TOMCAR Utility Vehicle Service Manual Download

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TOMCAR

USA, Inc.

1727 E. Deer Valley Road

Bldg. 2, Ste. 1

Phoenix, AZ 85024

Remove the gearshift and differential lock
lever connection.

Remove the three bolts on each side that
hold the gear box to the tray and remove the
gear box.

Note: it might be necessary to remove the exhaust
pipe for extra clearing.

126

06222010-v2.0

Summary of Contents for Utility Vehicle

Page 1: ...TOMCAR Service Manual 06222010 v2 0 ...

Page 2: ...ment 26 Steering System Steering Alignment 28 Steering Tie Rod End Replacement 33 Steering Rod Replacement 34 Ball Joint Replacement 35 A Arm Removal and Installation 38 CVT System CVT Belt Removal and Installation 40 CVT Removal and Installation 45 Transmission CVT Reconditioning 49 Engine CVT Reconditioning 58 Shock System Removal and Installation 63 Shock Disassembly and Assembly 64 Accumulator...

Page 3: ...emoval 91 Final Drive Disassembly 93 Final Drive Assembly 103 Final Drive and Axle installation 123 Transmission Transmission Removal 125 Transmission Disassembly and Assembly 127 Transmission Installation 135 Engine Engine Removal 137 Engine Installation 141 Water Pump Replacement Diesel 145 06222010 v2 0 ...

Page 4: ... Travel I 6 Wheel Lugs Nuts I 80ft lb Steel 110 ft lb alum 7 Frame Hardware I Frame nuts bolt and fasteners 8 Engine Oil Level I 9 Front Air Filter I C 10 Rear Engine Air Filter I C 11 Coolant Level I 12 Headlights Taillights I 13 Hand Brake Operation I 14 CVT Belt I I Inspect C Clean TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 1 06222010 v2 0 ...

Page 5: ...filter refer to engine maintenance chart 9 Change fuel filters refer to engine maintenance chart 10 Check rear air filter Inspect air intake hoses 11 Check spark plugs refer to engine maintenance chart 12 Check coolant level Inspect radiator hoses 13 Change transmission oil 14 Change final drive oil 1 qrt 80w90 gear oil each side 15 Grease CVT and axles 16 Grease the engine CVT CVT will have to be...

Page 6: ...clean replace as needed 24 Check brake fluid Dot 4 25 Clean battery terminals 26 Inspect fuses 27 Grease steering box and check steering system for free play 28 Check windshield washer fluid 29 Inspect throttle cable and linkage 30 Test CVT for proper operation 31 Test drive vehicle 3 06222010 v2 0 ...

Page 7: ...30 Below 20C Oil Dipstick Should Indicate SEA 15W 40 Above 20C Safe Range TMx7B Diesel Engine Oil SEA 15W 40 Transmission Case Oil SEA 80W140 synthetic 2 4L Maintain as Recommended Final Drive Oil SEA 80W90 0 75L Per Side Maintain as Recommended Brake Fluid DOT 4 0 5L Maintain Level Between Lines Coolant Front Ball Joints Steering Box Multipurpose Grease As Needed Locate Fittings and Grease Rear D...

Page 8: ...ean Clean Replace Clean Replace Replace Fuel Filter Replace Replace Coolant Check Add Check Add Check Add Replace Cooling System Hoses Check Tighten Check Tighten Check Tighten Valve Adjustment Check Adjust Fuel Injector Pressure Check Adjust Preliminary Fuel Filter Replace Replace Replace Replace Repeat Every 1500M Repeat Every 3000M Repeat Every 18000M Engine Oil SEA 15W40 TOMCAR USA Inc 1727 E ...

Page 9: ...ne hand on the top of the tire and the other hand on the bottom alternate pushing and pulling the top while pushing and pulling the bottom A 1 to 2 mm of free play is normal If the wheel bearings have excessive free play replace wheel bearings A arm bushing inspection Raise the front wheels off the ground and secure vehicle on jack stands Remove the front wheels Aggressively shake the a arms while...

Page 10: ...ring rack are not torn dry and or cracked Inspect that the tie rod end is straight The threaded section is the weakest point and will bend first Make sure the tie rod end lock nut 1 and the ball joint nuts 2 are tight Shock mounts With the wheel raised off the ground grab the bottom of the a arm and quickly lift and release the a arm repeatedly The suspension should feel solid and not have more th...

Page 11: ... fluid Upper final drive bearings CAUTION For this step make sure the vehicle is completely secure and solidly supported by jack stands Grab the brake rotor and repeatedly push and pull the final drive assembly checking for free play at the upper bearings If large amount of free play is present replace bearings Rear shock mounts CAUTION For this step make sure the vehicle is completely secure and ...

Page 12: ...ing the fuel lines to the filter Remove and replace the filter by removing the filter clamps Pay close attention when installing the filter there is an arrow indicating the direction of flow Located close to the rear firewall next to the fuel pump is the suction fuel filter Remove and replace filter paying close attention to the direction of flow indicated by an arrow stamped on the filter Spark p...

Page 13: ...cifications Fuel filters Carefully remove the spin on primary fuel filter and install a new filter Change fuel filter every 5000 Km Fuel filter bleed and primer procedure Locate the fuel filer housing Using a 19mm wrench loosen the rear Banjo Bolt to allow fuel to escape as pressure is built up Using the prime lever on the fuel pump 1 build fuel pressure by pressing down several times until fuel b...

Page 14: ...g system Inspect the upper and lower radiator hoses 1 for damage Make sure all hose clamps are tight and positioned properly Inspect the radiator and fans and thoroughly clean area Inspect the radiator cap Make sure the rubber seal is in good condition Check the coolant overflow bottle for leaks and fill bottle to the full level Transmission oil Position vehicle on level ground Remove the fill plu...

Page 15: ... to 3 pumps from a grease gun are all that is required Drive axles Inspect the drive axles and make sure the o ring is not exposed and or torn Grease the axle grease fittings There are 2 one at each end of each axle 1 to 2 pumps from a grease gun is all that is required CVT belt The gap should be 5 7 cm 2 0 2 9in measured at midpoint between the two CVTs If an adjustment is necessary see Belt Tens...

Page 16: ...move Leak Check Check vehicle for leaks Brake fluid Coolant Engine oil Transmission oil Final drive oil Shock oil Note Small leaks oil built up around the breathers and shafts of the final drives and transmission are normal Electrical System Check that all electrical components are in operating condition Check for any loose cables and or connectors Inspect harness to make sure the harness is clear...

Page 17: ...hould open and close in a smooth continuous motion From 1 to 2 3 If there is any hesitation or they do not reach full travel there is a problem in one or both of the CVTs See CVT repair section Test drive Test drive vehicle and check Steering operation Brake operation Acceleration Noises Gauge operation Seat belt operation Transmission operation High Low Reverse Diff lock 1 2 2 1 1727 E D Bldg 2 S...

Page 18: ...y 10 000 Km or 2 years Adjusting the distance of the brake pedal to the booster If the booster or rod were changed the pedal push rod length will have to be checked Note There is a small amount of free play encountered when pushing on the brake pedal before the pressure starts to build up this is ok but it should not be more than a 2 7mm movement at the pedal end 1 Break loose the ball joint jam n...

Page 19: ...hole in the push rod ball joint is aligned with the hole in the brake pedal and the bolt can be inserted freely into the holes Lock the bolt with a new self lock nut Bolt nut 19mm Retighten jam nut 1 2 shown in top picture once push rod distance is set Make sure that the ball joint can pivot freely on the bolt and does not bind Tech Tip It is very important that the push rod is adjusted properly I...

Page 20: ...he caliper bolt Raise caliper and remove brake pads Clean the exposed piston surface Push piston back into caliper Install new pads Install and tighten caliper bolt Rear brake pads 1 When replacing the rear brake pads it will be be necessary to reset the caliper piston Using a brake caliper wrench reset the piston by rotating the wrench clockwise until the piston completely retracted back into the...

Page 21: ... vehicle and take off the wheel Remove the 2 caliper mount bolts 2 Remove the brake caliper and mount bracket from the final drive 1 Disconnect the parking brake cable and the brake line TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 18 06222010 v2 0 ...

Page 22: ...unt bolts 2 Tighten the mount bolt and torque to 105nm 3 Connect the parking brake cable and hook up the brake line IMPORTANT After removing any brake hose and or fitting from the brake system the brake system will have to be bled for proper operation TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 19 06222010 v2 0 ...

Page 23: ...r mount bolts 2 Remove the brake caliper and mount bracket from the final drive Secure the caliper out of the way 3 Remove the cotter pin and remove the hub nut 4 Remove the rotor assembly from the spindle TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 20 06222010 v2 0 ...

Page 24: ...alley Road Bldg 2 Ste 1 Phoenix AZ 85024 5 Hub puller TM50171 may be required if the rotor assembly will not come off easily 6 Remove and inspect the 3 axle keys from both the left and right rear rotor assemblies 21 06222010 v2 0 ...

Page 25: ...install the 3 axle keys first Apply anti seize to the axle and install the rotor assembly 2 Tighten the nut until the nut stop Locate the hole in the shaft and tighten 1 additional notch and install the cotter pin 3 Install the brake caliper assembly TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 22 06222010 v2 0 ...

Page 26: ...y Road Bldg 2 Ste 1 Phoenix AZ 85024 4 Tighten the mount bolt and torque to 105nm IMPORTANT After removing any brake hose and or fitting from the brake system the brake system will have to be bled for proper operation 23 06222010 v2 0 ...

Page 27: ...cement 2 After removing the master cylinder remove the bolt 1 and nut 2 that locks the pedal shaft and the push rod ball joint together Bolt nut 19mm 3 Loosen the lock nut 1 Nut 14mm 4 Disconnect the push rod from the booster 4 Remove the two upper nuts and washers Nut 13mm 5 Remove the two lower nuts and washers through the access holes below the booster to pedal rod 1 1 2 1 TOMCAR USA Inc 1727 E...

Page 28: ...g 2 Ste 1 Phoenix AZ 85024 6 Install the new booster washers and tighten the 4 nuts 7 Install the push rod 8 Connect the push rod ball joint See Brake Pedal Adjustment Connect the master cylinder See Master Cylinder Replacement 25 06222010 v2 0 ...

Page 29: ...t up immediately Never reuse old brake fluid or mix different brands Doing so may cause the brake to be ineffective and or deteriorate the rubber hosing Only use brake fluid that has been properly sealed and stored 1 Disconnect the brake hoses and copper lines from the master cylinder 2 Remove the two nuts that hold the master cylinder in place Nuts 13mm 3 Replace the master cylinder tighten the n...

Page 30: ...re is 1 to 2 mm of clearance between the master cylinder valve 2 and the booster push rod 1 If adjustment is needed loosen the lock nut 3 and adjust the pushrod until the rod is flush with the booster surface Try fitting the master cylinder again Lock nut 8mm Push rod 6mm 1 3 2 1727 E D Bldg 2 Ste 1 Phoenix A 27 06222010 v2 0 ...

Page 31: ...wer A arm positioning tool according the model indications marked on it 4 Remove the bands that hold the dust guards in place on either side Reveal the steering rack shaft 5 Adjust the steering rack by a Turn the steering wheel all the way towards one side b Measure the distance exposed c Adjust the steering shaft equally on both sides to half the distance measured in step b TOMCAR USA Inc 1727 E ...

Page 32: ...e 2 Turn the hub with TM50410 so that it is upright Measure the angle of the hub 3 It needs to be 88 5 degrees or 1 5 depends on instrument measuring towards the inside of the vehicle 4 To adjust the angle increase or decrease the distance between the top ball joint and the A arm 5 When angle is reached tighten both nuts firmly and make sure that the ball joint is leveled 6 Set the hub with TM5041...

Page 33: ... Measuring the distance from the frame to the front and rear of the hub level bar Adjust the tow in so the side of the level bar closest to the front of the vehicle is 2mm closer to the frame then the rear side of the bar 9 Reattach the steering dust boot with cable ties 2mm TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 30 06222010 v2 0 ...

Page 34: ...The red line marks the needed inclination for the wheel 1 5 Top View Forward 2mm TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 31 06222010 v2 0 ...

Page 35: ... upper steering rod universal joint 2 Carefully pull the steering wheel up separating the steering column from the upper steering rod 3 Align the steering wheel so that it is level and reattach the steering column to the upper steering shaft 4 Remove vice grips installed on step 6 Check steering for smooth proper operation with vehicle on the ground 32 06222010 v2 0 ...

Page 36: ... grips 17mm wrench 2 Loosen the lock nut 1 and then remove the tie rod end 3 When installing new tie rod end make sure the number of exposed threads matches the number previously counted when removed If number is unknown steering alignment will need to be performed 19mm wrench 24mm wrench 4 Reattach the tie rod end to the spindle and tighten nut Tech Tip If ball joint spins and nut will not tighte...

Page 37: ... To remove the steering rod from the steering rack assembly 13mm 24mm 3 Install a new steering rod 4 Install a new steering tie rod end and reconnect to spindle Refer to Steering alignment section TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 34 06222010 v2 0 ...

Page 38: ...ing the nut 3 tighten the ball joint cap 1 to lock the ball joint in place Tech tip To remove the ball joint from the spindle Install the ball joint nut back on the ball joint finger tight Hit the nut to remove the ball joint This will protect the threads on the ball joint 4 Inspect the ball joint housing and cap for damage and or wear 5 Remove the 2 Allen set screws and remove the 2 copper washer...

Page 39: ...arance for smooth steering operation 3 Place two new copper washers in the housing these lock the cap in place 4 Reinstall and tighten the Allen set screws 5 Replace the rubber boot on the spindle and secure it with its snap ring The rubber boot is important for keeping the grease in the ball joint and keeping the dirt out replace it when it is cracked and or torn TOMCAR USA Inc 1727 E Deer Valley...

Page 40: ...nt The lower ball joint removal inspection and replacement is exactly the same as the upper ball joint except that the housing is part of the lower A arm If there is any damage to the housing then replace the whole A arm See A arm replacement section 1727 E D Bldg 2 Ste 1 Phoenix A 37 06222010 v2 0 ...

Page 41: ...t from the spindle 2 Remove the a arm bolts 1 and 2 and pull out the upper a arm Lower A Arm removal 1 Remove the nut 1 to detach the ball joint from the king pin Tech Tip If the ball joint just spins tighten the bottom ball joint cap to lock the ball joint in place 2 Disconnect the lower shock mount 3 Remove the a arm bolts 1 and 2 and pull out the lower a arm 1 2 1 1 1 2 TOMCAR USA Inc 1727 E De...

Page 42: ...e used for the upper a arm only One is installed at each bolt in the frame hole 1 closest to the rear of the vehicle 3 To reinstall the a arm into the frame use a plastic hammer 4 Apply a light coat of anti seize to the bolts Insert the bolts all the way in close with a nut and tighten to the required torque Tech Tip Insert the bolts from the front so the nuts will be towards the rear This will he...

Page 43: ...ing brake 3 Use wheel chocks to avoid vehicle movement 4 Wear gloves 1 Place the transmission in neutral 2 Pull C V T belt 1 up with right hand while sliding it over the rim of the Transmission CVT plate 2 with left hand 2 1 TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 40 06222010 v2 0 ...

Page 44: ...elt off the Transmission CVT 4 If belt is too tight to pull over the rim push down in the center of the belt until the belt sinks deeper in between the CVT plates This will give the belt more slack and make it easier to remove Belt Inspection 5 Width of belt Standard new 35mm 1 36 in Service limits 33 5mm 1 30 in 6 Belt should not be dry cracked or otherwise damaged 1 41 06222010 v2 0 ...

Page 45: ...ection To ensure the right direction make sure that the writing is in a readable direction to you when mounting it 2 Mount the belt completely on the Engine CVT first TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 42 06222010 v2 0 ...

Page 46: ...t hand 4 Make sure the transmission is in neutral Using your right hand hold the Engine CVT and turn counter clockwise until belt is seated 5 The gap should be 5 7 cm 2 0 2 9in measured at midpoint between the two CVTs If an adjustment is necessary see Belt Tension Adjustment TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 43 06222010 v2 0 ...

Page 47: ...two right side engine mount bolts 17mm 7 Loosen the two left side engine mount bolts 17mm 8 Loosen the four exhaust nuts 13mm 9 Move engine forward or backwards until correct belt tension is reached 10 Tighten all nuts and bolts 1727 E D Bldg 2 Ste 1 Phoenix A 44 06222010 v2 0 ...

Page 48: ...CVT Puller TM50165 1 Remove CVT belt 2 Remove CVT mount bolt 16mm 3 Using the CVT puller remove the CVT 4 Place the CVT on a firm surface and push down on the moving plate It should move smoothly all the way up and down TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 45 06222010 v2 0 ...

Page 49: ...t and CVT nut Nut 30mm socket 2 Attach the CVT puller TM50170 13mm wrench 24mm socket 3 Remove the CVT Note Be aware not to lose the spacer or the gear shaft key TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 46 06222010 v2 0 ...

Page 50: ...mission shafts keyways are in place 4 Apply anti seize to the shafts keys Transmission CVT 5 Align the transmission CVT groove to the keyway on the transmission and slide the CVT into place Important Do not force the CVT on the shaft If the CVT does not slide smoothly all the way on to the shaft remove the keyway and check again If CVT fits without the keyway check that the keyway is straight and ...

Page 51: ... into place Important Do not force the CVT on the shaft If the CVT does not slide smoothly all the way on to the shaft remove the keyway and check again If CVT fits without the keyway check that the keyway is straight and the groove is clean and smooth 8 Secure the engine CVT firmly in place with crankshaft washer bolt and torque to 67 7N m 50Ft lb Socket 16mm USA I c 1727 E D y ad Bldg 2 Ste 1 Ph...

Page 52: ...130 5mm Allen key 2 Vice Preparation Place the transmission CVT holder in a vice and place the transmission CVT on the holder Disassembly 1 Remove the CVT o ring housing TM6880 Inspect for cracks wear and condition of the o ring TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 49 06222010 v2 0 ...

Page 53: ...Note The outer guide is double sided The abrasion only occurs on one of the sides so the guide can be flipped over and reused 3 Using the TM50185 CVT wrench unscrew the inner guide 4 Take off the inner guide and inspect the guide keys They should be straight and parallel to each other Replace with new if damaged 5 Remove the move plate and inspect It should be smooth without deformation abrasion o...

Page 54: ...and the spring if there is any damage 7 It should be smooth without damage Here we see abrasion caused by damaged spring Replace the plate and the spring if there is any damage 8 Inspect the Fix plate and main shaft They should be smooth without grooves or deformations TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 51 06222010 v2 0 ...

Page 55: ...assembly Reassembly Exploded View 1 Place the Transmission CVT shaft on the holder and apply anti seize to the threads TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 52 06222010 v2 0 ...

Page 56: ...the fix plate 4 Turnover the fix plate and set it back on the holder 5 Insert the wear strips TM6930 two strips into the groove Note Make sure the ends for the top strip is 180 degrees opposite the end of the lower strip TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 53 06222010 v2 0 ...

Page 57: ...ide the move plate into place 7 Insert the TM6892 spring leg into the hole in the bottom of the inner spin guide TM6852 TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 54 06222010 v2 0 ...

Page 58: ... move plate spring hole 1 Make sure that the spring leg at the inner spin guide does not come out of its hole 9 Screw on and tighten the inner guide using TM50185 10 Grease generously 25gr 11 Slide the outer spin guide TM6832 into place make sure that the grease nipple TM7990 is in place 1 TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 55 06222010 v2 0 ...

Page 59: ...ding the Spring Spin the move plate back and forth The move plate should move freely and there should be no tension on the spring 1 After CVT has been assembled make a mark to note the position of the holes in the outer guide relative to the holes in the move plate 2 Using TM50130 rotate the move plate counter clockwise two more holes than the one marked this will preload the spring inside TOMCAR ...

Page 60: ...counter clockwise all the way the o ring should be visible as shown here Movement should be smooth and continuous Tech Tip If the belt slips during steep climbs loud squealing ratcheting noises from belt the CVT spring will have to be tightened by rotating the plate one more hole 1727 E D Bldg 2 Ste 1 Phoenix A 57 06222010 v2 0 ...

Page 61: ...Reconditioning Tools 1 Engine CVT Wrench TM50185 2 TM50080 scale 3 Wrench 10mm 4 5mm Allen bit 5 Sockets 10mm 13mm 6 Vice Exploded View TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 58 06222010 v2 0 ...

Page 62: ...the last nut 13mm 2 Remove the spring housing spring and sleeve 3 Clean out the grease and inspect all of the nuts and bolts Make sure none are missing loose or broken 4 Secure the CVT holder in a vice and place CVT on the holder 5 Use CVT wrench TM50185 to unscrew roller plate counter clockwise TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 59 06222010 v2 0 ...

Page 63: ... should spin freely The roller pin should be fastened with no free play tighten if necessary Reassembly 1 Apply anti seize to the threads 2 Apply anti seize to the main shaft 3 Close the roller plate tightly with tool TM50185 TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 60 06222010 v2 0 ...

Page 64: ...d the spring 6 Inspect the wiper PW022 and ring RT222 inside the spring housing TM6725 guide hole Grease lightly 7 Grease the guide shaft thread 8 Place the spring housing into position and tighten the 4 nuts TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 61 06222010 v2 0 ...

Page 65: ...TOMCAR USA Inc eer Valley Road Z 85024 9 Test for proper function by pushing the Variator up and down check for smoothness 1727 E D Bldg 2 Ste 1 Phoenix A 62 06222010 v2 0 ...

Page 66: ...bsorber out of the a arm area disconnect the lower a arm from the lower ball joint this will provide more Note If there is a problem removing the shock absorber out of the a arm area disconnect the lower a arm from the lower ball joint this will provide more clearance Tech Tip When removing a shock remove the o rings and bushings before removing the shock When installing the shock install the bush...

Page 67: ...Change the O ring 3 in the cap 4 Check and replace any other damaged components either from wear or incident 4 Before beginning make sure you have all the parts needed Shock absorber TM4370 TM4380 disassembly and renovation 1 The only difference between TM4370 and TM4380 is the spring diameter TM4370 12mm TM4380 13 5mm 2 Secure the shock absorber in a vice Do not to lock the vice jaw on the ball j...

Page 68: ...shock spring 5 With a hammer lightly tap on the shock cap to release it 6 Use the Tomcar special shock holding tool TM50500 7 Place the shock with the holder in the vice 8 Using a wrench loosen the shock cap Do not unscrew completely off TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 65 06222010 v2 0 ...

Page 69: ... air repeat this several times during the unscrewing of the shock cap 10 Feel the shock cap it should feel loose and turn easily if not there could be air pressure still inside CAUTION Make sure that the shock absorber is not pointed at anybody 11 Unscrew the shock cap TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 66 06222010 v2 0 ...

Page 70: ... the springs and plastic spacer 14 With a hammer lightly tap on the cylinder in the area around the shock seal housing This will help loosen the housing TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 67 06222010 v2 0 ...

Page 71: ... 16 Using the special tool TM50196 loosen the seal housing Do not unscrew it completely all the oil will spill out 17 Place the shock in an upright position and unscrew the seal housing TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 68 06222010 v2 0 ...

Page 72: ...Drain the oil from the shock cylinder 20 Insert a long screw driver to remove the shock piston 21 Examine the inside of the cylinder for abrasion damage TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 69 06222010 v2 0 ...

Page 73: ... the nut 1 from the rod 24 Remove the piston from the rod Remove the plastic bushing and the O ring underneath 25 Remove the inner seal and the wiper Reasembly 1 Install the new O ring on the shock seal housing 1 TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 70 06222010 v2 0 ...

Page 74: ...ner needs to be installed a specific way It should be installed with the rim 1 toward the inside of the seal housing facing the oil There is writing on the outer side of the retainer 2 To insert the oil retainer in to the seal housing squeeze it in and press it into place 3 Install the wiper with the rims towards the outside 1 TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 71...

Page 75: ...e vice on the ball joint Inspect the shock rod for any scratches dents and or pits Any damage to the rod will result in the shock leaking 5 Place the shock spring support on the rod TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 72 06222010 v2 0 ...

Page 76: ...bber support on the rod 7 Apply a thin coat of oil to the shock seal housing and place on the rod with the thread towards the top TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 73 06222010 v2 0 ...

Page 77: ...washer onto the shock rod 9 Install the O ring from PR038 onto the shock oil piston 10 Install the nylon bushing from PR038 stretch it slightly TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 74 06222010 v2 0 ...

Page 78: ...on the rod and tighten the nut 12 Make sure that the shock rebound washer still has free play 13 Install the O ring onto the shock gas piston TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 75 06222010 v2 0 ...

Page 79: ...ston spacer 1 17 Place the cylinder on the piston spacer and tighten the vice securely Do not over tighten the vice or the cylinder can be damaged IMPORTANT Make sure the cylinder stays lock in place over the air piston spacer through to step 26 to ensure the air chamber will be correct size TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 76 06222010 v2 0 ...

Page 80: ...set to a depth of 33mm from the end of the cylinder 19 Fill the cylinder with oil 6 oz of 10 weight hydraulic oil 20 There should be enough space left after the thread for the piston 21 Roughly 35mm 22 Insert the piston into the cylinder until the oil just starts to come over the top of the piston This pushes out the excess air Piston spacer 33mm TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1...

Page 81: ...f a turn just to grip 25 Push the piston down to push all the excess air out 26 Slowly tighten the housing The remaining trapped air and a slight amount of oil will be forced out around the threads TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 78 06222010 v2 0 ...

Page 82: ... ball joint Fit the shock spring over the cylinder IMPORTANT Do not let the rod retract into the cylinder If this happens the air piston be forced up and the air chamber size will change 28 Install the shock spacer TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 79 06222010 v2 0 ...

Page 83: ...29 Apply anti seize approximately 1 3 of the way down the threads of the cylinder 30 Install the second shock spring TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 80 06222010 v2 0 ...

Page 84: ...31 Install the shock spring nut until it touches the spring 32 Prepare the shock cap 33 Insert the O ring TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 81 06222010 v2 0 ...

Page 85: ...to the O ring and threads 35 Apply anti seize to the air valve 36 Screw in the valve and tighten not to tight 37 Screw on the shock cap TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 82 06222010 v2 0 ...

Page 86: ...lace the shock side ways in the vice 39 Tighten the shock cap 40 Turn the spring nut and set the spring preload 41 There should be about 1 5cm of thread TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 83 06222010 v2 0 ...

Page 87: ...TOMCAR USA Inc eer Valley Road Z 85024 42 Inflate the shock with pressurized air 100psi 43 Check that there are no air leaks from the valve or shock cap 1727 E D Bldg 2 Ste 1 Phoenix A 84 06222010 v2 0 ...

Page 88: ... from the accumulator Make sure all the air pressure is removed 2 Remove the hose from the shock 3 Loosen and remove the accumulator cylinder cap 4 Remove the piston from the cylinder and replace the o ring TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 85 06222010 v2 0 ...

Page 89: ...e piston down just enough for the cylinder cap to be installed 7 Install new cylinder cap o ring 8 Apply anti seize on the threads and install the cap 9 The piston will need to set at the depth of 61mm TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 86 06222010 v2 0 ...

Page 90: ...umulator over and fill up with 10w hydraulic oil 12 Install a copper washer on both sides of the banjo hose fitting 13 Tighten the fitting onto the accumulator while holding the hose in place TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 87 06222010 v2 0 ...

Page 91: ...both sides of the hose fitting 16 Put a copper washer on the other side of the connector 17 The accumulator must be positioned based on which side of the vehicle the shock will be installed on Right side of vehicle Left side of vehicle TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 88 06222010 v2 0 ...

Page 92: ...tor for approximately 1 to 2 seconds Just so there is enough pressure to bleed the air out 22 Loosen the hose banjo fitting slowly till a small amount of oil bleeds out This procedure will bleed the air from within the shock 23 Retighten the hose bolt TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 89 06222010 v2 0 ...

Page 93: ...TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 24 Pressurize the accumulator to 100psi 90 06222010 v2 0 ...

Page 94: ...r wheel 1 Remove the rear wheel 2 Disconnect the brake caliper 3 Disconnect the brake hose 1 from the final drive case 4 Disconnect the shock absorber 2 from the final drive case 5 Secure the brake caliper hoses and shock out of the way 6 Remove the cam wheel by loosening the 2 Allen set screws 1 7 Remove grease nipple 2 8 Remove final drive nut 3 using the special Tomcar wrench TM50190 2 2 3 1 1 ...

Page 95: ...the final drive from the vehicle by removing the 6 bolts and nuts that hold the final drive bracket 1 10 Carefully pull out the final drive Axle Removal 1 Remove the final drive spanner nut and speedometer speed ring 2 Remove the axle from the transmission assembly 1 92 06222010 v2 0 ...

Page 96: ...l the final drive nut This will help protect the threads on the housing Lower axle shaft disassembly 1 Remove the plug 1 and turn over the final drive to let the oil drain out Remove one of the cover bolts to let the air in 2 After draining the oil turn over and remove all the bolts that hold the final drive cover 3 Remove the cover and gasket 4 Remove the three retainer plates TOMCAR USA Inc 1727...

Page 97: ...inal drive nut Use a screw driver to hold the sprocket while removing the nut 7 Turn over the final drive and remove the brake rotor 8 Remove the lower drive axle TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 94 06222010 v2 0 ...

Page 98: ... 10 Remove the three keys 11 Remove the sprocket and examine for any damage broken teeth or deformations 12 Remove the two inner axle bearings from the final drive housing TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 95 06222010 v2 0 ...

Page 99: ...n over the housing and remove the two outer bearings 15 Examine the bearings they should roll smooth and should not have any free play 16 Inspect housing for damage TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 96 06222010 v2 0 ...

Page 100: ...n it and might need heat to be easily removed 2 Place the TM50149 final drive bolt holder in a vice 3 Place the bearing housing on the holder and remove the nut 4 Remove the final drive bracket and spacer 5 Remove the snap ring retainer TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 97 06222010 v2 0 ...

Page 101: ... a press 7 Examine the bearing replace if necessary 8 Remove the final drive spacer examine for damage 9 Remove the upper axle shaft nut Note Securing the axle from below will prevent it from spinning TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 98 06222010 v2 0 ...

Page 102: ...al splines on the axle shaft Note Avoid letting the shaft hit the floor 11 Remove the spacer 12 Remove the upper sprocket and chain 13 Examine the sprocket for any broken teeth deformation or any other damage TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 99 06222010 v2 0 ...

Page 103: ...xamine for damage 15 Remove the inner housing O ring 16 Use a hammer and long bar to push out the center bearing plate 17 Remove the O ring TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 100 06222010 v2 0 ...

Page 104: ...18 Remove the bearing 19 Remove the inner bearings inside the housing 20 Remove the inner seal TOMCAR USA Inc 1727 E Deer Valley Road Bldg 2 Ste 1 Phoenix AZ 85024 101 06222010 v2 0 ...

Page 105: ...TOMCAR USA Inc eer Valley Road Z 85024 21 Remove the chain tensioner 1727 E D Bldg 2 Ste 1 Phoenix A 102 06222010 v2 0 ...

Page 106: ...Final Drive Assembly TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 103 06222010 v2 0 ...

Page 107: ...ing installer and install the first inner bearing into the housing 4 Install the second bearing When both bearings are installed the second bearing should be flush with the casing 5 Use a chisel to stake the bearing in 3 locations TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 104 06222010 v2 0 ...

Page 108: ...fers to final drives with drum brakes On versions with disc brakes the seal has been relocated to the outer edge of the housing The seal will be installed after the bearing and the spacer have been installed See exploded view at beginning of this section 3 Result Install lower outer axle bearings 1 Install new O ring OR030 in the spacer TM25400 TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg ...

Page 109: ...and second bearings TM88401 4 Use chisel to stake the bearing in three locations Install upper outer axle bearing 1 Reposition the case with the outer side facing up 2 Coat the bearing housing with oil TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 106 06222010 v2 0 ...

Page 110: ... facing up Tmx7 TM87040 4 Use a seal installer and install the seal 5 Result 6 Use a bearing installer TM50316 to install small bearing Tmx7 TM88302 TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 107 06222010 v2 0 ...

Page 111: ... the housing 2 Check that the chain reaches the end of the case 3 Install an O ring into the groove on the final drive shaft O ring Tmx7 OR019 Shaft Tmx7 TM25353 4 Brush oil on Shaft TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 108 06222010 v2 0 ...

Page 112: ...acer onto the shaft Tmx7 TM25415 7 Install the sprocket on the shaft with the shoulder facing up Tmx7 TM25633 8 Result 9 Install the chain onto the sprocket and make sure that each link of the chain is seated onto the sprocket teeth TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 109 06222010 v2 0 ...

Page 113: ... block TM25346 in to place through main opening Slot should face up and the curve towards the middle 2 Push the tension block in and align the holes in the block with the holes in the case 3 Position case on its side TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 110 06222010 v2 0 ...

Page 114: ...nches to tighten 7 NOTE It is important that the nuts be on the inner side of the final drive Install lower sprocket 1 Spread the chain to make room to install the lower sprocket 2 Install the lower sprocket with the shoulder facing down 3 Tmx7 4 TM25654 nuts TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 111 06222010 v2 0 ...

Page 115: ...ves on the axel are aligned with the grooves on the sprocket Make sure the beveled end of the axle is inside the FD housing this is so it can be knocked in place using a hammer 8 Carefully install the axel all the way in until the bottom edge of the threaded portion of the axle is flush with the sprocket TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 112 06222010 v2 0 ...

Page 116: ...and the sprocket to keep the sprocket from spinning Tighten the axle nut 12 Align the cotter pin hole in the shaft with the groove in the axle nut 13 Install the cotter pin and bend the ends so it can not fall out TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 113 06222010 v2 0 ...

Page 117: ...lates TM25325 with case holes 2 Install 2 6mmx12mm guide studs in each of the retainer plates 3 Install the gasket into place 4 Install the cover plate TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 114 06222010 v2 0 ...

Page 118: ...ht to the bolts 6 Pull up on the guide studs and install bolts 7 Replace the guide studs with bolts 8 Tighten all 24 cover bolts TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 115 06222010 v2 0 ...

Page 119: ... with the lip facing down into aluminum bearing housing TM25386 Oil seal Tmx7 TM87040 11 Turn over the bearing housing and apply oil inside the bearing housing 12 Install the bearing Tmx7 TM88302 TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 116 06222010 v2 0 ...

Page 120: ...emble outer bearing housing and bracket 1 Apply oil to the inside of the outer bearing housing TM25383 and install the bearing 2 Install the snap ring TM89180 TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 117 06222010 v2 0 ...

Page 121: ...he bearing 4 Install the bearing shaft TM25380 with the nut end towards the inside the side with the snap ring 5 Use press to install the shaft TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 118 06222010 v2 0 ...

Page 122: ...l the final drive bracket TM25925 onto the shaft 9 Make sure that the 3 holes on bracket are located at the top This will determine if the bearing housing will fit right or left side 10 Install the lock nut TM7099 TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 119 06222010 v2 0 ...

Page 123: ...nstall center bearing housing 1 Install 3 keys TM86626 all the way until they are flush with the sprocket 2 Apply oil to the inside of the case TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 120 06222010 v2 0 ...

Page 124: ...sing into the final drive 4 Carefully push the bearing housing into position 5 Install spacer all the way into the housing seal Tmx7 TM25424 6 Install and tighten the self locking nut Tmx7 TM7099 TOMCAR USA Inc eer Valley Road Z 85024 1727 E D Bldg 2 Ste 1 Phoenix A 121 06222010 v2 0 ...

Page 125: ... sure to install the left or right bearing housings according to corresponding final drive 10 Using TM50192 install the bearing housing until the o ring comes in contact with both the bearing housing and the final drive housing 11 Use a marker and mark the bearing housing and the final drive housing 12 Use hammer to tighten the bearing housing one complete revolution Use tool TM50192 1727 E D Bldg...

Page 126: ...the spanner nut 2 and the speed ring 3 are placed on the center axle 3 While pushing the final drive into place rotate the brake rotor to align the center axle splines with the upper final drive axle 4 Push the final drive in place until the o ring just comes in contact with the upper final drive axle Using a flat tip screw driver push the o ring into the gap between the center axle and the final ...

Page 127: ... drive nut 3 using the special Tomcar wrench TM50190 7 Install and tighten the cam wheel and tighten the Allen bolt 1 8 Install and tighten the grease nipple 2 9 Reconnect the brake hose and parking brake cable to the final drive housing 1 10 Connect the parking brake cable to the brake caliper 2 12 Reconnect the rear shock 13 Bleed brakes 2 1 3 1 2 1727 E D Bldg 2 Ste 1 Phoenix A 124 06222010 v2 ...

Page 128: ...emove the wheel 2 Remove the cam wheel by releasing the Allen bolt 1 3 Remove grease nipple 2 4 Remove final drive nut 3 using the special Tomcar wrench TM50190 5 Disconnect the final drive from the vehicle by removing the 6 bolts and nuts that hold the final drive bracket 1 6 Carefully pull out the final drive It will hang on the shock absorber 7 Remove the gear side variator 2 1 3 1 TOMCAR USA I...

Page 129: ...x AZ 85024 8 Remove the gearshift and differential lock lever connection 9 Remove the three bolts on each side that hold the gear box to the tray and remove the gear box Note it might be necessary to remove the exhaust pipe for extra clearing 126 06222010 v2 0 ...

Page 130: ...Part TM50175 remove the pie shaped gear Remove the selector sprocket and the key Remove the shift bracket from the transmission case by unbolting the 4 small bolts on the left side case and the 3 case bolts that attach it to the case Remove the drain plug using a 22mm wrench and drain all of the gear oil from the transmission Remove the remaining 17 case bolts that hold the two halves of the trans...

Page 131: ...t output shaft housing from the right side of the transmission by removing the 6 bolts retaining it to the case Some transmissions may have a 1mm shim under the shaft housing and it must be used on reassembly On the left side transmission case Remove the 8mm hex head plug located on the left side transmission case using a 4mm hex key This bolt hole will be used to separate the transmission case ha...

Page 132: ...emove the spacer and the complete reverse gear assembly off of the reverse shaft The shift drum with shift forks long CVT shaft and the large selector gear off the secondary shaft should all come out of the transmission together as one unit These parts can now be pulled apart for cleaning and inspection The long CVT Shaft has an external snap ring that secures the primary reverse gear onto the sha...

Page 133: ...sembly Remove the differential lock collar from the inside of the long output shaft housing All bearings races and seals should now be removed from the case halves Remove and replace the O Ring from the inner lip of the output shaft housing The output shaft bearing is kept in place with an external snap ring Remove and replace the bearing and reinstall the snap ring TOMCAR USA Inc 1727 E Deer Vall...

Page 134: ...or signs of wear The reverse gears have beveled teeth that assist in engagement If there is any damage these gears should be replaced Set the differential into the bearing race The flat side of the final gear faces up and is positioned onto the center bearing The secondary shaft with low gear installed between the snap rings should seat into the case s center bearing The large steel spacer can be ...

Page 135: ... Set into the case and verify that all gears and shafts are seated into the case properly Install the reverse gear assembly complete with bearing snap ring bearing rolls and spacer onto the reverse shaft as shown The beveled teeth on both reverse gears are designed to face each other Install the special washer onto the secondary shaft Mount the large high gear cog onto the secondary shaft Next pla...

Page 136: ...shift drum shaft Rotate the shift drum shaft through its range of motion checking for engagement in all the gears It may be necessary to turn the long CVT shaft to allow the gears to mesh and release If the transmission works properly you may install the remainder of the case bolts minus the 3 for the shifter bracket Install the shifter bracket Use loctite on the 4 small bolts on the left side of ...

Page 137: ...que the shift rod nut to 54nm 40ft lb 1727 E D Bldg 2 Ste 1 Phoenix A As you move the transmission through the gears the pie shaped gear should end up with 1 full tooth clear of engagement from the top of the pie shaped gear as shown Install the Fill and Drain plugs into the transmission case with new crush washers Install the differential lock lever assembly When installing the roller bearing 1 n...

Page 138: ... on the vehicle make sure the spanner nut 2 and the speed ring 3 are placed on the center axle 3 While pushing the final drive into place rotate the brake rotor to align the center axle splines with the upper final drive axle 4 Push the final drive in place until the o ring just comes in contact with the upper final drive axle Using a flat tip screw driver push the o ring into the gap between the ...

Page 139: ...e the shifter from neutral towards high but do not put shifter all the way in high Pay close attention to the point when the gears just start to engage and look to see where the lever is positioned on the shift plate A This position is important Perform this process a few times if needed Perform this same process for the neutral to low range position and pay close attention to when the gears start...

Page 140: ...mm nuts from the studs on the bottom of the exhaust manifold 4 Remove the 13mm nut and the exhaust system can be removed from the left side of the engine compartment Remove exhaust gasket from manifold 5 Remove the CVT drive belt This can be done by pulling the belt up and over the top of the clutch plate on the transmission and rotating the clutch in a counter clockwise direction If there is not ...

Page 141: ... a 16mm socket loosen the center bolt on the engine mounted CVT clutch If the clutch does not slide easily off the shaft you may need to use special tool TM50165 CVT Extractor Also remove the Key off of the shaft 8 Loosen the band clamp from the air inlet hose on the air filter elbow Remove the hose and move out of the way 9 Loosen the band clamp and remove air hose from the engine intake manifold...

Page 142: ...e engine mounted fuel pump 13 Loosen the band clamp and remove the fuel return line at the engine mounted fuel filter block Plug both fuel lines remove the ties holding them to the frame and route out of the way 14 Disconnect and label all wires and battery cable from the rear of the engine This should include the main battery cable fuel solenoid wire and wiring for the glow plug timer 15 Loosen t...

Page 143: ... ties and straighten out the cable for removal of cable through the sleeve 18 Remove the throttle cable by pulling it from the throttle lever at the engine 19 Attach appropriate winching mechanism to the lifting hooks on the engine With sufficient tension to support the weight of the engine on the winching mechanism remove the four 17mm bolts that secure the engine to the engine tray After verifyi...

Page 144: ...he engine tray but leave the bolts loose for CVT belt tension adjustment Insert the throttle cable through the throttle lever on the engine Feed the cable through the liner and pull the free end through the cable holder under the hood Install the rubber dust boot into place Route the free end through the pinch bolt and reinstall to the throttle arm Verify the action and free play at both the throt...

Page 145: ... wire and glow plug power cable back the main lug of the starter Attach the yellow start wire to the starter solenoid Replace the wires for the Glow Plug Timer Relay Return the fuel lines to their correct location on the fuel block Connect the red fuel shut off wire to the solenoid Prime the fuel system by cracking the rear fitting 19mm wrench on the fuel block and depressing the fuel pump prime l...

Page 146: ...m Install the CVT Belt over the clutches so that the wording is facing away from the engine After the belt tension has been set you may now tighten the 4 engine mounting bolts at the engine tray These bolts should be tightened to 60 ft lbs 81nm Install the exhaust assembly through the left side of the engine bay Mount the muffler studs loosely to the frame with the exhaust flange up to the exhaust...

Page 147: ...th coolant at the radiator filler neck Once coolant comes out of the air bleed you can replace the plug Use Teflon sealant on this plug Replace radiator cap Start engine and check for leaks loose connections and verify fluid levels before returning to service 1727 E D Bldg 2 Ste 1 Phoenix A 144 06222010 v2 0 ...

Page 148: ...ure the engine from rotation and remove the main crankshaft pulley center bolt CAUTION THE CENTER BOLT IS LEFT HAND THREAD 5 Remove the 4 M6 hex head bolts holding the pulley to the crankshaft Remove the crankshaft pulley 6 Remove and note the position of the 5 hex head screws attaching the timing cover to the engine The attaching screws are differing lengths Remove the timing cover and set aside ...

Page 149: ...ration and subsequent re installation will not allow replacement in identical position as prior 10 Loosely install the timing belt idler pulley washer and nut onto the tensioner Install new timing belt onto pulleys again using caution not to upset the timing of the camshaft and crank pulleys 11 Setting the timing belt tension requires special tension tool 1460 049 to be installed over the tabbed e...

Page 150: ...ley by first installing the 4 M6 bolts and torque to 12Nm Then clean and apply Loctite to the left hand threaded center bolt Torque to 360Nm 14 Replace the cooling system hoses and the alternator belt Tension the alternator belt and fill the cooling system before returning to service 147 06222010 v2 0 ...

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