ODES UTV Desertcross 1000cc-3, Maintenance Manual

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11. TROUBLESHOOTING
11-
6
COUPLING UNIT
Symptom: 4 WHEEL DRIVE INDICATION FAILS
1.
Check contact screw on gear housing right side for damage and/or wear.

Shifting indicator switch pin is worn and/or damaged.
Replace shifting indicator switch.

Contact is corroded and/or contact screw for wiring harness got loose.
Clean contact surface and retighten contact screw with recommended torque.

Wiring harness has broken cable. Replace wiring harness.
Symptom: 4 WHEEL DRIVE DOES NOT ENGAGE OR DISENGAGE
1.
Check actuator wireharness are loose.
2.
Remove the actuator cover, and check if actuator is stuck or over travel.

Eliminate the binding or return to normal position by hand.
3.
Check actuator and/or actuator shifting fork for wear and/or damages.

Check if selector works properly. If so, check actuator.

If selector is out of specifications, check wires, connectors and/or replace
selector.

Actuator shifting fork is worn out and/or damaged.
Replace shifting fork of actuator.

Check function of actuator. Replace if actuator is not turning, refer to 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 engagement pin is damaged.
Replace shifting fork.
CVT
Symptom: UNUSUAL ACCELERATION BEHAVIOR
1. Check drive belt condition.

Belt is too narrow (drive belt engagement is higher in drive pulley).replace belt if
width is less than specified.
2. Check lever condition on drive pulley sliding sheave and/or roller(s) on governor cup.

Lever(s) on drive pulley sliding sheave is (are) worn and/or damaged. Replace all
levers at the same time (lever kit).

Roller(s) is (are) worn and/or damaged. Replace governor cup assembly.
3. Check drive/driven pulley sliding sheave for free axial movement.

Sliding sheave is stuck. Replace damaged part(s).
4. Check condition of drive/driven pulley spring.

Drive pulley spring tension is too smooth and/or damaged. replace spring.

Driven pulley spring tension is too stiff. Replace spring.
5. Check if cam of driven pulley is worn.
-- Replace if out of specifications.
6. Check condition of fixed and sliding sheaves (drive and driven pulley).

Check surface of fixed and sliding sheaves (drive and driven pulley) for grooves
or other damages.