Odes Industry UTV170-10 Maintenance Manual Download Page 38 | Manualshive

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6. DRIVE TRAIN

6-2

Inspection

Check wheel hub for cracks or other damages.
Check inner splines and wheel rim bolts for wear or
other damages.
If any damage is detected on wheel hub, replace it with
a new one.

REAR DRIVE SHAFT

Removal

Remove the appropriate wheel hub.
Remove the bolts holding the drive shaft bearings in
place
Lift the drive shaft out of the support
Check splines for excessive wear. Replace if necessary.
If the splines on plunging joint are worn, a check of
differential inner splines should be done.

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Summary of Contents for UTV170-10

Page 1: ...UTV170 10 Maintenance Manual Shandong Odes Industry Co Ltd Any copy or without written permission or authorization of Odes Industry is prohibited to use the manual version 1 May 2020 All rights reserved ...

Page 2: ...e basic principles of operation and work procedures They may not represent the actual vehicle exactly in detail Manufacturer reserves the right of no prior notice on product improvement or modification Repair and maintenance shall be carried out according to actual situation of vehicle WARNING GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 COOLING SYSTEM 4 FUEL SYSTEM 5 DRIVE TR...

Page 3: ...ded Vaporized gasoline is explosive as well Operation shall be carried out at places with good ventilation 7 Battery may produce explosive hydrogen in charging Please ensure charging at places with good ventilation 8 Use legal parts lubricating oil and lubricating grease 9 Before overhauling please clean soil and dust 10 Keep accessories of each part well for correct assembly 11 Replace dismantled...

Page 4: ...ase check whether all parts are of perfect tightening and flexible movement 23 Brake fluid and coolant may damage shell and plastic and rubber parts In case of being splashed by them please use water for washing 24 In installing pipeline please insert them to bottom of connecting pipeline In installing pipe clamp please install them to groove if there is As for pipeline or pipe clamp that cannot b...

Page 5: ...ay Oil pressure 0 08 0 26MPa at 3000rpm Type of oil SAE 15W 40 Oil quantity 1000mL Replacement of capacity 830 860mL Fuel Type Unleaded gasoline only 93 or higher Fuel pressure 250 kpa Fuel tank capacity 23L Valve clearance Intake 0 06 to 0 08mm Exhaust 0 06 to 0 08mm Diameter of valve rod IN New 4 975 to 4 99mm Service limit 4 95mm Diameter of valve rod EX New 4 955 to 4 97mm Service limit 4 93mm...

Page 6: ...al clearance Service limit 0 06mm Crankshaft deflection Service limit 0 15mm Crankshaft pin diameter New 30 to 29 994mm Service limit 29 98mm Connecting rod big end diameter Service limit 37 026mm Connecting rod big end radial clearance Service limit 0 04mm Connecting rod big end axial clearance New 0 1 to 0 3mm Service limit 0 55mm Connecting rod small end diameter New 15 016 to 16 027mm Service ...

Page 7: ...eration Suspension and shock absorber Front suspension Double A swing arm Rear suspension towed Front shock absorber Coil spring oil damper Front shock absorber travel 80mm Rear shock absorber Coil spring oil damper Rear shock absorber travel 60mm Electrical Ignition system EFI DELPHI Battery Type Maintenance Free Voltage 12V capacity 9AH Fuses Electric spray and indicator light 20A The light 20A ...

Page 8: ...40 6 51 7 66 4 81 2 5 6 3 7 5 2 8 9 11 1 18 5 23 6 33 2 40 6 51 7 66 4 81 2 103 3 6 8 5 2 6 6 12 5 17 24 4 33 2 42 8 57 6 68 6 91 5 107 142 4 8 8 6 6 8 6 16 2 22 1 33 2 43 5 57 6 76 8 91 5 121 8 142 4 189 7 10 9 9 6 11 8 22 1 26 6 48 57 6 81 2 95 9 132 8 148 3 206 6 243 5 12 9 11 8 15 5 28 37 6 55 4 73 8 96 7 129 2 154 2 205 2 240 6 320 3 CAUTION Bolt length comparison table Length mm 12 14 16 20 ...

Page 9: ...M10 80 59 Rear Brake Brake disc bolts M8 26 19 2 Bolt of front brake stop pump calipers M8 26 19 2 Front Brake Brake disc bolts M6 15 11 Lock nut of steering rod M8 40 29 5 Bolt of exhaust pipe M6 15 11 Spark plug M10 20 14 8 Adjusting nut of valve clearance M6 12 8 9 Main pulley bolt M12 100 73 8 Driven pulley bolt M10 60 44 3 Magneto flywheel bolt M16 150 110 7 Magneto stator bolt M6 12 5 9 2 On...

Page 10: ...0 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check vale clearance Adjust if necessary O O O O Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months O O O O O Spark plug Check condition Adjust gap and clean Replacement every 24 months O O O O O Air filter elements Clean Replacement every 24 months Every 20 40 hours More often in w...

Page 11: ... O O Steering system Check operation and for looseness Replace if damage Check toe in Adjust if necessary O O O O O Rear knuckle pivots and suspension arms Lubricate with lithium soap based grease O O O Drive shaft universal joint Lubricate with lithium soap based grease O O O Engine mount Check for cracks or damage Correct bolt tightness O O O Front and rear axle boots Check operation Replace if ...

Page 12: ...requently than specified in MAINTENANCE SCHEDULE If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption never remove or modify any component in the air filter housing The engine management system is calibrated to operate specifically with these components Otherwise engine performance degradation or d...

Page 13: ... pay attention to the seal gasket of air filter housing is not skew CAUTION 1 If liquid deposits are found squeeze and dry the foam filter Replace filter element if damaged 2 Do not start engine if liquid or deposit are found If there is oil in the air filter housing check engine oil level Oil level may be too high 3 Inspect the air cleaner element for tears a torn element must be replaced ...

Page 14: ...throttle cable bracing cable Turn adjuster to adjust free play of throttle pedal After adjustment tighten nut If free play after adjustment cannot reach designated requirement or there is viscosity for throttle valve replace it with new throttle cable ENGINE OIL Oil level verification Strictly follow this procedure otherwise wrong oil level may be indicated 1 Ensure vehicle is on a level surface 2...

Page 15: ...ly from crankcase 9 Clean the magnetic drain plug from metal shavings and residue 10 Install a new gasket ring on drain plug Torque drain plug to 20 N m 11 Remove oil filter screws oil filter cover and oil filter 1 Oil filter nut 2 Gasket ring 3 Spring 4 Oil filter 12 Check and clean the oil filter inlet area for dirt and other contaminations 13 The installation is the reverse of the removal proce...

Page 16: ... for further inspection Park vehicle at flat ground and turn handle left or right slowly to see whether it can be turned flexibly In case of obstacles check whether it is caused by main cable or other wiring installation If it is not caused by above situations please check the bottom of steering tie rod and see whether steering column bearing is damaged or not Park vehicle on flat ground make sure...

Page 17: ...the brake fluid level is below the lower edge of sightglass replenish with brake fluid DOT4 Brake pedal adjustment The brake pedal stroke is 30 40mm If less than equal 30mm it will be a hidden dangers must adjust the brake pin connecting the brake pedal A Af ft te er r a ad dj ju us st ti in ng g t to oe e i in n f fi is st t r ro ot ta at te e s st te ee er ri in ng g w wh he ee el l f fr ro om m...

Page 18: ...ecessary slacken the cable by loosening the locknut and screwing the adjuster on the brake holder After adjusting the play tighten the locknut Or screwing the adjustment nut on the parking brake caliper GEAR SHIFT Check the shift lever as to change gearshift from N to R and reverse smoothly Also the meter display is correct The shift lever should be vertical when the gear is in neutral If not adju...

Page 19: ... whether they can be swung No adequate tightening tightening Swing replace rocker arm Tire pressure Improper tire pressure will lower comfort of operation and driving and may lead to wear to side edges of tires Front wheel Rear wheel Rated pressure 62kPa 0 62kgf cm2 62kPa 0 62kgf cm2 Dimension of tire 26 9 14 26 11 14 Tire thread When the tire groove decreases to 6 mm 0 24 in due to wear replace t...

Page 20: ... rotation After the sprocket wears seriously the new sprocket and new chain should be replaced at the same time to ensure good meshing It is not possible to replace new chains or sprockets alone Otherwise it will cause poor meshing and accelerate the wear of the new chain or new sprocket The old chain can not be mixed with some new chains otherwise it will easily cause impact in the transmission a...

Page 21: ...TALLING THE OIL PUMP 3 8 CHECK THE STARTER WHEEL 3 8 CHECKING THE STARTER CLUTCH 3 8 REMOVING THE PRIMARY SHEAVE 3 9 REMOVING THE SECONDARY SHAEAVE 3 9 SEPARATING THE CRANKCASE 3 9 CHECKING THE CRANKCASE 3 9 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 3 9 CHECKING THE CRANKSHAFT 3 10 CHECK THE BEARINGS 3 10 ASSEMBLING CRANKCASE 3 10 REMOVING THE TRANSMISSION 3 11 CHECKING THE SHIFT FORK 3 11 ...

Page 22: ...move them CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with a rounder scraper TIP Do not use a sharp instrument to avoid damaging or scratching Spark plug bore threads Valve seats 2 Check Cylinder head Damage scratches Replace 3 Measure Cylinder head warpage Out of specification resurface the cylinder head CHECK THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner...

Page 23: ...d cylinder bolts in the proper tightening sequence as show and torque them in two stages 5 Install Camshaft sprocket 1 Timing chain 2 NOTICE Do not turn the crankshaft when installing the camshaft sprocket to avoid damage or improper valve timing 6 Install Timing chain tensioner gasket 3 Timing chain tensioner 2 TIP To push in the timing chain tensioner rod release the lock by pushing in the one w...

Page 24: ...to all of the rocker arms and rocker arm shafts REMOVING THE VALVES The following procedure applies to all of the valves and related components TIP Before removing the internal parts of the cylinder head e g valves valve springs valve seats make sure the valves properly seal 1 Check Valve sealing Leakage at the vale seat Check the valve face valve seat contact width 2 Remove Valve cotters TIP Remo...

Page 25: ...age wear Replace CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance elimina...

Page 26: ...t Dowel pins 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Offset Piston ring end gaps 6 Install Dowel pins Cylinder gasket Cylinder 1 TIP While holding the piston 2 with one hand install the cylinder other hand Pass the timing chain and timing chain guide intake side thought the timing chain cavity REMOVING THE CDI MAGNETO ROTOR 1 Remove CDI magneto rotor cover TIP Loo...

Page 27: ...y and CDI magneto rotor 2 Tighten CDI magneto rotor nut 1 Pickup coil bolt Stator coil bolt TIP While holding the CDI magneto rotorwith the rotor holding tool tighten the CDI magneto rotor nut 3 Apply Sealant onto the pickup coil stator coil assembly lead gromment 1 4 Install CDI magneto rotor cover 5 Tighten CDI magneto rotor cover bolt TIP Tighten the CDI magneto cover bolts in stages and in a c...

Page 28: ...ws make sure the oil pump turns smoothly CHECK THE STARTER WHEEL 1 Check Bearing Damage wear Replace 2 Check Starter clutch idle gear Starter wheel 1 Burrs chips roughness wear Replace the defective part s 3 Check Starter wheel s contacting surfaces Damage patting wear Replace the starter wheel CHECKING THE STARTER CLUTCH 1 Check Starter clutch operation a Install the starter wheel 1 onto the star...

Page 29: ...ATING THE CRANKCASE 1 Remove Crankcase bolts TIP Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them M6 50mm bolts 1 2 2 Remove Crankcase NOTICE Tap on the one side of the crankcase with a soft face hammer Tap only on reinforced portion of the crankcase not on the crankcase mating surfaces Work slowly and carefully an...

Page 30: ... then rotate the inner race with your finger Rough movement Replace ASSEMBLING CRANKCASE 1 Install Timing chain guide intake side Timing chain guide bolt 12N m 2 Cut Gasket 1 TIP Cut the gasket as show in the illustration to remove the gasket portion that covers the crankcase opening a 3 Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces 4 Apply Sealant onto the crankcas...

Page 31: ...2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARING Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shaft fork guide bar as a set CHECKING THE SHIFT DRUM 4 Check Shift drum groove Damage scrat...

Page 32: ... Shift fork guide bar 4 2 Check Shift cam operation Rough movement Repair TIP Apply engine oil to each gear shift and bearing thoroughly Check the transmission and shift fork for smooth operation by turning the shift cam with your hand INSTALLING THE SHIFT LEVER 1 Install Shift shaft 1 TIP Position the center tooth a on the cam portion of the shift shaft 1 between the teeth identified with punch m...

Page 33: ...ed air to clean soil If damaged area reaches 20 please replace radiator 2 After dismantling cooling system check leakage situation of joint 3 Check the oil pipe for oil leakage If so please repiace it 4 Check whether the oil in the engine is sufficient 5 Check whether the oil pipe is well connected with the engine and replace the gasket or oil pipe in case of oil leakage ...

Page 34: ...remain under pressure at all times Always proceed with care and use appropriate safety equipment when working on pressurized fuel system Wear safety glasses Proceed with care when removing installing pressure test equipment or disconnecting fuel line connections Cover the fuel line connection with an absorbent shop rag Slowly disconnect the fuel hose to minimize spilling Wipe off any fuel spillage...

Page 35: ... left seat Disconnect outlet hose Install fuel pressure gauge and T fitting between disconnected hoses Turn ignition key ON and set engine stop switch to RUN and observe fuel pressure Turn ignition key off then back on Repeat the test Standard fuel pressure 350kpa A rapid pressure drop indicates leakage is from the fuel rail If there is not leaking then replace fuel pump A slow pressure drop indic...

Page 36: ...tion to the following Install a new gasket Pay attention to pump orientation Tighten retaining screws as per illustrated sequence Install hose properly on OUT nipples and harness FUEL TANK Fuel tank draining Never perform this operation when the engine and or the exhaust system is are hot Never sue a hose pincher on injection system high pressure hoses Remove fuel tank cap and siphon gas in an app...

Page 37: ...allation The installation is the reverse of removal procedure Install belleville washer so that the inside deameter protrudes outward and contacts the nut Tighten the castellated nut on the drive shaft end to 300N m and further tighten until one of its grooves is aligned with a cotter pin hole Install a new cotter pin and the wheel cap Raise front of vehicle support it securely on jack stands and ...

Page 38: ...s detected on wheel hub replace it with a new one REAR DRIVE SHAFT Removal Remove the appropriate wheel hub Remove the bolts holding the drive shaft bearings in place Lift the drive shaft out of the support Check splines for excessive wear Replace if necessary If the splines on plunging joint are worn a check of differential inner splines should be done ...

Page 39: ... the bead from the rim completely Separate the tire from the rim by using a set of tire levers and rim protectors CAUTION Apply tire lubricant to the new tire bead and the flange of the rim But never apply grease oil or gasoline to the tire bead because they will deteriorate the tire CAUTION Mount the new tire on the rim CAUTION When using the tire lever do not scratch or hit the sealing portion o...

Page 40: ...rom the wheel rim all the way around If the distance between the rim line and the wheel rim varies this indicates that the bead is not properly seated If this is so deflate the tire completely and unseat the tire bead on bosh sides Then coat the bead with clean water and re seat the tire Adjust the tire pressure to specification ...

Page 41: ...tion or damage If any damage are found replace the tie rod with a new one Inspect the tie ends for smooth movement If there are any abnormalities replace the tie rod end with a new one Inspect the tie rod end boot for wear or damage If any damage are found replace the tie rod end with a new one ...

Page 42: ... distance A and B of the front wheels and calculate the difference Toe in B A 5mm A front of front wheel B rear of front wheel Out of range of toe in Adjust nut of tie rod CAUTION A Af ft te er r a ad dj ju us st ti in ng g t to oe e i in n f fi is st t r ro ot ta at te e s st te ee er ri in ng g w wh he ee el l f fr ro om m c ce en nt te er r p po os si it ti io on n t to o t th he e l le ef ft t...

Page 43: ... of vehicle please do not dismantle left and right suspensions simultaneously Before overhauling front suspension system please ensure stable support of vehicle REMOVALAND DISASSEMBLY Loosen wheel nut of the appropriate Install a jack stand under the frame to lift the front of vehicle off the ground until shock absorber is fully extended then Remove wheels brake caliper and hub remove steering knu...

Page 44: ...arm from side to side There should be no noticeable loose Replace bushing if necessary Move suspension arm up and down There should be no noticeable loose Replace bushing if necessary Upper Suspension Arm Inspect the suspension arm and for damage or distortion If any damages or distortion are found replace the suspension arm with a new one Move suspension arm from side to side There should be no n...

Page 45: ...k absorber Inspect the shock absorber for oil leakage or damage inspect the bushing for wear or damage If any damage are found replace the rear shock absorber with a new one Extend and compress the piston several times over its entire stroke Check that it moves smoothly and with uniform resistance with rod up Any of the following conditions will denote a defective shock A skip or hang up when reve...

Page 46: ...r reuse brake fluid left over from the last servicing or which has been stored for a long periods of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get dust into fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performan...

Page 47: ... succession and hold the pedal fully squeezed Loosen the air bleeder valve for about quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake pedal Then close the bleeder valve pump and squeeze the pedal and open the valve Repeat this process until the fluid flowing into the receptacle contains no air bubbles Tighten the air bleeder valve to 6N m...

Page 48: ... Inspect the brake disc for cracks or damage and measure the thickness using the micrometer If any damage are found or the thickness is less than the service limit replace the brake disc with a new one Minimum thickness of front brake disc 3 5mm Minimum thickness of rear brake disc 3 0mm Measure the warpage using the dial gauge If the warpage exceeds the service limit replace the brake disc with a...

Page 49: ...essure to the fluid inlet to remove piston Remove piston seal Clean piston grooves caliper cylinder and piston with clean brake fluid Clean slide pins with brake cleaner and a rag Inspection If boots are deteriorated or hard replace with new ones Check caliper cylinder for scratches rust or other damages If so replace caliper Check piston for scratches rust or other damages If so replace caliper A...

Page 50: ...es This damage can cause hose failure under pressure When hoses are removed or disconnected cleanliness must be observed Clean all joints and connections before disassembly New hoses should be cleand with brake fluid before installation to remove any contamination Replace any defective parts Removal Before removing any hoses drain brake system Remove all necessary parts to reach the hoses Thorough...

Page 51: ...xhaust pipe and take out the exhaust pipe 4 Disassemble silencer from the car frame 5 Disassemble the tailpipe of silencer take out the fire retardant net SILENCER INSPECTION 1 Check the leaks in exhaust pipe and the cracks in heat insulating shield 2 Check whether the rubber parts in silencer are cracked or weathered etc 3 Clean the sundries and inspect any damage in the fire retardant net If the...

Page 52: ...n sleeve is badly worn and replace it in time if it cracks When the rear seat is used for a long time it will be damaged such as cracked leather and broken rubber 1 Check whether the leather of the seat cushion and backrest is damaged If there is any please replace it with a new seat cushion or backrest 2 When the thickness of the rear seat rubber pad is reduced by 6 mm 0 24 inches due to wear rep...

Page 53: ... car roof 3 Inspect the wear consumption of steel ball if there are pits on the surface of steel ball and the use is affected 4 Check whether the limit end of the handrail is seriously worn such as the lack of material smoothed flat 5 Check whether the compression movement of the limit spring is in uniform motion and the stretch movement cannot be completed due to resilience blocked In case of the...

Page 54: ...s wear for the following parts if so please replace it with a new one in time 1 Seat hinges 2 Seat rubber pads 2 Check whether have cracks and breakage for the seat and backrest leather if so please replace it with a new one in time 3 Check whether the safety belt can return to the retractor after stretching if can not please replace it with a new one in time ...

Page 55: ...ove on the rough road for a long time 1 Keep the vehicle in a horizontal plane 2 Use a jack under the car frame to keep it off the ground 3 check whether the car frame chassis base is broken or damaged if so please replace it with a new one in time Be careful not to operate when the engine is running or the silencer is at high temperature ...

Page 56: ...CHES 11 10 CHARGING SYSTEM RESISTAMCE OF GENERATOR COIL Measure the resistance between three wires If the resistance is not within the specified value replace the stator coil Check the generator core whether it is insulated Install multimeter 1 10Ω Resistance of generator coil 0 9 1 5Ω color white Insulation resistance Ω white grounding wire NO LOAD PERFORMANCE OF THE GENERATOR Start the engine wi...

Page 57: ...ator rectifier NOTE If the probe is not connected and the multi meter reading is lower than 1 4V replace the multi meter battery Red B W Black Black Black B W Red ground Black Black Black B W Red ground STARTING SYSTEM STARTER MOTOR 1 Bracket 2 Brush holder 3 Brush spring 4 O Ring 5 Washer 6 Motor housing 7 Washer 8 Armature coil 9 Washer supporting tools 10 Inner bracket 11 O Ring ...

Page 58: ...r If they are not connected replace the armature shaft OIL SEAL Check the oil seal lip for damage or leak Damage or leakage Replace the starter motor STARTER RELAY Inter terminal voltage is 12V Test the direct connection of positive and negative poles with the multimeter If the starter relay clicks and connected the starter relay is OK When there is no voltage of 12V they are not connected the sta...

Page 59: ...TEM schematic diagram of EFI system The function of EFI system includes two parts fuel injection management and ignition management which are realized by the following institutions 1 ECU it is responsible for the receiving of sensor signal the formulation of control strategy and the issue of control signal 2 Oil supply device it is composed of oil pump tubing and injector The pump pressurizes the ...

Page 60: ...ction and ignition control d The throttle position sensor is mounted on the throttle body to measure the rotation angle of the throttle valve 5 Other including a throttle body which controls air intake through throttle pull wire b Fault alarm lamp which is installed on the dashboard for fault alarm c Battery door lock fuse for power supply to EFI system LGNITION SYSTEM LGNITION COIL Primary peak v...

Page 61: ...imary winding 0 58 0 058 Ω terminal ground Secondary coil 7 1 0 71 terminal spark plug cap Peak voltage of coupling coil Z Check the peak voltage of the coupling coil with following steps Z As shown in right figure connect the multi meter with the peak voltage adapter Probe Green wire Probe BL Y wire Z Move the gear to the neutral position turn on the ignition device Z Press the start button and c...

Page 62: ...h the multi meter NOET If the speedometer is not normal first check whether the magnet of the speed sensor is in good condition the polarity is correct and confirm the gap between the probe and the magnet The S pole of the magnet faces the probe and the gap between the probe and the magnet is 2 3 mm BATTERY When the battery is not in use for more than one month remove the positive and negative ele...

Page 63: ... the battery every 2 3 months Before the first time use or when the battery voltage is below 12 75V please charge the battery NOTE Remove the negative pole first and then the positive pole Install the positive pole first in assembly process Open the seat remove the suitcase and remove the belt and then remove the negative and positive ...

Page 64: ...k fuse first whatever any system doesn t work AND three spare fuses for reserve Open the seat remove the suitcase remove the cover of fuses box Check the fuse and relay NOTE Please refer to electrical schematic for specific function of fuse and relay LAMPS LED Turning light and headlight ...

Page 65: ...ashboard Remove the rocker switch from the dashboard first Unplug the connector then Ignition switch USB and auxiliary DC Jack are fixed on dashboard with nuts Firstly remove the top of the hood remove the both plastic snaps and then remove the debugging cover Remove the self contained nut and Unplug the connector NOTE The nut of the ignition switch is fixed outside the dashboard USB and auxiliary...

Page 66: ...cyl Oil below recommended refer to cooling system 2 Check temperature sensor for electrical mechanical failure Temperature sensor defective Replace 3 Check thermostat Thermostat defective does not open when engine gets hot Replace refer to cooling system 5 If the oil leaks check whether the pipe is broken and whether the seal ring at the joint is intact If it is damaged replace it with a new one 6...

Page 67: ...ystem 7 Check oil pump function Oil pump rotor is out of wear limit Replace oil pump refer to lubrication system Oil pump seized due to oil leakage and or air inclusion Replace oil pump refer to lubrication system Gears driving oil pump are broken or otherwise damaged Replace gears Incorrect oil being used Use recommended oil refer to technical specifications 8 Check oil pressure regulator valve s...

Page 68: ... and refill with oil up to specified level refer to TECHNICAL SPECIFICATIONS and GEARBOX 2 Check bearings in the gearbox for free movement Bearing s do es not move freely Replace bearing s 3 Check for knocking noise Tooth of gears are damaged and or worn Replace respective gears Symptom GEAR INDICATION FAILS 1 Check contact screws on gear housing center Check contact screw outside for contaminatio...

Page 69: ...s drive and driven pulley for grooves or other damages 7 Check valve adjustment Intake and or exhaust valves are not adjusted correctly Adjust valves 8 Check engine condition Low engine compression 9 Check ignition condition Faulty spark plug Install new spark plug s 10 Check differentials operation Vehicle on Neutral is hard to move Repair or replace defective part s Symptom ENGINE MAXIMUM RPM IS...

Page 70: ...EY 1 Check fixed and sliding sheave bushings on driven pulley Excessive gap between bushings and CVT shaft thus restraining sliding sheave movements Replace fixed and or sliding sheave of driven pulley polish CVT shaft area with fine emery cloth and wipe clean with a cloth Symptom PULLEYS DO NOT DOWN UP SHIFT PROPERLY 1 Check drive pulley bushings cleanliness wear etc Check items 1 and 2 of UNUSUA...

Page 71: ...y injector s Replace defective part s 7 Check idle bypass valve Stuck or defective 8 Check encoder wheel Bent tooth Refer to MAGNETO SYSTEM 9 Check engine compression Insufficient engine compression Replace defective part s 10 Check fault codes in B U D S system Check if electrical actuator s is are defective Replace defective part s refer to COMPONENT INSPECTION AND ADJUSTMENT Symptom ENGINE DOES...

Page 72: ...aks and lowers coolant level Tighten clamps or replace defective parts Add antifreeze in cooling system until appropriate level s reached Replace damaged parts 6 Cracked or broken piston Cracked or broken piston due to excessive piston cylinder clearance or engine overheating Replace piston Check piston cylinder clearance refer to CYLINDER AND HEAD 7 Check piston rings and cylinder surface for gro...

Page 73: ...EL SYSTEM 7 Check air intake system Air filter is clogged due to contamination Replace air filter 8 Check if EMS engine management system is in limp home mode Check fault codes in B U D S system Check if electrical actuator s is are defective Replace defective part s 9 Check drive belt Worn Replace belt if its width is less than specified Symptom HIGH ENGINE OPERATING TEMPERATURE 1 Check if coolin...

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