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ODES UTV Desertcross 1000cc-3, Maintenance Manual

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3. ENGINE

3-

99

Block drive pulley with the pulley holding tool.

1. Pulley holding tool
2. Torque wrench

When the drive pulley is blocked, mark sliding
sheave  and  governor  cup  to  ensure  correct
reinstallation.

Unscrew  the  drive  pulley  screw  (right  hand
thread),  then  remove  it  as  well  as  the  conical
spring washer and thrust washer.

1. Drive pulley
2. Thrust washer
3. Drive pulley screw

Inspection

Drive  pulley  should  be  inspected  annually  for
wear or damages.
Check  drive  pulley  for  cracks  and  sliding
contact surface for excessive wear. Replace it if
necessary.
Check  one-way  clutch  bearing  for  excessive
play  and  smooth  operation.  Replace  one-way
clutch if necessary.

Installation

For installation, reverse the removal procedure. Pay attention to the following details.

Do not apply any lubricant on crankshaft and drive pulley tapers.
Clean pulley faces and shaft with dry cloth.
Install drive pulley on crankshaft extension.
Do not forget to place thrust washer

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Summary of Contents for UTV Desertcross 1000cc-3

Page 1: ...UTV Desertcross 1000cc 3 Maintenance Manual Shandong ODES Industry Co Ltd Any copy or without written permission or authorization is prohibited to use the manual version 2 May 2020 All rights reserved...

Page 2: ...w the 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 modific...

Page 3: ...per working suit boots and hat If necessary please wear long sleeve working suit and gloves for operation 6 Gasoline is highly inflammable No smoking or firing At the same time fire sparks shall be av...

Page 4: ...ation please carry out lubrication with oil or lubricating oil 21 Please correct install elastic retaining ring Assembling after opening can ensure installation of snap ring into slot 22 After assembl...

Page 5: ...1250rpm Type of oil SAE10W 50 SJ Oil quantity 2200mL Replacement of capacity 2000mL Fuel Type Unleaded gasoline only 93 or higher Fuel pressure 350 kpa Fuel tank capacity 48L Valve clearance Intake 0...

Page 6: ...limit 0 07mm 0 0028in Crankshaft pin diameter New 41 986 to 42 010mm 1 653in to 1 654in Service limit 41 967mm 1 6522in Connecting rod big end radial clearance Service limit 0 09mm 0 0035in Connectin...

Page 7: ...spring oil damper Rear shock absorber travel 160mm 6 30in Drive train Front differential Shaft driven single auto lock differential Front differential ratio 3 67 1 Rear axle Shaft driven single differ...

Page 8: ...n Specifications mm Torque N m kgf m Fastening bolt of engine M10 60 65 44 3 48 Fastening nut of suspension arm M12 78 100 57 6 73 8 Bolt of rear shock absorber M12 78 100 57 6 73 8 Bolt of front shoc...

Page 9: ...to flywheel bolt M16 150 110 7 Magneto stator bolt M6 12 5 9 2 One way bolt M8 30 22 1 Engine oil drain plug M12 20 14 76 Gearbox oil drain plug M12 20 14 76 Decompression valve plug M22 20 14 76 Cyli...

Page 10: ...time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a dealer as they require special tools and technical skills In case of complicated road con...

Page 11: ...O O O O Wheel bearings Check bearing assemblies for looseness or damage Replace if damaged O O O O Front and rear Suspension Check no deformation and looseness Correct if necessary O O Steering syste...

Page 12: ...o operate specifically with these components Otherwise engine performance degradation or damage can occur Check and clean the air cleaner element in the following manner Remove the middle seat Release...

Page 13: ...to specification if necessary Valve clearance is to be checked when the engine is cold The intake and exhaust valves must be checked an adjusted when the piston is at TOP DEAD CENTER TDC on the compr...

Page 14: ...on camshaft timing gear 2 Cylinder head base Insert the feeler gauge between the valve stem end and adjusting screw on the rocker arm to check the clearance If the valve clearance is out of specifica...

Page 15: ...kwise Until marks on magneto flywheel 1 and magneto cover are aligned 1 Mark 1 on magneto flywheel 2 Notch on magneto cover 3 Location of crankshaft position sensor At TDC ignition the printed marks o...

Page 16: ...ent screw 2 Adjustment nut 3 Feeler gauge Valve clearance adjuster locknut 12N m 8 856Lbf ft CAUTION Install the valve cover of both cylinders spark plug cable and spark plug of both cylinders the plu...

Page 17: ...moves smoothly without sticking and snaps back automatically when it is released Check to see that the gas pedal operates correctly It must operate smoothly and fully spring back to the idle position...

Page 18: ...rk 7 There is a capacity of 300 ml between the two marks Refill oil as necessary and recheck oil level Do not overfill 8 Wipe any spillage Install and propery tighten the dipstick 9 Lower the rear car...

Page 19: ...n plug from metal shavings and residue 11 Install a new gasket ring on drain plug Torque drain plug to 30 N m 22Lbf ft 12 Remove oil filter screws oil filter cover and oil filter 1 Oil filter screw 2...

Page 20: ...20 N m 14 76Lbf ft 8 Pour the specified oil GL 4 90 about 360 450mL by syringe through the oil level check hole 9 Tighten the oil level check dipstick FRONT DIFFERENTIAL OIL To change the front diffe...

Page 21: ...ERENTIAL OIL To change the rear differential oil locate the vehicle on a level position and carry out the following steps Clean the oil level check plug area and remove the oil level check plug Clean...

Page 22: ...he bottom of steering tie rod and see whether steering column bearing is damaged or not Park vehicle on flat ground make sure the tire pressure for right and left tires is same and set to the proper s...

Page 23: ...evel Check the brake fluid level by observing the lower limit line on the brake fluid reservoir When the brake fluid level is below the lower edge replenish with brake fluid DOT4 Brake pedal adjustmen...

Page 24: ...rizontal line of cooling liquid by looking at the side of the auxiliary radiator through the front wheel of driver side direction Check the level of cooling water in fluid reservoir auxiliary radiator...

Page 25: ...nt comes out by the radiator bleed hole install the bleed bolt with its gasket ring and torque to 10 N m 7 38Lbf ft Press and relax the throttle pedal five times to bleed air bubbles completely Refill...

Page 26: ...their connecting parts are installed tightly and check whether they can be swung No adequate tightening tightening Swing replace rocker arm Tire pressure Improper tire pressure will lower comfort of o...

Page 27: ...er pressure 0 9 1 2Mpa 130 5PSI 174PSI Too low cylinder pressure may cause the following Excessive wear to cylinder Wear to piston or piston ring Blockage of piston ring in groove Close valve seat Dam...

Page 28: ...gauge and adapter hose Installation oil pressure switch to 12 N m 8 86Lbf ft and the oil pressure switch wire connector Lower the rear cargo bed SUSPENSION SYSTEM Check suspension arm for cracks pitti...

Page 29: ...TENANCE 2 21 Grease fitting location of front suspension arms Grease fitting location of rear suspension arms Lubricate rear knuckles with lithium soap based grease There are two grease fittings on ea...

Page 30: ......

Page 31: ...3 ENGINE 3 1 3 ENGINE COMPONENTS 3 1 TIMING CHAIN 3 65 COOLING SYSTEM 3 10 BOTTOM END 3 75 MAGNETO SYSTEM 3 28 CONTINUOUSLY VARIABLE 3 95 TOP END 3 39 GEARBOX AND4X4 COUPLING UNIT 3 102 COMPONENTS...

Page 32: ...NE LUBRICATION CIRCUIT 1 Camshaft bearings 2 0il pressure switch 3 0il filter 4 0il pressure regulator valve 5 0il strainer 6 0il pump 7 Crankshaft main bearings 8 Crankshaft support bearing 9 Connect...

Page 33: ...OUBLESHOOT ING subsection Check for engine oil leaks For leak indicator hole refer to COOLING SYSYTEM INSPECTION in the PERIODIC MINTENANCE PROCEFURES subsection Rapair if necessary 2 Use of unsuitabl...

Page 34: ...ning screws 1 Retaining screws 2 Oil cooler Place rags or towels under oil cooler to catch re maining oil and coolant Remove oi1 cooler and discard gasket 1 0il cooler 2 Gasket Oil Cooler Inspection C...

Page 35: ...G ENGINE RUNNING PIN RESISTANCE 4 Engine ground Close to 0 normally reaches Infinite open when pressure 30kPa 10kPa 4 35PSl 1 45PSl If resistance values are incorrect replace the oil pressure switch I...

Page 36: ...hread in the magneto housing from metal shavings and other contaminations Oil Pressure Regulator Installation For installation reverse the removal procedure Pay attention to the following details NOTE...

Page 37: ...es in crankcase between outer rotor and oil pump bore lf so replace damaged parts Check oil pump cover for damages and for surface straightness with a straightedge 1 Oil pump bore 2 Outer rotor 3 Oil...

Page 38: ...ract measurement B from measurement A to obtain axial clearance OIL PUMP AXIAL CLEARANCE SERVICE LIMIT 0 2 mm 0079in NOTE When the axial clearance of the oil pump shaft assembly increases the oil pres...

Page 39: ...l Strainer Installation The installation is the reverse of the removal procedure OIL STRAINER RETAINING SCREWS Service product LOCTITE243 BLUE P N293 800 060 Tightening torque 6N m 0 7N m 53lbf in 6lb...

Page 40: ...3 ENGINE 3 10 COOLING SYSTEM RADIATOR 1000R Engine...

Page 41: ...3 ENGINE 3 11 WATER PUMP 1000R Engine...

Page 42: ...Models The thermostat is mounted in line in the cooling system circuit THERMOSTAT LOCATION RH FRONT WHELL WELLACCESS 1 ln line thermostat Thermostat Removal 800R Models 1 Install a hose pincher on bot...

Page 43: ...ecified temperature Check if gasket is brittle hard or damaged lf so replace gasket Thermostat Installation 800R Models For installation reverse the removal procedure Pay attention to the following TH...

Page 44: ...s the front of the vehicle NOTE Turning steering to LH stop or removing LH front wheel assembly provides greater access for radiator removal 9 Carefu1ly remove radiator through LH wheel well Radiator...

Page 45: ...g Fan NOTE Relay may be inverted by 180 at installation and it will work correctly Ensure to align tabs of relay with terminals of fuse holder at installation 1 R1 Radiator coo1ing fan relay Relay Ope...

Page 46: ...cated in the fuse box underneath the dashboard on the driver s side 1 Cooling fan fuse Radiator Cooling Fan Test 1 Connect the vehicle to B U D S refer to COMMUNICATION TOOLS AND B U D S for procedure...

Page 47: ...Remove 4 fan retaining screws 4 Remove the radiator fan Radiator Cooling Fan Installation For the installation reverse the removal procedure WATER PUMP HOUSING Water Pump Housing Location 1t is locate...

Page 48: ...if damaged Water Pump Impeller Installation The installation is the opposite of the removal procedure NOTICE Be careful not to damage impeller fins during installation WATER PUMP SHAFT AND SEALS Use t...

Page 49: ...MOVED 3 Carefully bend down the outer part of rotary seal lip using a smal1 chisel 1 Small chisel 4 Use 2 screwdrivers and carefully remove the outer part of the rotary seal 7 Screwdrivers NOTICE Be c...

Page 50: ...ankcase by pulling screws with pliers 1 Pull on screws to remove seal 8 Check water pump shaft axial play lf not adequate engine must be disassembled to replace the water pump shaft 9 Clean oil seal s...

Page 51: ...he shaft 8 Place a robust M8 flat washer P N420227935 onto water pump shaft 9 Install a M8 1 25 nut onto water pump shaft by hand 10 Then thread nut1 1 2 turns to pull the shaft into rotary seal 1 Rot...

Page 52: ...l seal pusher between rotary seal pusher plate and water pump shaft SEAL PUSHER INSTALLTION 1 Seal pus1lerai1gneol with pusher bolt 12 5 lighten the pusher bolt by hand until it stops against the sea1...

Page 53: ...ump Shaft and Seals Replacement Disassembled Engine Water Pump Shaft and Seals Removal 1 Remove the following parts WATER PUMP HOUSING WATER PUMP IMPELLER WATER PUMP GEARS 2 Push out water pump shaft...

Page 54: ...t area of the oil seal and rotary seal Clean rotary seal surface of any old sealant Install oil seal REQUIED TOOL OIL SEAL PUSHER P N 529035757 HANDLE P N 420877650 1 Handle 2 Pusher When installing t...

Page 55: ...rotary seal must rotate freely WATER PUMP GEARS Water Pump Gears Identification 1 Water pump shaft 2 Water pump gear 3 Water pump intermediate drive gear 4 Water pump intermediate shaft 5 Water pump d...

Page 56: ...mp gear Needle pin Thrust washer CRANKCASE MAG SIDE 1 Water pump gear 2 Needle pin 3 Thrust Washer Water Pump Intermediate Drive Gear 1 Remove clrclip retaining water pump intermediate drive gear and...

Page 57: ...in water pump gear NOTICE Never use the circlip a second time Always install a NEW one 1 Circlip 2 Water pump gear Water Pump Intermediate Drive Gear Install the following parts on water pump intermed...

Page 58: ...3 ENGINE 3 28 MAGNETO SYSTEM...

Page 59: ...ection and Cleaning Check magneto cover for cracks or other damage Replace if necessary NOTE Clean all metal components in a nonferrous metal cleaner Use LOCTITE CHISEL GAS KET REMOVER P N413 708 500...

Page 60: ...istance between YELLOW wires REQUIED TOOL FLUKE115 MULTIMETER P N529 035 868 TERMINAL RESISTANCE 20 C 68 F 1 and2 0 15 0 30 1 and3 2 and3 TYPICAL 3 If any reading is out of specification replace stato...

Page 61: ...ce stator 6 Re plug connectors properly Stator Removal Remove MAGENTO COVER See procedure in this subsection Remove screws securing the wire holding strip Remove stator retaining screws then the stato...

Page 62: ...5617 Heat screw in order to break the Loctite Remove screw and washer securing rotor to crankshaft Remove rotor REQUIRED TOOL MAGNET0 PULLER P N529 035 748 CRANKSHAFT PROTECTOR P N529 036 034 NOTE Use...

Page 63: ...gear 4 Apply engine oil here Slide rotor onto crankshaft The woodruff key and the keyway must be aligned Rotate starter double gear counterclockwise to align intermediate gear teeth with sprag clutch...

Page 64: ...amaged Sprag Clutch Installation For installation reverse the removal procedure Pay attention to the following details Apply LOCTITE648 GREEN P N413 711 400 on threads of sprag clutch housing screws I...

Page 65: ...arter drive gears are located on the engine MAG side behind the magneto cover Starter Drive Gear Removal Remove MAGENTO COVER See procedure in this subsection Remove location pins starter double gear...

Page 66: ...3 ENGINE 3 36 INTAKE MANIFOLD...

Page 67: ...B U D S Select the ECM and Activation tabs then click on Disabled in the fuel pump area 1 Click Dosable 2 Release fuel pressure by running engine until it runs out of gas 3 Disconnect the fuel hoses a...

Page 68: ...ue one cylinder at a time INTAKE MANIFOLD RETAINING SCREWS Tightening torque 20N m 2 5N m 15lbf ft 2 lbf ft Tighten elbow retaining screws to specification INTAKE MANIFOLD RETAINING SCREWS Tightening...

Page 69: ...3 ENGINE 3 39 TOP END CYLINDER HEAD NO 1...

Page 70: ...3 ENGINE 3 40 CYLINDER HEAD NO 2...

Page 71: ...3 ENGINE 3 41 CYLINDER AND PISTONS...

Page 72: ...NSPECTION LEAK TEST Before performing the cylinder leak test verify the following Clamp s tightness Radiator and hoses NOTE For best accuracy the leak test should be done with the engine at normal ope...

Page 73: ...ive pulley Second Procedure 1 Remove plug screw with 0 ring from magneto cover 2 Use a14 mm Allen key and turn crankshaft NOTICE Turn only clockwise to avoid loosening of magneto flywheel Allen screw...

Page 74: ...apter into previously cleaned spark plug hole Supply combustion chamber with air pressure TYPICAL 1 Leak tester 2 Air supply hose Note the amount or percentage of leakage depending on tester LEAKAGE P...

Page 75: ...console LH and RH lateral console panels Valve Cover Removal Remove valve cover screws of valve cover 1 Valve cover screws 2 Valve cover Remove valve cover and gasket 1 Valve cover 2 Gasket Repeat th...

Page 76: ...s 1 Rocker arm exhaust side 2 Rocker arm intake side 3 Thrust washers NOTICE Pay attention not to lose thrust washers or drop them into the timing chain compartment 1 2 thrust washers 2 Rocker arm exh...

Page 77: ...n to 4731 in SERVICE LIMIT 11 990mm 472in Any area worn excessively will require parts replacement Rocker Arm Installation NOTE Use the same procedure for exhaust and intake rocker arm Apply engine oi...

Page 78: ...ALVE COVER in this subsection Refer to TIMING CHAIN subsection and remove the following parts Timing chain tensioner Camshaft timing gear Remove the camshaft retaining plate 1 Camshaft retaining plate...

Page 79: ...his subsection Camshaft Journal Inspection Check each journal for scoring scuffing cracks or other signs of wear Measure camshaft journal using a micrometer A Camshaft lobe exhaust valves B Camshaft l...

Page 80: ...PRODURES subsection NOTE Before removing cylinder head blow out remaining coolant by air pressure During cylinder head removal the remaining coolant in cylinder head could overflow into the engine an...

Page 81: ...supply to camshaft bearing journal spark plug side Cylinder Head Camshaft Bearing Inspection Measure camshaft bearing in cylinder head A Cam shaft bearing timing chain side B Cam shaft bearing spark...

Page 82: ...engine Location no 1 M10 140 Location no 2 M6 85 1000 engine Location no 1 M10 159 Location no 2 M6 105 Tighten M10 cylinder head screws FIRST as per following specifications TIGHTENCE SEQUENCE M10 C...

Page 83: ...rings Be careful when unlocking valves Components could fly away because of the strong spring preload LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE Remove valve cotters 1 Valve spring co...

Page 84: ...perly engaged in valve stem grooves 1 Position of the valve spring 2 Valve cotter After spring is installed ensure it is properly locked by tapping on valve stem end with a soft hammer so that valve o...

Page 85: ...INTAKE VALVE NEW 4 966mm to4 980 mm 1955in to 1961 in SERVICE LIMIT 4 930mm 1941 in Valve Face and Seat 1 Valve seat 2 Exhaust valve contaminated area 3 Valve face contact surface to valve seat Check...

Page 86: ...e opens and c1oses a few times NOTICE An improperly locked valve spring wi1l cause engine damage VALVE GUIDES Valve Guide Inspection Always replace valve stem seals whenever valve guides are removed M...

Page 87: ...4 00mm to14 40mm 5512 in to 5669 in Apply some lapping compound to valve face and work valve on its seat with a lapping tool 1 Valve seat 2 Valve face contact surface to valve seat 3 Turn valve while...

Page 88: ...ent 90 from first one and compare NOTE Take the same measuring points like described in CYLINDER TAPER above A Perpendicular to crankshaft axis B Parallel to crankshaft axis CYLINDER OUT 0F ROUND NEW...

Page 89: ...fer to following procedures in this subsection to remove Cylinder head Cylinder Place a rag under piston and in the area of timing chain compartment WARNING Piston circlips are spring loaded Remove on...

Page 90: ...1 Use the micrometer to set the cylinder bore gauge 2 Dial bore gauge TYPICAL 1 Indicator set to 0 zero Position the dial bore gauge20 mm 787 in above cylinder base measuring perpendicularly 90 to pis...

Page 91: ...m to20 020 mm 7878in to 7882in SERVICE LIMIT 20 060 mm 7898 in 1000 NEW 20 010 mm to20 020 mm 7878in to 7882in SERVICE LIMIT 20 050 mm 7894in Replace connecting rod if diameter of connecting rod sma1l...

Page 92: ...ays replace disassembled piston circlip s by NEW ones Place a rag on cylinder base to avoid dropping the circlip inside the engine Place circlip in sleeve as per following illustration 1 Circlip 2 Sle...

Page 93: ...MIT 0 60 mm 024in LOWER COMPRESSION RING NEW 0 20 mm to 0 40mm 008in to 016in SERVICE LIMIT 0 70 mm 028 in OIL SCRAPER RING NEW 0 20 mm to 0 70mm 008in to 028in SERVICE LIMIT 1 00 mm 039in To measure...

Page 94: ...second rings are not interchanged Check that rings rotate smoothly after installation Space the piston ring end gaps120 apart and do not align the gaps with the piston pin bore or the thrust side axis...

Page 95: ...3 ENGINE 3 65 TIMING CHAIN...

Page 96: ...etighten screws to recommender torque 6 INCORRECT CAMSHAFT TIMING Replace damaged components and readjust camshaft timing ENGINE LACKS ACCELERATION OR POWER 1 INCORRECT CAMSHAFT TIMING _Replace damage...

Page 97: ...shaft timing gear can be moved back and forth MOVE GEAR BACK AND FORTH 2 Apply engine oil on the plunger before insta1lation 3 Slightly turn the camshaft timing gear in order to get the timing chain p...

Page 98: ...piece of wire Camshaft Timing Gear Inspection Check camshaft timing gear for wear or deterioration If gear is worn or damaged replace it as a set with the timing chain For crankshaft gear refer to BO...

Page 99: ...3 Printed marks on camshaft timing gear 6 Install and adjust timing chain tensioner refer to TIMING CHAIN TENSIONERS in this subsection 7 Install and tighten camshaft timing gear retaining screws to...

Page 100: ...mark on the magneto flywheel is aligned with notch in the magneto cover PISTON N0 2 AT TDC 1 Mark 2 on magneto flywheel 2 Notch on magneto cover 3 Crankshaft position sensor location 5 2 Confirm print...

Page 101: ...ockwise REQUIED TOOL Allen key 14mm TURN CRANKSHAFT 280 COIUNTERCLOCKWISE 1 Allen key14 mm 3 1 The front piston is at TDC when it s index mark on the magneto flywheel is aligned with the notch in the...

Page 102: ...AIN The engine is equipped with two timing chains MAG side timing chain is located behind the magneto cover PT0 side timing chain is located behind the PT0 cover Timing Chain Removal MAG Side Refer to...

Page 103: ...lve cover Refer to following procedures in this subsection and remove following parts Chain tensioner Camshaft timing gear Remove timing chain guide tensioner side and lower timing chain guide 1 Timin...

Page 104: ...shaft timing gear NOTE Ensure to carry out proper valve timing refer to CAMSHAFT TIMING GEARS in this subsection NOTICE Improper valve timing will damage engine components TIMING CHAIN GUIDE TENSIONER...

Page 105: ...3 ENGINE 3 75 BOTTOM END ENGINE DRIVE SHAFT...

Page 106: ...3 ENGINE 3 76 CRANKCASE AND PTO COVER...

Page 107: ...3 ENGINE 3 77 CRANKSHAFT...

Page 108: ...engine remove the bearing cover and its O ring 1 Bearing cover screws 2 O ring 3 Bearing cover gearbox Front Bearing Cover Removal Remove the bearing cover at the front of the engine NOTICE Check end...

Page 109: ...NT When beginning the application of the bearing cover sealant the assembly and the first torquing should be done within10 minutes it is suggested to have all you need on hand to save time Use a plexi...

Page 110: ...lled 1 Remove front propeller shaft 2 Remove adapter sleeve between propeller shaft and front engine drive shaft 3 Remove the front bearing cover refer to ENGINE DRIVE SHAFT REMOVAL INSTALLATION in th...

Page 111: ...r of removal PTO COVER OIL SEAL To replace oil seal it is not necessary to remove engine from vehicle PTO Oil Seal Removal Refer to CONTINUOUSLY VARLABLE TRAINSMISSION CVT subsection to remove the fol...

Page 112: ...emove the following parts CVT cover Drive pulley Driven pulley CVT air guide Disconnect vent hose Remove PT0 cover screws and pul1 PTO cover 1 PTO cover 2 PTO cover screws 3 Vent hose nipple PT0 Cover...

Page 113: ...install plain bearings Use a press only Carefu1ly remove the PT0 oil seal with a screwdriver without damaging the PT0 cover Press out the plain bearings from the outside towards the inside PLAIN BEARI...

Page 114: ...in bearings must be positioned near to oil bore in counterclockwise direction 1 Partition 2 PTO cover inside 3 Oil bore PT0 Cover Installation For installation reverse the removal procedure Pay attent...

Page 115: ...Remove needle pin and pull water pump drive gear out Remove thrust washer from intermediate shaft 1 Thrust washer 2 Water pump drive gear 3 Needle pin Drive Gears Inspection Intermediate Gear 0il Pump...

Page 116: ...parts PTO cover Drive gears Bearing covers of engine drive shaft 8 Refer tonM 0 al 1l 4 Vsubsection to remove following parts Chain tensioners Camshaft timing gears Timing chains Timing chain guides...

Page 117: ...strainer 2 Retaining plate 3 Screws Crankcase Cleaning WARNING Use safety goggles to avoid eye injuries Clean crankcase using a part cleaner Dry crankcase using compressed air Blow the oil supply lin...

Page 118: ...leeve Plain Bearing Installation Main NOTICE Unless otherwise instructed never use hammer to install plain bearings Use press only NOTE Place the proper crankcase support sleeve under crankcase halves...

Page 119: ...of the plain bearings in crankcase half PT0 side must be positioned near to oil bore in counterclockwise direction 152 1 Partition 2 Oil bore 3 Crankcase half PTO inside Crankcase Assembly The assembl...

Page 120: ...is at TDC ignition refer to CRANKSHAFT TIMING GEAR in the TIMING CHAIN subsection Remove 1 Spark plug cables and spark plugs of both cylinders 2 Plug screw and 0 ring of magneto cover 1 Plug screw 2...

Page 121: ...acks or other signs of wear NOTE Replace crankshaft if the gears are worn or otherwise damaged NOTICE Components out of specifications always have to be replaced If this is not observed severe damage...

Page 122: ...om crankshaft NOTICE Connecting rod screws are not reusable Always discard screws and replace by NEW ones It is recommended to install new plain bearings when reinstalling connecting rods 1 Connecting...

Page 123: ...ification replace plain bearings and recheck Crankshaft Radial Play MAG PTO Side Measure crankshaft on MAG PTO side Compare to inside diameter of MAG PT0 plain bearing refer to CRANKCASE 1 Micrometer...

Page 124: ...f plain bearing of connecting rod big end 2 Split surface of the connecting rod 3 Nose of plain bearing in line with connecting rod groove Oil the plain bearing surface of the connecting rod and crank...

Page 125: ...g rod small ends 2 Connecting rod offset 3 Connecting rod screws CONNECTING RODS SCREWS TIGHTENING SEQUENCE 1 Tighten to1 2 of specified torque 2 Tighten to30N m 2N m 22lbf ft 1 lbf ft 3 Torque by an...

Page 126: ...3 ENGINE 3 96 1 Crankcase half MAG side 2 Connecting rod cylinder 1 3 Connecting rod cylinder 2...

Page 127: ...ulleys have metric threads Do not SAE threads puller Always tighten puller by hand to ensure that the drive pulley has the same type of threads prior to fully tightening DRIVE BELT Removal Remove Dist...

Page 128: ...ulley rear 4 Rotation direction The maximum drive belt life span is obtained when the drive belt has the proper rotation direction Install it so that the arrow printed on belt is pointing towards fron...

Page 129: ...ew Inspection Drive pulley should be inspected annually for wear or damages Check drive pulley for cracks and sliding contact surface for excessive wear Replace it if necessary Check one way clutch be...

Page 130: ...efer at the beginning of this section When the drive pulley is blocked torque screw to 100N m DRIVEN PULLEY Removal remove variator cover and gasket Remove belt Using the pulley holding tool hold the...

Page 131: ...Pay attention to the following details Chamfer on inside diameter of the spacer must face engine side Clean pulley faces and shaft with dry cloth Driven pulley is a spring loaded system Always place...

Page 132: ...3 ENGINE 3 102 GEARBOX AND4X4 COUPLING UNIT GEARBOX COMPONENTS AND 4 4 COUPING MECHANISISM...

Page 133: ......

Page 134: ...on sensor GBPS Perform a gearbox position sensor test Damaged wires Repair as required GEAR S IS ARE HARD TO SHIFT 1 Incorrect shifter cable adjustment Adjust shifter cable refer to SHIFTER CABLE in S...

Page 135: ...KE115 MULTIMETER P N529 035 868 VSS INPUT VOLAGE TEST TEST PROBES RESULIT KEY ON PIN A RED wire PIN C BLACK GREEN wire Battery voltage If voltage is not as specified test positive and ground separatel...

Page 136: ...ollowing parts has been replaced Gearbox assembly Shift drum GBPS ECM 1 Connect vehicle to the latest applicable version Of B U D S software refer to COMMUNICATION TOOLAND B U D S subsection NOTE Igni...

Page 137: ...BPS Access To reach the GBPS sensor remove the following parts Passenger seat RH lateral console panel Fuel tank cowl GBPS Input Voltage Test NOTE Prior to conduct testing check fault codes in B U D S...

Page 138: ...on 4WDINDICATOR SWITCH 4WDlndicator Switch Access To reach the4WD indicator switch remove the fo1lowing parts _ Passenger seat RH lateral console panel Fuel tank cowl 4WDlndicator Switch Removal Disco...

Page 139: ...WHIT E Battery voltage 4WD WHITE BLACK If the selector is out of specifications check wires connectors and replace the selector if necessary If the selector is good check the vehicle harness If the v...

Page 140: ...2WD position Turn front wheel again The front propeller shaft should turn easily If the front propeller shaft does not turn the actuator is not installed correctly Remove actuator and reinstall it NO...

Page 141: ...E Oil seal must be installed with sealing lip toward gearbox Shift Drum Shaft Oil Seal To replace the shift drum shaft oil seal remove the GBPS GEARBOX POSITION SENSIR See procedure in this subsection...

Page 142: ...exagonal screw 1 Output shaft oil seal 2 Oil seal installer 3 Flat washer P N250 200 102 4 M12 1 25 35 hexagonal screw 5 Apply engine oil on outer diameter of oil seal GEAR BOX Gearbox Removal Remove...

Page 143: ...Unscrew all bolts retaining the gearbox left cover 1 3 screws M6x35 2 13 screws M6x55 Place the center housing on a wood stand left cover pointing upwards Using a big flat screwdriver and a soft hamm...

Page 144: ...er 2 Index lever 3 Step ring 4 Index spring Main Shaft and Shift Forks Remove bearing pin reverse intermediate gear and thrust washers NOTE Take care not to lose lower thrust washer during removal 1 B...

Page 145: ...3 Free pinion LOW range gear 4 Needle bearings 5 Main shaft assembly Remove from main shaft assembly Snap ring discard Shifting sleeve LOW REVERSE range gear Snap ring discard REVERSE range gear Need...

Page 146: ...ers POSITION FOR BIG FLAT SCREWDRIVER POSITION FOR BIG FLAT SCREWDRIVER Shift Shaft and Shift Drum Withdraw shift shaft assembly 1 Shift shaft assembly Remove screw retaining the shifting intermediate...

Page 147: ...from center housing and withdraw4X4 coupling sleeve NOTICE Use a soft hammer to remove output shaft 1 Output shaft 2 4 4 coupling sleeve 3 Soft hammer Remove set screw coupling fork shaft and coupling...

Page 148: ...emoved Housing damages may occur if this procedure is not performed correctly To remove ball bearings of countershaft right cover and main shaft left cover use following tool REQUIED TOOL BLIND HILE B...

Page 149: ...gs and use special pliers to install them Check free pinions for wear TYPICAL 1 Micrometer 2 Free pinion DIAMETER FREE PINION NEW 29 000 mm to29 013mm 1 1417in to1 1422in SERVICE LIMIT 29 015mm 1 1423...

Page 150: ...Check main shaft for wear A Bearing journal MAG side B Free pinion bearing C Bearing journal CVT side MAIN SHAFT FREE PINION BEARING NEW 24 987mm to25 000 mm 984in to 984in SERVICE LIMIT 24 984 mm 98...

Page 151: ...ndex Lever and Parking Lever Index lever with roller must move freely Check parking lever for cracks or other damages Output Shaft Check output shaft and its gear for cracks bend pitting or other visi...

Page 152: ......

Page 153: ...oil of fins is blocked or damaged Correct curved fins Use water and compressed air to clean soil If damaged area reaches 20 please replace radiator 3 Pump overhauling can be carried out before dismant...

Page 154: ...k indicator hole if there is oil or coolant NOTE Flowing coolant indicates a defective rotary seal Oil indicates a defective inner oil seal If either seal is leaking both seals must be replaced at sam...

Page 155: ...al procedure pay attention to the following details Install the thermostat cover then torque screws to 10N m Check coolant level in radiator and coolant tank and top up if necessary Do not forget to b...

Page 156: ...f cooling fan Pull out upward the radiator from the lower mounting holes on the frame remove the radiator from the left side of the vehicle Radiator Installation For installation reverse the removal p...

Page 157: ...an Removal Remove radiator shroud Remove bolts Remove the radiator fan Radiator fan test NOTE The ECM controls the radiator fan via the input of the coolant temperature sensor CTS The radiator fan sho...

Page 158: ...4 COOLING SYSTEM 4 6...

Page 159: ...event leaking take care that the gasket is exactly in groove when you reinstall the water pump housing Tighten screws of water pump housing in a crisscross sequence WATER PUMP IMPELLER Impeller remova...

Page 160: ...er pump gear to disengage the inner drive gear 1 water pump gear 2 Inner drive gear Sharply strike water pump shaft out with a plastic hammer Pull out water pump shaft through the engine drive shaft o...

Page 161: ...mechanism to the needle pin Replace if damaged Shaft Seal installation For installation reverse the removal procedure However pay attention to the following NOTE For installation use the torque value...

Page 162: ...the shaft hole so that pin can be installed Position pin between your fingers push in water pump shaft to fully expose hole then install pin Position pin equal distance out of shaft hole so gear can b...

Page 163: ...t allow fuel to spill on hot engine parts and or electrical connectors Never use a hose pincher on injection system high pressure hoses Replace any damage or deteriorated fuel lines When the repair is...

Page 164: ...ce fuel pump A slow pressure drop indicates leakage either from the fuel injector or from the fuel pressure regulator Check fuel injector and the fuel pressure regulator for leaks If it is not leaking...

Page 165: ...ttention to pump orientation Tighten retaining screws as per illustrated sequence Install hose properly on OUT nipples and harness FUEL SENSOR The level sensor is part of the fuel pump module mounted...

Page 166: ...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 approved fuel container Fuel tank removal Remove the se...

Page 167: ...tion For installation reverse the removal process but pay attention to the following Install a new gasket Pay attention to pump orientation Tighten retaining screws as per illustrated sequence Install...

Page 168: ......

Page 169: ...DRIVE 6 1 FRONT PROPELLER SHAFT 6 2 FRONT WHEEL HUB 6 3 FRONT DRIVE SHAFT 6 4 FRONT DIFFERENTIAL 6 5 REAR DRIVE 6 6 REAR PROPELLER SHAFT 6 4 REAR WHEEL HUB 6 5 REAR DRIVE SHAFT 6 6 REAR DIFFERENTIAL...

Page 170: ...from the steering knuckle Remove propeller shaft bolts on front differential side Inspection Inspect the propeller shaft for wear or damage If any defects are found replace the propeller shaft with n...

Page 171: ...k 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 Installation The installation is the reverse of removal procedure Install...

Page 172: ...the nuts of knuckle upper and lower ball joint Remove the knuckle Pull drive shaft out of differential Inspection Inspect the condition boots If there is any damage or evidence of leaking lubricant r...

Page 173: ...ve Insert the other end of drive shaft in the knuckle and install the knuckle to the lower suspension arm Install and torque the ball joint retaining bolts to 45N m Install all other removed parts FRO...

Page 174: ...bber case for wear or damage Also check that the joint of rubber case fits tightly Installation The installation is the reverse of the removal procedure Pay attention to refill the oil GL 4 90 Ensure...

Page 175: ...Removal Loosen wheel nut of the appropriate Install a jack stand under the frame to lift the rear of vehicle off the ground until the shock absorber is fully extended Remove the rear wheel Remove cott...

Page 176: ...tighten until one of its grooves is aligned with a cotter pin hole Install a new cotter pin and the wheel cap Fold one pin of cotter pin over drive shaft end REAR DRIVE SHAFT Removal Remove the approp...

Page 177: ...ifferential and pull joint a little to make sure that the stop ring is locked in differential side gear groove Insert the other end of drive shaft in the knuckle and install the knuckle to the upper s...

Page 178: ...side Remove propeller shaft bolts on rear differential side Remove the rear propeller shaft Inspection Inspect the propeller shaft for wear or damage If any defects are found replace the propeller sha...

Page 179: ...e case cover bearing oil seals and dust seal for wear or damage If any damage or wear is found replace the oil seal or dust seal with a new one Check back lash and drag torque Check the breather rubbe...

Page 180: ...moving the air valve cap release the tire pressure by depressing the valve Dismount the bead from the rim completely Separate the tire from the rim by using a set of tire levers and rim protectors CAU...

Page 181: ...d 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 s...

Page 182: ......

Page 183: ...7 STEERING SYSTEM 7 1 7 STEERING SYSTEM ADJUSTMENT 7 2 TROUBLESHOOTING 7 3...

Page 184: ...side to side 3 2 Position the steering wheel at half the total rotations NOTICE Steering wheel angle 5 Front Toe Adjustment 4 Adjust the tire mmmmmake sure the tire is 10 degrees inside 1 1 Adjust th...

Page 185: ...ws on each side of the steering support 1 3 Remove steering column from vehicle Inspecting Check steering shaft for wear cracks or bending Ensure universal joints are not worn and move freely Replace...

Page 186: ......

Page 187: ...3 3 Remove the retaining bolts of Redirector Assembly 3 4 Remove the tie Rod Inspecting Check Internal spline for wear cracks or bending Ensure universal joints are not worn and move freely Whether t...

Page 188: ......

Page 189: ...8 5 KNUCKLE 8 5 LOWER SUSPENSION ARM 8 6 UPPER SUSPENSION ARM 8 6 REASSEMBLY 8 6 FRONT SUSPENSION The procedure explained below is the same for the RH and LH sides unless otherwise noted During assem...

Page 190: ...s smoothly and with uniform resistance with rod up Any of the following conditions will denote a defective shock A skip or hang up when reversing stroke at mid travel Seizing or binding conditions exc...

Page 191: ...or distortion are found replace the suspension arm with a new one Move suspension arm from side to side There should be no noticeable loose Replace bushing if necessary Move suspension arm up and down...

Page 192: ...ess otherwise noted During assembly or installation use the torque values and service products as in the torque table REMOVAL AND DISASSEMBLY Loosen wheel nut of the appropriate Install a jack stand u...

Page 193: ...resistance with rod up Any of the following conditions will denote a defective shock A skip or hang up when reversing stroke at mid travel Seizing or binding conditions except at extreme end of eithe...

Page 194: ...e 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...

Page 195: ...8 BRAKES SYSTEM 9 1 9 BRAKES SYSTEM NOTICE 9 2 BRAKE FLUID REPLACMENT 9 3 BRAKE PADS REPLACMENT 9 4...

Page 196: ...s been stored for a long periods of time 3 When storing brake fluid seal the container completely and keep it away from children 4 When replenishing brake fluid take care not to get dust into fluid 5...

Page 197: ...d brake fluid is completely eliminated and the new brake fluid flows out 5 Tighten the exhaust valve and press the brake pedal deeply several times Make sure that the brake pedal is pressed completely...

Page 198: ...e cap and the sealing gasket BRAKE PADS REPLACMENT 1 Take off the tire 2 The fixing shaft pin of the brake Caliper fixing bolt and the disc brake shoe is removed respectively 3 Remove the disc brake s...

Page 199: ...e and measure the thickness with a micrometer If you find any damage or thickness below the service limit please replace the new brake disc Minimum limit thickness of front brake disc 3 5 mm Minimum l...

Page 200: ......

Page 201: ...wear clean gloves in replacing bulb Use cloth with alcohol or banana water to clean glass to prevent any grease sticking to glass Check battery to confirm whether it is normal Regularly check switch a...

Page 202: ...l for fixing fuse box 3 Installation sequence is opposite to disassembly sequence Inspection of ignition switches 1 Remove battery negative connection 2 Open hood cover 3 Disconnect ignition switch co...

Page 203: ...mp and front turn lamp are LED lamp band structure can use ohmmeter to detect bulb resistance resistance infinity or 0 replacement lamp combination Removal and installation of light control switches 1...

Page 204: ...t of the back of the meter 4 Check the conductivity between the ignition switch terminals with an ohmmeter and replace the switch if it does not meet the technical requirements Removal and installatio...

Page 205: ...an be replaced by 0 Removal and Installation of Electric Top Switch 1 Disconnect electric top switch plug in 2 Remove the electric top switch from the dashboard 3 ignition switch terminals if not meet...

Page 206: ...light is turned on the indicator lights up at the same time 9 EPS the fault indicator light is effectively on the ground the alarm indicator light EPS extinguished after the engine is running and the...

Page 207: ...nt DTC Description Related Calibration P0107 Manifold Absolute Pressure Sensor MAP MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh P0112 Intake...

Page 208: ...System Voltage Low KsDGDM_SysVoltLow P0563 System Voltage High KsDGDM_SysVoltHigh P0650 MIL MIL Circuit Malfunction KsDGDM_MIL_Circuit P1693 Tachometer Tachometer Circuit Low Voltage KsDGDM_TAC_Circu...

Page 209: ...10 ELECTRICAL SYSTEM 10 9 STARTING SYSTEM Starter motor Brush Z Check the brush on the brush holder whether it is worn abnormal cracked or not smooth Worn cracked or not smooth Replace...

Page 210: ...Check the oil seal lip for damage or leak Damage or leakage Replace the starter motor Starter relay Z Inter terminal voltage is 12V Test the direct connection of positive and negative poles with the m...

Page 211: ...nals of the starter relay Test the connection between A and B with the multimeter Z If the starter relay clicks and is connected the starter relay is OK Z When there is no voltage of 12V they are not...

Page 212: ...wire NOTE Z Make sure the battery voltage 12V The ignition coil wires are connected Z When using multimeter and the peak voltage adapter please refer to the user manual Z Move the gear to the neutral...

Page 213: ...eak voltage of coupling coil Z Check the peak voltage of the coupling coil with following steps Z As shown in right figure connect the multimeter with the peak voltage adapter Probe Green wire Probe B...

Page 214: ...ulated Install multimeter 1 10 Resistance of generator coil 0 9 1 5 color yellow Insulation resistance yellow grounding wire No load performance of the generator Z Start the engine with the speed at 5...

Page 215: ...s not within the range of specified values replace the regulator rectifier NOTE If the probe is not connected and the multimeter reading is lower than 1 4V replace the multimeter battery Red Black Yel...

Page 216: ......

Page 217: ...tom STARTER KEEPS RUNNING 1 Refer to starting system COOLING SYSTEM Symptom HIGH ENGINE OPERATING TEMPERATURE 1 Check coolant level Coolant level lower than recommended Refill refer to cooling system...

Page 218: ...t leakage Replace 14 Check coolant drain screw on water pump housing MAG side Copper ring on drain screw leaks Retighten screw and or replace copper ring 15 Check intermediate gear s behind of PTO cov...

Page 219: ...leak indicator hole if oil leaks in crankcase MAG side water pump housing area Oil leaking from leak indicator hole means a damaged oil seal on water pump shaft Replace oil seal refer to cooling syst...

Page 220: ...e possible engine internal damages Oil contamination due to metal or plastic particles Replace possibly damaged part s including oil and oil filter Use recommended oil refer to technical specification...

Page 221: ...ng center Check contact screw outside for contamination and wetness Clean contact screw and screw for wiring harness Contact s is are corroded and or contact screw for wiring harness got loose Clean c...

Page 222: ...GEARBOX 4 Check shifting sleeve splines and or shifting fork for wear and or damages Check sleeve shows damaged splines Replace shifting sleeve refer to GEARBOX Shifting fork is worn out and or engag...

Page 223: ...een driven pulley outer and inner sheave Mechanism is stuck and or damaged Replace driven pulley assembly 3 Check roller s and or levers for wear located on sliding sheave of drive pulley Roller s on...

Page 224: ...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 a...

Page 225: ...VT area Clean pulley surfaces with fine emery cloth wipe clean with a cloth or replace drive driven pulley sheaves and belt ENGINE GENERAL Symptom ENGINE CRANKS BUT FAIL TO START 1 Check fuel level in...

Page 226: ...e bypass valve Stuck or defective Refer to ENGINE MANAGEMENT 2 Check closed throttle and idle actuator with DELPHI Wrong TPS zero setting idle bypass valve reset Refer to ENGINE MANAGEMENT 3 Check eng...

Page 227: ...system leaks 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 Cra...

Page 228: ...rong spark plug gap Readjust gap and clean spark plugs or replace 2 Check spark plugs type Improper spark plugs heat range Install recommended spark plugs refer to TECHNICAL SPECIFICATIONS 3 Perform e...

Page 229: ...nder 1 heater of oxygen sensor is existing short circuit to ground P0032 Cylinder 1 heater of oxygen sensor is existing short circuit to power supply P0037 Cylinder 2 heater of oxygen sensor is existi...

Page 230: ...lamp is damaged P1693 Signal of speed gauge is existing short circuit to ground P1694 Signal of speed gauge is existing short circuit to power supply Clear fault code After correcting the problem that...

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