 3 1 Removal and Installation of Engine 3 2 Engine Overhaul Information 3 3 Checks Adjustment 3 4 Engine Removal Inspection Installation 3 5 FUEL INJECTION SYSTE...

Page 27: ...o avoid any possible damage when removing or installing the engine Following operation doesn t require removal of engine from the vehicle Fuel pump Throttle body air filter Cylinder head cover cylinde...

Page 28: ...t Air Filter Throttle Body Clamp Water Inlet Hose Remove cable shifter Remove bolt Remove shifting anchor plate Remove connector of water temperature transducer Remove clamp Remove water outlet hose R...

Page 29: ...TER 3 ENGINE PAGE 3 4 Remove spark plug cap from cylinder Remove protection sleeve of starter relay Remove Nut Disconnect positive wire of starter relay Remove Bolt Remove negative wire of starter rel...

Page 30: ...CHAPTER 3 ENGINE PAGE 3 5 Remove 2 Bolts and Nuts of lower engine hanger Remove 4 Bolts of lower engine hanger Remove 4 Bolts of front steering kunckle connected with the engine Remove 4 Bolts of rea...

Page 31: ...nstall the upper and lower engine hangers Tightening torque Engine upper hanger bolt 50 60N m Engine lower hanger bolt 50 60N m Install Water outlet and inlet hoses to engine with proper clamps Positi...

Page 32: ...rhaul Information Conversion Table 3 2 1 General Precautions 3 2 2 Fuel Oil and Coolant 3 2 3 Brake in Procedures 3 2 4 Engine Exterior and Engine No 3 2 5 Engine Specification 3 2 6 Overhaul Data 3 2...

Page 33: ...these signal words Warning Indicates a potential hazard that could result in injury or death Caution indicates a potential hazard that could be result in vehicle damage Note provides key information t...

Page 34: ...lubricating or exhaust system Do not dispose used oil coolant or defective parts optionally for environmental purpose CAUTION Use genuine LINHAI parts or their equivalent Place and store the disassem...

Page 35: ...gines 3 2 4 BREAK IN PROCEDURES During manufacturing only the best possible material are used and all machined parts are finished to a very high standard It is still necessary to allow the moving part...

Page 36: ...CHAPTER 3 ENGINE T Boss550 SERVICE MANUAL20 0 CHAPTER 3 ENGINE PAGE 3 11 3 2 5 Engine Exterior and Engine No...

Page 37: ...ive 10 Lubrication System Lubrication Type Pressure Splash Oil Pump Trochoid Filter Type Full Flow Filter Screen Oil Type SAE15W 40 SG 11 Cooling System Cooling Type Closed Coolant Circulation Coolant...

Page 38: ...5 Play of Valve Head Seal IN EX 0 03 Width of Valve Seat Seal IN EX 0 9 1 1 Valve Spring Free Length IN EX 40 38 8 Valve Spring Tension IN EX 182 210N when compressed to 31 5mm Cam Height IN 33 430 3...

Page 39: ...g 0 97 0 99 2ND Ring 1 17 1 19 Piston Ring Groove Width Top Ring 1 03 1 05 2ND Ring 1 22 1 24 Oil Ring 2 51 2 53 Inner Diameter of Piston Pin Hole 23 002 23 008 23 030 Outer Diameter of Piston Pin 22...

Page 40: ...Functioning Temperature of Thermoswitch OFF ON 88 ON OFF 82 Coolant Type 35 antifreeze corrosion resistant high boiling point coolant Item Standard Service Limit Remark Clutch Plate Inner diameter 14...

Page 41: ...e Primary 0 1 0 5 Secondary 12 22 Magneto Coil Resistance Pick up 150 300 Magneto Voltage Without load 100V AC 5000r min Max Magneto Output Power 300W 5000r min Regulated Voltage 13 5V 15 0V 5000r min...

Page 42: ...iven Bevel Gear 1 M16 1 5 150 Fixing Nut Clutch 1 M18 1 5 70 Counter Clockwise Limit Nut Drive Bevel Gear Bearing 1 M60 110 Apply Thread Locker Nut Universal Joint Yoke 1 M55 80 Counter Clockwise Appl...

Page 43: ...il Starter Motor 2 M6 10 Bolt Cylinder Head 4 M10 42 Bolt Cylinder Head 2 M6 10 1 M8 25 Bolt Cylinder Upper Lower 4 M6 10 Bolt Cylinder Head Cover 12 M6 10 Bolt Chain Tensioner 2 M6 10 Bolt Chain Tens...

Page 44: ...For measuring the clearance 12 Spring Balance For measuring the spring tension 13 Tachometer For measuring engine speed 14 Oil Pressure Gauge For measuring oil pressure 15 Compression Gauge Adapter Fo...

Page 45: ...se 8 Crankshaft Installation Set For installing crankshaft to left crankshaft 9 Valve Spring Compressor For removal and installation of valve spring 10 Valve Seat Cutter For valve seating 11 Ring Nut...

Page 46: ...Lubricating Grease 3 MoS2 Lithium Base Grease Oil seal lip O ring and sealing faces of other rubber seal materials bearings with seals CVT bearing and collar Coolant 35 antifreeze corrosion resistant...

Page 47: ...ntenance and Adjustment 3 3 2 Valve Clearance 3 3 2 1 Engine Idle Speed 3 3 2 2 Spark Plug 3 3 2 3 Filter 3 3 2 4 Fuel Hose 3 3 2 5 Drive Belt 3 3 2 6 Inspection of Lubrication System 3 3 3 Inspection...

Page 48: ...e I Replace every 4 years Clutch I Drive Belt I R Engine Oil R R Oil Filter R R Coolant Level I I I Water Hose Pipes I I I Coolant Replace every 2 years 3 3 1 Periodic Maintenance Table The table belo...

Page 49: ...sary Remove cover Remove inspection cap on left crankcase Remove 2 valve adjusting cover Turn the crankshaft until the line of T D C on rotor is aligned with mark of inspection hole on left crankcase...

Page 50: ...NE IDLE SPEED Inspect initially at 20 hours run in and every 40 hours or 1000km thereafter Start the engine and warm it up for several minutes measure engine speed with a tachometer Set the engine idl...

Page 51: ...2 4 Air Filter Inspect every 40 hours or 1000 km clean it if necessary If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power output and an inc...

Page 52: ...ngine without the element or with torn element Make sure that the air filter element is in good condition at all times Remove the drain plug of air box to drain out any water 3 3 2 5 Fuel Hose Inspect...

Page 53: ...s low as possible between secondary sliding sheave and primary fixed sheave Hold secondary sheave and tighten the nut to the specified torque Nut Secondary Sheave 115 N m Install primary sheave and nu...

Page 54: ...not tighten it Take out oil dip rod and check if oil is between upper and lower limit If the engine oil is insufficient fill more oil until the sufficient oil is obtained Engine Oil SAE10W 50SN Note K...

Page 55: ...should be changed when the engine is warm If the oil filter should be replaced replace engine oil at the same time Replacing Oil Filter Remove relative parts see Replacing Engine Oil Remove oil filte...

Page 56: ...uid or vapor Engine coolant is harmful If coolant splashes in your eyes or clothes thoroughly wash it away with water and consult a doctor If coolant is swallowed induce vomiting and get immediate med...

Page 57: ...nder Wear of piston or piston ring Piston ring jam in groove Poor closure of valve seat Damaged cylinder gasket or other defects Note When cylinder pressure too low check the above items Testing Cylin...

Page 58: ...ombination of above items Oil pressure is too high Oil viscosity is too high Clogged oil passage Combination of above items Testing Oil Pressure Install hose and hose Connect tachometer with ignition...

Page 59: ...2400r min If the engagement speed is out of the above range check the following Clutch shoes Clutch shoe wheel Primary and secondary sheave Refer to Chapter 12 for inspection of clutch II Clutch Lock...

Page 60: ...ools Drain up engine oil Drain up coolant Engine Periphery Water Hose Pipe Remove water hose clamp and Remove water hose Remove screw and water hose Left Side Cover Remove 4 bolts M6X12 of left side c...

Page 61: ...s of cylinder head cover Remove cylinder head cover Timing Chain Tensioner Remove screw plug insert a flat screwdriver into slot of timing chain tensioner adjuster turn it clockwise to lock tensioner...

Page 62: ...mshaft Note Take care not to drop spacer bolt bolt lock and C ring into crankcase Remove tensioner plate Cylinder Head Remove cylinder head bolt Remove cylinder head bolts diagonally Remove cylinder h...

Page 63: ...Piston Remove piston pin circlip with long nosed pliers Note Put a clean rag under piston so as not to drop piston pin circlip into crankcase Remove piston pin and piston Notes When installing piston...

Page 64: ...emove oil filter with special tools Tool Oil filter Remover Sector Gear Remove bolt of sector gear housing cover Remove wire clip and sector gear housing cover Remove dowel pin and gasket Remove drive...

Page 65: ...RVICE MANUAL20 0 CHAPTER 3 ENGINE PAGE 3 40 Water Pump Screw out bolt of water pump Remove water pump Remove left crankcase cover 1 Remove nut Install special tool to rotor thread Remove rotor and woo...

Page 66: ...NE PAGE 3 41 Starting Motor Gear Remove driven gear and needle bearing Remove spacer Remove dual gear and shaft Remove idle gear and shaft Oil Pump Sprocket and Chain Remove drive sprocket nut Remove...

Page 67: ...olt of CVT cover Remove CVT cover Remove gasket and dowel pin CVT Continuously Variable Transmission Remove primary sheave nut Remove primary sliding sheave Remove secondary sheave nut Remove secondar...

Page 68: ...move bolt 1 of CVT case Remove bolt 2 of CVT case Remove outer clutch face and CVT case Remove dowel pin front and rear gasket Clutch Remove one way clutch Remove clutch shoe fixing nut Remove clutch...

Page 69: ...rankcase Remove left crankcase bolts Remove right crankcase bolts Separate right crankcase with special tool Caution The Crankcase separator plate should be parallel with the end face of crankcase Cra...

Page 70: ...emove Oil seal Bearing limit nut Remove Bearing Front Output Shaft Shift Cam Fork Shaft Remove Shift Cam Fork Shaft Drive Bevel Gear Remove left crankcase from driven bevel gear Drive Shaft Drive Shaf...

Page 71: ...NGINE T Boss550 SERVICE MANUAL20 0 CHAPTER 3 ENGINE PAGE 3 46 Crankshaft Separate crankshaft from left crankcase with special tool Tool Crankshaft Separator Oil bump Relief Valve Remove oil bump and r...

Page 72: ...aft bolts A Remove rocker arm shaft by using M6 bolts B Cylinder Head Cover Distortion Clean off sealant from the fitting surface of cylinder head cover place cylinder head cover on a surface plate an...

Page 73: ...f the camshaft contact surface Rocker Arm I D 000 12 018mm Tool Dial Calipers Assembly Note Intake rocker arm shaft A has oil holes Apply engine oil to rocker arms and shafts Install rocker arms and t...

Page 74: ...PAGE 3 49 Remove thermostat Compress the valve spring and remove valve cotter with tweezers Tools Valve Spring Compressor Tweezers Remove valve spring upper seat and valve spring Remove valve from th...

Page 75: ...ve lapper to hold the valve head The ring like dye impression on the valve face should be continuous without any break The width of the dye ring which is the visualized seat width should be within the...

Page 76: ...run out as illustrated on the right Valve head Radial Run out out of range Replace Service Limit 0 03mm Tool Dial Gauge 1 100 Magnetic Stand V Block Valve Face Wear Check each valve face for wear or d...

Page 77: ...e to compress the spring to the specified length Valve spring tension out of range Replace Service Limit IN EX 182N 210N 31 5mm Tool Spring Scale Measure valve spring incline Spring incline out of ran...

Page 78: ...two cotter halves to the stem end and release compressor to allow the cotter to wedge in between seat and stem Make sure that the rounded lip of the cotter fits into the groove in the stem end Tool Va...

Page 79: ...pecified torque Water temperature sensor Tightening torque 10 N m Install intake pipe apply lubricant to 0 ring Camshaft Check camshaft for wear and run out of cams and journals if the engines produce...

Page 80: ...l Wear Check whether each journal is worn to the limit by measuring camshaft journal oil clearance with the camshaft installed Camshaft journal oil clearance Service limit 0 15mm Check according to th...

Page 81: ...Other end 17 466mm 17 484mm Tool micrometer 0 25mm Camshaft Run out Measure the run out with a micrometer Replace camshaft is the run out is out of range Service limit 0 10mm Timing Sprocket and Chain...

Page 82: ...n tensioner with a new one Cylinder Cylinder Distortion Check the gasket face of cylinder for distortion with a straightedge and thickness gauge and take clearance readings at 7 points as illustrated...

Page 83: ...arance according to the above measurement If the clearance is more than 0 15mm replace the cylinder or piston or both Piston Ring to Groove Clearance Use a thickness gauge to measure the side clearanc...

Page 84: ...ring Piston ring free end gap limit Top ring 8 9mm 2nd ring 9 5mm Piston ring end gap limit Top Ring 0 60mm 2nd ring 0 60mm Tool Vernier caliper Thickness gauge Piston Pin and Pin Bore Use a bore gaug...

Page 85: ...s also applicable to check and inspection of big end Connecting Rod Deflection 3 0mm Tools Dial Gauge Magnetic stand V block Connecting Rod Big End Side Clearance Push the big end to one side and use...

Page 86: ...h should be replaced as a set Clutch Wheel Check the inner clutch wheel for scratches scuffs or blue discoloration or uneven wear If any damage is found replace the clutch wheel with a new one Check o...

Page 87: ...CHAPTER 3 ENGINE T Boss550 SERVICE MANUAL20 0 CHAPTER 3 ENGINE PAGE 3 62 Primary and Secondary Sheave...

Page 88: ...Sliding Sheave Disassembly Remove spacer Remove Cam and Roller Roller Check each roller and sliding face for wear and damage Wear and damage Replace Note rollers should be replaced as a set Oil Seal C...

Page 89: ...oval procedure of primary sliding and fixed sheave for installation Pay attention to the following Apply grease to inner bore and oil seal lip Note Wipe off any excessive grease thoroughly Take care n...

Page 90: ...ing compressor Tool Nut Wrench Sheave Holder Attach special tool to the secondary sliding sheave and compress it by turning in the tool handle Note Make sure that spring end A is inserted into slot B...

Page 91: ...UAL20 0 CHAPTER 3 ENGINE PAGE 3 66 Remove spring Remove spring seat Remove guide pin and spacer Remove secondary sliding sheave O ring and Oil Seal Check the O ring and oil seal for wear and damage We...

Page 92: ...check the spring free length If the length is shorter than the service limit replace with a new one Service Limit 145 4mm Secondary Sliding and Fixed Sheave Check drive face for any abnormal conditio...

Page 93: ...slide the lip with a 0 1mm steel sheet as guide Install spring seat Align hole A with hole B Install spring and spring plate Insert spring end into the hole Compress spring with special tool Align the...

Page 94: ...rque 100N m Tool Ring nut wrench Sheave Holder Drive belt Check belt for any greasy substance Check contact surface of belt for any cracks and damage Check belt width with vernier caliper Damage width...

Page 95: ...E 1 2 SHIFT CAM 1 11 DRIVEN GEAR LOW RANGE 1 3 RIGHT CRANKCASE 1 12 SPRING SHIFT FORK 1 4 LEFT CRANKCASE 1 13 RIGHT SHIFT FORK 1 5 DRIVEN SECTOR GEAR 1 14 GUIDE BAR 1 6 SPROCKET REVERSE GEAR 1 15 DRIV...

Page 96: ...et surface for any damage or over wear Damage or over wear Replace Check reverse gear chain for any damage or over wear Damage or over wear Replace Disassemble driven shaft as illustrated Check each g...

Page 97: ...arance Standard clearance 0 10 0 30mm Service Limit 0 50mm Measure shift fork groove width with vernier caliper Standard shift fork groove width 6 05 6 15mm Measure shift fork thickness with vernier c...

Page 98: ...heck shift cam groove for scratches damage Scratch or damage Replace Assembly Reverse the removal procedure for assembly Pay attention to the following Use new retainers Pay attention to the direction...

Page 99: ...PUMP Disassembly oil pump as illustrated 1 Oil pump housing 2 Dowel pin 3 Oil pump shaft 4 Straight pin 5 Inner rotor oil pump 6 Outer rotor oil pump 7 Oil pump cover Check oil pump housing and cover...

Page 100: ...n drive bevel gear nut 3 remove the drive bevel gear 4 and adjust washer 5 Check the drive bevel gear 4 and output driven gear 2 Output driven gear 6 Drive bevel gear shaft 3 Drive bevel gear nut 7 Be...

Page 101: ...ss out driven bevel gear Place a clean rag under bevel gear cover Remove bearing limit nut 10 with special tool and remove bearing Check driven bevel gear 8 surface for scratches wear Scratch or wear...

Page 102: ...en gears to the crankcase Wrap a screwdriver with a rag and insert it into the speed sensor hole of left crankcase to fix the drive bevel gear Install special tool and micrometer Tool Bevel gear side...

Page 103: ...ns in both directions Remove drive and driven bevel gear shafts and check the coated teeth of the drive bevel gear Refer to the illustration on the right for tooth contact pattern and Incorrect contac...

Page 104: ...PAGE 3 79 Balancer Shaft Remove the parts as illustrated on the right Check each part for abnormal wear or damage Wear or damage Replace Balancer shaft gear Woodruff key Balancer shaft Balancer shaft...

Page 105: ...ply engine oil to starter clutch Apply thread locker to bolt and tighten to the specified torque Tightening torque of starter clutch bolt 30N m Material Thread Locker Install the starter driven gear M...

Page 106: ...ectric Starter Gear Check the gear surface for scrap or damage Scrape or Damage Replace LEFT CRANKCASE COVER MODEL2 Check magneto stator coil 2 pickup coil 3 for damage burn or short circuit if any re...

Page 107: ...e Use a new oil seal Install oil seal limitator and tighten screw after applying thread locker Tool Bearing Remover Oil Seal Remover Bearing Installer CVT Case Check bearing 5 for smooth turning In ca...

Page 108: ...Bearing 12 Bolt 22 Bearing 3 Seal 13 Left Crankcase 23 Oil Dip Rod 4 Bearing 14 Oil Pipe 1 24 O ring 5 Bearing 15 Oil Pipe 2 25 Bolt 6 Bearing 16 Link Bolt 26 Speed Sensor 7 Oil Seal 17 Washer 27 O r...

Page 109: ...e gear sensor 9 and tighten to the specified torque Reverse gear sensor tightening torque 20N m Install speed sensor 26 Install oil pipe and tighten the link bolt to the specified torque Link bolt tig...

Page 110: ...special tool Note Do not hammer the conrod into crankcase with plastic mallet Use special tool to avoid affect of conrod precision Tool Conrod Installer Balancer Shaft Install balancer shaft Caution...

Page 111: ...pray adequate engine oil to each part Drive Bevel Gear Install drive bevel gear and tighten to the specified torque Drive bevel gear tightening torque 32N m Material Thread Locker Right Crankcase Driv...

Page 112: ...fitted Install bolt and tighten to the specified torque Crankcase bolt tightening torque M6 10N m M8 25N m Note Crankcase bolts should be tightened diagonally in several steps Place the steel ball an...

Page 113: ...T case assembly to right crankcase Install bolt and nut Note Tighten bolt nut diagonally Use a new gasket Install air guide plate and screw Primary Sheave Secondary Sheave Drive Belt Install primary f...

Page 114: ...to the specified torque Primary sheave nut tightening torque 115 N m Tighten secondary sheave nut to the specified torque Secondary sheave tightening torque 115 N m Note Turn the primary fixed sheave...

Page 115: ...cket and Chain Install oil pump drive sprocket Install oil pump driven sprocket Install oil pump drive chain Install oil pump sprocket bolt Install sprocket retainer with a long nose pliers Tool Long...

Page 116: ...T Boss550 SERVICE MANUAL20 0 CHAPTER 3 ENGINE PAGE 3 91 Install starting driven gear Magneto Rotor Install Magneto Rotor 1 Install Nut 2 Nut tightening torque 160N m Install left crankcase cover 1 In...

Page 117: ...ump shaft into groove of water pump shaft Sector Gear Install the parts as illustrated on the right 1 sector gear cover and gasket 2 dowel pin 3 drive sector gear 4 driven sector gear 5 driven sector...

Page 118: ...ed torque Tool Oil Filter Wrench Starting Motor Apply engine oil to new O ring Install starting motor Install bolt and tighten to the specified torque Tightening torque 10N m Engine Top Side Piston In...

Page 119: ...ck that the gaps are so located Apply a light coat of moly oil to the piston pin Install piston pin into holes of piston and conrod small end Note When installing the piston the IN mark on piston top...

Page 120: ...tween sprocket and crankcase Install chain guide Fit the dowel pin and new cylinder cover gasket Note Use a new cylinder cover gasket to prevent oil leakage Cylinder Head Install the cylinder cover ti...

Page 121: ...be caught between sprocket and crankcase Align the mark A on the camshaft so that they are parallel with the mating surface of the cylinder head Note Do not rotate the magneto rotor while doing this w...

Page 122: ...15 N m Bend up the lock washer to lock the bolts Cylinder Head Cover Clean the mating surface of cylinder head and cylinder head cover Install dowel pin to the cylinder head Apply sealant to the matin...

Page 123: ...on adjuster turn it clockwise to lock the tensioner spring Install the chain tensioner and the new washer 1 Install the bolt 2 tighten it to the specified torque Chain tensioner bolt tightening torque...

Page 124: ...Valve Inspection Cap Install valve inspection cap bolt Spark Plug Install spark plug with special tool and tighten to the specified torque Note To avoid damage to the cylinder head thread screw in th...

Page 125: ...CHAPTER 3 ENGINE T Boss550 SERVICE MANUAL20 0 CHAPTER 3 ENGINE PAGE 3 100 Water Pipe and Hose Install water hose 5 Install bolt 4 Install water hose 3 Install clamp 1 and 2...

Page 126: ...y 3 5 3 1 Description and Working Principle 3 5 3 2 Appearance 3 5 3 3 Throttle Body Removal 3 5 3 4 Cleaning Procedure 3 5 3 5 Throttle Body Installation 3 5 4 Engine Coolant Temperature Sensor 3 5 4...

Page 127: ...arance 3 5 8 3 Operating Conditions 3 5 8 4 Service Procedure 3 5 8 5 Fuel Module Removal 3 5 8 6 Fuel Module Installation 3 5 8 7 Fuel Pressure Relief Procedure 3 5 8 8 Fuel Leakage Check Procedure 3...

Page 128: ...can damage the ECU DO NOT Place the ECU close to or pour water oil or any other liquids ECU is susceptible to water and liquids DO NOT Allow mud or other debris to accumulate on the surface of the EC...

Page 129: ...ng Date Total kms run on the vehicle Location of use Vehicle No Date of return 3 5 2 INJECTOR 3 5 2 1 Appearance The figure below shows the standard M3 5 Fuel Injector appearance 3 5 2 2 Temperature R...

Page 130: ...or If an injector is to be re used and no new seal rings are available take care to inspect each seal ring for signs of damage Even minor defects in the seal ring can lead to leakage Take extra care i...

Page 131: ...into the manifold Check that the injector is installed in the original orientation to maintain proper spray targeting and that the retaining clip is properly seated on the injector and the fuel line...

Page 132: ...y Assembly is an interactive system comprised of the following subsystems the main casting body bearing system shaft and valve system return spring system cable interface system throttle position sens...

Page 133: ...t varies as a function of temperature within prescribed tolerance limits The sensor has a negative temperature coefficient of resistance 3 5 4 2 Appearance 3 5 4 3 Installation Requirements Dynamic To...

Page 134: ...e reference of 5 0 1 VDC 3 5 5 4 Sample Cleaning When necessary the samples may be cleaned in isopropyl alcohol or gasoline for one minute with mating connectors in place and then air dried 3 5 6 Oxyg...

Page 135: ...undle as the Crank sensor wires There is around 200 V peak potential between C wire and engine ground This voltage potential could cause a noise on sensor cables 3 5 7 4 DOs and DONTs ACTION REASON DO...

Page 136: ...high voltage secondary leads by hand is preferred Damage to the coil tower secondary boot or mating connection surfaces might occur DO Install the secondary leads before connecting the primary leads...

Page 137: ...specifications All harnesses should be supported within 6 of a mating connection Adequate retention force might not be achieved if the fastener is not designed to be reused Mating connections are not...

Page 138: ...ue is different for various plug type cylinder head material If the thread is damage it prevents a good heat transform from the shell to the cylinder head Do not use any type of anti seize compound on...

Page 139: ...l ventilated area and away from any open fire flames Wear Safety glasses To relieve fuel vapor pressure in fuel tank remove fuel filler cap fuel filler neck and then reinstall it As fuel lines are at...

Page 140: ...eakages from hoses hose joints 2 Check Fuel Pump 3 Check Pressure Regulator 1 Clogged Filter 2 Kink Blockage in Fuel Hoses 3 Check Re 3 5 8 5 Fuel Module Removal Relieve fuel pressure in fuel lines re...

Page 141: ...uel module electrical coupler from vehicle harness Start engine and run till it stops due to lack of fuel Repeat ignition key ON and OFF for 2 3 times of about 3 seconds each time to relieve fuel pres...

Page 142: ...c connector link one end is 6PIN connector the other is the interface for connecting diagnostic main cable They are shown as below S The 6 PIN diagnostic connector link cable and USB type main unit s...

Page 143: ...e used to diagnose Delphi Engine Management System with functions Read DTC Clear DTC Data Stream Status Stream and Record Data Operations When the unit is powered up the screen will display the interf...

Page 144: ...diagnostic software version press to continue the interface will display as below Diagnostic Function Here we take diagnostic function for demonstration Select diagnostic function and press the screen...

Page 145: ...are as follows Read DTC Clear DTC Data Stream Status Stream Record Data Press or key to select function you needed 1 Read DTC Select Read DTC and press it will display fault code as below Press or ke...

Page 146: ...d press it will display as below 3 Data Stream Select Data Stream and press it will display as below Press or key for page up down to view more Press key to exit 4 Status Stream Select Status Stream a...

Page 147: ...uit High Voltage 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 Inje...

Page 148: ...oling Circuit 3 6 2 Inspection and Cleaning of Radiator and Water Hoses 3 6 3 Inspection of Fan Motor 3 6 4 Inspection of Water Temperature Sensor 3 6 5 Inspection of Thermostat 3 6 6 Water Pump 3 6 7...

Page 149: ...eep coolant away from reach of children 3 6 2 Inspection of Cooling Circuit Remove radiator cap and connect tester to filler Warning Do not open the radiator cap when the engine is still hot Give a pr...

Page 150: ...annot meet the pressure requirement replace it Radiator Cap Valve Opening Pressure Standard 110 140 kPa Tool Radiator Cap Tester Radiator Inspection and Cleaning Remove dirt or trash from radiator wit...

Page 151: ...Inspection of Thermoswitch Remove thermoswitch Check the thermoswitch for closing or opening by testing it at the bench as illustrated Connect the thermoswitch to the circuit tester place it in a ves...

Page 152: ...vessel with engine oil Place the vessel above a stove Heat the oil to raise the temperature slowly and take the reading from thermometer and ohmmeter Water Temperature and Resistance Installation Appl...

Page 153: ...thermometer when the thermostat valve opens Thermostat Valve Opening Temperature 68 74 Keep heating the water to raise the water temperature Just when the water temperature reaches the specified value...

Page 154: ...AGE 3 129 Remove clamps and water hoses Release bolts and remove water pump Remove O ring Note Do not reuse the O ring Remove the overflow tube Release water pump cover screws water pump cover and gas...

Page 155: ...e a removed oil seal Remove bearing with special tool Note The bearing does not need to be removed if there is no abnormal noise Note Do not reuse a removed bearing 3 6 7 2 Inspection of Water Pump Be...

Page 156: ...ce the oil seal Water Pump Body Check the mating mace of water pump body with bearing and mechanical seal Damage Replace Impeller Check the impeller and shaft for damage Damage Replace 3 6 7 3 Assembl...

Page 157: ...f mechanical seal Install bearing with special tool Tool Bearing Installer Note The stamped mark on the bearing faces outside Install seal ring to impeller Clean off the oil and grease from mechanical...

Page 158: ...water pump shaft Install new gasket to water pump body Install water pump cover and tighten the bolts and bleed bolt Water Pump Cover Bolts Tightening Torque 6N m Check impeller for smooth turning In...

Page 159: ...20 0 CHAPTER 3 ENGINE PAGE 3 134 Install water pump and tighten the bolts to the specified torque Water pump bolts tightening torque 10N m Note Set the water pump shaft slot end B to oil pump shaft fl...

Page 160: ...CHAPTER 3 ENGINE T Boss550 SERVICE MANUAL20 0 CHAPTER 3 ENGINE PAGE 3 135 3 6 7 8 Lubrication System Illustration...

Page 161: ...nt hose Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty fuel injection system relay Clogged or damaged fuel hose 3 Throttle body Deteriorated or contaminated fuel Sucked in air E...

Page 162: ...d air filter element Fuel system 1 Fuel pump Faulty fuel pump FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components Symptoms Possible Causes 1 A pronounced hesitation...

Page 163: ...e components are damaged remove the components and check them FAULTY GEAR SHIFTING Shifting is difficult Refer to FAULTY CLUTCH on next page EJSDCDICDI SHIFT LEVER DOES NOT MOVE Shift drum and shift f...

Page 164: ...ave Worn primary fixed sheave 4 Primary sliding sheave Worn primary slicing sheave 5 Secondary fixed sheave Worn secondary fixed sheave 6 Secondary sliding sheave Worn secondary sliding sheave OVERHEA...

Page 165: ...g knuckles 3 Shock absorber assemblies Faulty shock absorber spring Leaking oil or gas 4 Tire s Uneven tire pressures left and right Incorrect tire pressure Uneven tire wear 5 Wheel s Incorrect wheel...

Page 166: ...CHAPTER 3 ENGINE T Boss550 SERVICE MANUAL20 0 CHAPTER 3 ENGINE PAGE 3 141 NOTES...

Page 167: ...versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 4 1 FRONT A ARM REPLACEMENT 4 2 RE...

Page 168: ...rt Lh 17 Screw M5X10 18 Grease Fitting M6 19 Front Shock Absorber Assy 20 Bolt M10X1 25X57 21 Arm Upper Frt Lh Assy 22 Arm Lwr Frt Lh Assy 23 Carrier Bearing Wheel Lh Assy 1 Elevate and safely support...

Page 169: ...cle is on the ground DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 10 Attach A arm to strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If...

Page 170: ...16 Arm Lwr Rear Lh 17 Plug 18 Shaft Rear Lwr Arm 19 Cover Arm Lwr Rear Lh 20 Screw M5X10 21 Rear Shock Absorber Assy 22 Bolt M10X1 25X62 5 23 Bolt M10X1 25X57 24 Stabilizer Bar 25 Ball Pin Lh 26 Ball...

Page 171: ...move the spindle nut and washer Remove the hub assy by sliding it off of the shaft 5 Loosen two bolts that secure the rear knuckle to the A arm Remove the rear knuckle assembly by sliding it off of th...

Page 172: ...njury or death could result if fasteners come loose during operation 13 Attach A arm to rear knuckle Tighten upper and lower bolts to 44 ft lbs 60 Nm 14 Install the shock and tighten shock bolt to 44...

Page 173: ...ss to the stabilizer bar each side 3 Remove the stabilizer bar nut from the lower A arm each side 4 Remove the two bolts that secure the stabilizer bar to the main frame each side 5 Remove the stabili...

Page 174: ...afely support the box during the rest of the removal process The box is not as stable with the hinge pin removed 7 With the hinge pins removed remove the box from the frame Two people maybe needed to...

Page 175: ...12 19 Nut M12 20 Shoulder Bolt M10 1 25 30 21 Bushing For Adjustable Steering Wheel 22 Nut M10 23 Nut M10 24 Adjustment Cylinder 25 Shoulder Bolt M8 1 25 30 26 Washer 6 27 Bolt M6X12 1 With the steer...

Page 176: ...CHAPTER 4 CHASSIS T Boss550 SERVICE MANUAL20 0 CHAPTER 4 CHASSIS PAGE 4 10 NOTES...

Page 177: ...REMOVAL INSPECTION 5 4 FRONT HUB INSTALLATION 5 5 FRONT HUB BEARING REPLACEMENT 5 6 FRONT DRIVE AXLE REMOVAL INSPECTION 5 7 FRONT DRIVE AXLE INSTALLATION 5 8 FRONT DRIVE AXLE DISASSEMBLY INSPECTION 5...

Page 178: ...ION Locking nuts and bolts with pre applied locking agent should be replaced if removed The self locking properties of the nut or bolt are reduced or destroyed during removal 5 2 FRONT HUB EXPLODED VI...

Page 179: ...isture dirt or corrosion or roughness is evident 5 4 FRONT HUB INSTALLATION 1 Inspect the hub strut bearing surface for wear or damage 2 Apply grease to drive axle spindle 3 Install spindle through th...

Page 180: ...pport casting on outer edges so bearing can be removed 4 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bear...

Page 181: ...ter and Chapter 4 CAUTION To avoid damage to the front gearcase oil seal hold the front drive shaft horizontal and straight out from the front differential during removal 3 Hold the drive shaft straig...

Page 182: ...front differential 2 Push the drive shaft straight into the front differential and push it in all the way until it bottoms out If necessary carefully tap on the outer end of the drive shaft with a rub...

Page 183: ...be reused b Slide the outboard boot off the drive axle and discard the boot band A it cannot be reused 9 Inspect the drive axle as described in this chapter INNER CV JOINT INSPECTION 1 Clean the bear...

Page 184: ...er end splines and the front hub cotter pin hole for wear or damage If any of these areas are worn or damaged replace the drive axle Check the movement of the joint NOTE Inner CV joint must be replace...

Page 185: ...mbly Work the grease in between the balls the race and the case Make sure all voids are filled with grease 9 Apply a liberal amount of molybdenum disulfide grease to the inner surfaces of the inboard...

Page 186: ...e stopper ring and make sure it is seated correctly in the drive axle groove 18 Apply molybdenum disulfide grease to the end splines 5 10 REAR HUB EXPLODED VIEW 5 11 REAR HUB AND KNUCKLE REMOVAL INSPE...

Page 187: ...LE INSTALLATION 1 Start the rear hub and knuckle assembly onto the drive shaft 2 Align the bottom of knuckle and lower control arm Secure with the lower control arm bolt 3 With the driveshaft placed i...

Page 188: ...of the frame Use short sharp jerks to free the circlip from the gearcase The circlip holds the axle in the gearcase 4 Inspect the axle splines and CV boots for any damage 5 14 REAR DRIVE SHAFT INSTAL...

Page 189: ...e bolt to 45 ft lbs 60 Nm 5 Install the washer and the new spindle nut 6 Lower the vehicle Torque the spindle retaining nut to 103 ft lbs 140 Nm 7 Knock on the edge of the spindle nut so that it can b...

Page 190: ...CHAPTER 5 FINAL DRIVE T Boss550 SERVICE MANUAL 20 0 CHAPTER 5 FINAL DRIVE 5 14 5 15 REAR GEARCASE EXPLODED VIEW REAR GEARCASE EXPLODED VIEW...

Page 191: ...Ring 69 3 1 33 Rear Axle Box Cover 1 10 Bearing Sleeve AR 34 Bolt M8 25 8 11 Adjusting Shim Bevel Gear Driving 1 35 Wearing Ring 2 12 Bearing 30206 1 36 Planetary Gear 2 13 Bevel Gear Driving 1 37 Ge...

Page 192: ...replaced Pinion and ring gear shimming information is NOT provided due to manufacturing requirement 1 remove the breathing airbag NO 48 Fig 0 Fig 0 2 Remove the oil drain plug NO 23 and let the oil dr...

Page 193: ...ig 4 6 Remove the differential assembly B from the housing Fig 5 Fig 5 7 Remove the shims from the differential assembly Be sure to keep the shims together for reassembly Fig 6 Fig 6 8 Inspect the bev...

Page 194: ...gear NO 25 from the gearcase cover Fig 8 Fig 8 10 Inspect the shift lever NO 43 shift level spring NO 42 shift return spring NO 41 and shift yoke NO 45 for excessive wear or damage If disassembly is r...

Page 195: ...1 NOTE The pinion gear assembly is NOT intend to be disassembled from the case as it requires special tooling in order to properly reassemble If there is any damage to the pinion gear bearings or cas...

Page 196: ...onto the Rear Axle Box Cover NO 33 then assemble the Rear Axle Box Cover NO 33 and install the bolts that secure the cover to the housing Torque the bolts in a criss cross pattern to 25 30Nm Fig 18 Fi...

Page 197: ...AL DRIVE T Boss550 SERVICE MANUAL 20 0 CHAPTER 5 FINAL DRIVE 5 21 Fig20 12 Mount the oil drain bolt NO 23 and washer NO 24 Add 250 25mL oil 85W 90GL 4 Fig 21 Fig21 13 Assamble the breath airbag NO 48...

Page 198: ...CHAPTER 5 FINAL DRIVE T Boss550 SERVICE MANUAL 20 0 CHAPTER 5 FINAL DRIVE 5 22 5 18 FRONT GEARCASE EXPLODED VIEW FRONT GEARCASE EXPLODED VIEW...

Page 199: ...Vent Pipe 1 10 Oil Seal 24 38 8 2 35 O Ring 81 2 1 9 1 11 Fill Plug 1 36 Gear Motor 1 12 O Ring 30 5 3 1 37 Screw M8 20 4 13 Drain Bolt 1 38 Pin Shaft 1 14 Washer 10 1 39 Shift Fork 1 15 Front Axle Bo...

Page 200: ...36 is protected if mounted Never clean the gearbox with a high pressure water jet Fig 0 Fig 0 1 Remove the DRAIN BOLT NO 13 and let the oil drain from the gearbox Important Clean the plug carefully a...

Page 201: ...ove the OIL SEAL NO 5 and repalce with a new seal Fig 5 Fig 5 6 Remove the four SCREW NO 37 Fig 6 Fig 6 7 Remove the GEAR MOTOR NO 36 Fig 7 Fig 7 8 Remove the six bolts M8 X L28 NO 29 Fig 8 Fig 8 9 Re...

Page 202: ...eth NOTE The DIFFERENTIAL GEAR ASSY A is NOT intended to be disassembled as it requires special tooling in order to properly reassemble If there is any damage to the gear bearings or others the assemb...

Page 203: ...38 SHIFT FORK NO 39 Fig 14 Fig 14 14 Remove the DRIVE CLUTCH NO 23 Fig 15 Fig 15 15 Inspect the bearing NO 26 If the bearing was damaged remove the RETAINER NO 25 first and then remove the bearing NO...

Page 204: ...pecial tool Fig 19 Fig 19 20 Remove the DRIVE PINION GEAR B Fig 20 Fig 20 NOTE The DIFFERENTIAL GEAR ASSY A AND THE DRIVE PINION GEAR B MUST BE REPLACED SIMULTANEOUSLY NOT SEPARAT 5 20 FRONT GEARCASE...

Page 205: ...5 29 2 Mount the retainer 62 NO 25 Fig 2 Fig 2 3 Mount the drive clutch NO 23 Fig3 Fig 3 4 Mount the pin shaft NO 38 and the shift fork NO 39 Fig 4 Fig 4 5 Install the screw NO 30 and washer NO 29 th...

Page 206: ...VE 5 30 Fig 6 7 Install the DIFFERENTIAL GEAR ASSY A into the carrier housing Fig 7 Fig 7 8 Install the DRIVE PINION GEAR B and install the BEARING RETAINER NO 6 with special tool Fig 8 Fig 8 9 Instal...

Page 207: ...l the bolts NO 29 that secure the cover to the housing Torque the bolts in a criss cross pattern to 20 25Nm Fig 11 Fig 11 12 Mount the gear motor A Important Before assemble the gear motor NO 36 make...

Page 208: ...TER 5 FINAL DRIVE 5 32 14 Mount the coupler NO 4 Fig 14 Fig 14 15 Mount the O ring NO 3 Fig 15 Fig 15 16 Apply some Loctite 263 thread locker on screw thread mount the nut NO 3 tighten it to a torque...

Page 209: ...CHAPTER 5 FINAL DRIVE T Boss550 SERVICE MANUAL18 0 CHAPTER 5 FINAL DRIVE 5 33 NOTES...

Page 210: ...ormation 6 1 SPECIFICATIONS 6 2 TORQUE 6 3 BRAKE SYSTEM SERVICE NOTES 6 4 BURNISHING PROCEDURE 6 5 BRAKE BLEEDING FLUID CHANGE 6 6 PARKING BRAKE AND BRAKE LINE INSPECTION 6 7 PARKING BRAKE ADJUSTMENT...

Page 211: ...e Disc 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 6 2 TORQUE Item Torque ft lbs except where n...

Page 212: ...raking effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the brake pads use the following procedure 1 Choose an area large enough to safely ac...

Page 213: ...n clear hose to the fitting and place the other end in a clean container Be sure the hose fits tightly on the fitting 6 Slowly pump foot pedal until pressure builds and holds 7 Hold brake pedal on to...

Page 214: ...reservoir cover 13 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve should be no less than 1 2 13m...

Page 215: ...e 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...

Page 216: ...e 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 C...

Page 217: ...caliper 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...

Page 218: ...until 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...

Page 219: ...to 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 Fron...

Page 220: ...ne and slowly increase speed to 30 mph Gradually apply brakes to stop machine Repeat procedure 10 times 6 12 REAR BRAKE PAD REMOVAL INSPECTION INSTALLATION NOTE The brake pads should be replaced as a...

Page 221: ...ump 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 sho...

Page 222: ...aking 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 Inst...

Page 223: ...r 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 m...

Page 224: ...CHAPTER 6 BRAKES T Boss 550 SERVICE MANUAL20 0 CHAPTER 7 BRAKES PAGE 7 15 NOTES...

Page 225: ...SPECTION AND SERVICE 7 2 BATTERY 7 3 IGNITION SYSTEM 7 4 CHARGING SYSTEM 7 5 ELECTRICS STARTING SYSTEM 7 6 COOLING SYSTEM 7 7 LIGHTING SYSTEM 7 8 GEAR SHIFT SWITCH TEST 7 9 SPEEDOMETER SYSTEM 7 10 SWI...

Page 226: ...V 35W 35W HEADLIGHT ADJUSTMENT 1 The headlight beam can be adjusted vertically all models and horizontally 2 Place the vehicle on a level surface with the headlight approximately 25 7 6m from a wall 3...

Page 227: ...ool water and seek immediate medical attention Battery Maintenance 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If...

Page 228: ...the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To per...

Page 229: ...faulty 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...

Page 230: ...on 5 Spark plug cap resistance entire ignition system 1 Fuse NO CONTINUITY Check switches Replace the fuse CONTINUITY 2 Battery INCORRECT Check the battery condition Refer to BATTERY INSPECTION Clean...

Page 231: ...y Minimum 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 pocke...

Page 232: ...e harness Connect the pocket tester 1 to the ignition coil Check if the primary coil has the specified resistance Primary coil resistance 0 5 1 0 20 Tester lead Spark plug lead Tester lead Green Termi...

Page 233: ...r lead BI Y Terminal Tester lead B R Terminal OUT OF SPECIFICATION Check the pickup coil has the specified resistance Primary coil resistance 115 145 20 Replace the pickup coil NO CONTINUITY MEETS SPE...

Page 234: ...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 loa...

Page 235: ...CORRECT Clean battery terminals Recharge or replace the battery 3 Charging voltage Connect the engine tachometer to the spark plug lead Connect the pocket tester DC20V to the battery Test lead Battery...

Page 236: ...tester X1 to the stator coil Tester lead yellow terminal Tester lead yellow terminal Measure the stator coil resistance Stator coil resistance 0 5 0 8 20 OUT OF SPECITICATION Replace the stator coil M...

Page 237: ...L T Boss550 SERVICE MANUAL 20 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 13 7 5 ELECTRICS STARTING SYSTEM DI AGRAM TROUBLESHOOTING THE STARTER MOTOR OPERATES WHEN THE BRAKE SWITCH IS ON IF THE STARTER MOTO...

Page 238: ...he battery 3 Starter motor Connect the battery positive terminal and starter motor cable using a jumper lead Check the starter motor operation DOES NOT MOVE Repair or replace the starter motor 4 Start...

Page 239: ...INUITY Replace the starter replay 4 Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 1 Brake switch CHECKING SWITCHES NO CONTINUITY Replace the brake switch 7 Starter switch CHECKING S...

Page 240: ...RICAL PAGE 7 16 7 6 COOLING SYSTEM IF THE FAN MOTOR FAILS TO TURN Procedure Check 1 Fuse Main Fan 4 Fan motor inspection 2 Battery 5 Thermo switch 3 Main switch 6 Relay 7 Wiring connection entire cool...

Page 241: ...Y Replace the main switch 4 1 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...

Page 242: ...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 O...

Page 243: ...olant if the thermostat or the fan fails to work the coolant temperature will keep rising The heat alarm unit operates the moment the temperature reaches 115 5 and the signal flashing Stop the engine...

Page 244: ...ttom of the heated vessel Coolant temperature Resistance OUT OF SPECIFICATION Replace the thermo unit 80 47 5 56 8 100 26 2 29 3 MEETS SPECIFICATION 8 Voltage Connect the pocket tester DC20V to the Te...

Page 245: ...CHAPTER 7 ELECTRICAL T Boss550 SERVICE MANUAL 20 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 21 7 7 LIGHTING SYSTEM...

Page 246: ...ECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section INCORRECT Clean battery terminals Recharge or replace the battery 3 Mai...

Page 247: ...low beam light and direction indicator light couplers A When the High low beam switch is on high beam High beam light Tester lead Blue lead Tester negative lead Green lead B When the High low beam swi...

Page 248: ...aulty Replace the bulb If the light is LED replace the light directly 2 the taillight fails to come on 1 Voltage Connect the pocket tester DC20V to the taillight couplers Tester lead Green Yellow term...

Page 249: ...CHAPTER 7 ELECTRICAL T Boss550 SERVICE MANUAL 20 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 25 7 8 GEAR SHIFT SWITCH TEST DI AGRAM...

Page 250: ...CHAPTER 7 ELECTRICAL T Boss550 SERVICE MANUAL 20 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 26 Switch table...

Page 251: ...e gearbox This sensor is used to detect the rotating speed of the engine output shaft and provide the signal for ECU and speedometer to determine the vehicle speed It belongs to Hall effect sensor tha...

Page 252: ...n 3 with 12V power Fix a gear 2 5mm away from a speed sensor as the right figure illustrates Turn multimeter to DCV range Slowly turn the gear and measure the voltage between pin 2 and pin 3 to determ...

Page 253: ...perature Meter 3 High Beam Indicator Light 12 2WD 4WD DIFF Lock Indicator 4 Parking Brake Indicate Lamp 13 Gear Position Indicator 5 Safety Belt Lamp 14 The Odometer and Engine Working Hour Counter 6...

Page 254: ...CHAPTER 7 ELECTRICAL T Boss550 SERVICE MANUAL 20 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 30 7 10 SWITCHES Optional...

Page 255: ...remove fuel sensor attached to fuel tank Hold fuel sensor in an upright position after removing it It is normal if indicator shows E otherwise circuitry connection fuel sensor or instrument should be...

Page 256: ...CHAPTER 7 ELECTRICAL T Boss550 SERVICE MANUAL 20 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 32 Fuel sensor resistance range FLOAT POSITION RESISTANCE 20 68 F TOP FULL 16 BOTTOM RESERVE 100...

Page 257: ...PLE OF THE ELECTRIC 4WD SHIFT 1 The rider shifts 2WD to 4WD by the Switch on panel 2 When shift 2WD 4WD or Diff Lock the mechanics in the front gear box maybe still engaged disengaged the mechanics wo...

Page 258: ...CHAPTER 7 ELECTRICAL T Boss550 SERVICE MANUAL 20 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 34 7 13 WIRING DIAGR...

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