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Engine

4

‐

8

Installation

1. Installing the rocker arms:



Rocker arms (1)



Rocker arm shafts (2)

Note:

The thread hole (a) of the rocker arm
shaft must face the outside. After
installation make sure (a) is correctly
positioned.

2. Installing the camshaft.



camshaft



camshaft sprocket:

Turn the crankshaft counterclockwise to
align the “I” mark (1) with the stationary
pointer (2) on the A.C. magneto cover.
This will set the motor at Top Dead Center.

Caution:

Do not turn the crankshaft during the
camshaft installation.

Temporarily install the camshaft sprocket
on the camshaft. (Do not install the bolts)
Install the timing chain on the sprocket.

Align the notches (4) on the decompression
cams with the projections (5) on the
decompression spring lever, then install the
camshaft sprocket on the camshaft.

Check the position as shown in the
diagram

(6) punch mark on spring lever.
(7) Top front of cylinder head.
Install decompression cam guide plate
(8) and camshaft sprocket bolts (9).

Camshaft sprocket bolt (20 Nm or 15 ft lbs)

NOTE:

UPDATED TIMING PROCEDURE ON PAGE 4-48

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Содержание Challenger 500

Страница 1: ...SERVICE MANUAL Challenger 500 Challenger 700...

Страница 2: ...ce data Please read the handbook through and fully understand it otherwise any improper repairing could cause problems and or an accident may occur Proper use and maintenance will reduce malfunctions...

Страница 3: ...roubleshooting Wiring Diagram Chapter 6 Electrical Chapter 7 Engine Management System Chapter 4 Engine Chapter 5 Chassis Chapter 2 Specifications Chapter 3 Periodic Maintenance and Adjustments I ndex...

Страница 4: ...8 1 9 1 10 1 11 1 11 1 11 1 12 1 13 1 14 1 15 1 15 1 16 1 17 1 17 1 18 1 19 1 20 1 20 1 21 1 22 1 23 1 24 Electrical System Fundamentals Voltage Resistance Amperage Basic Service Methods Removing Fro...

Страница 5: ...ction 4 7 Chapter 5 Installation 4 8 Valves and Valve springs 4 9 Inspection 5 1 Inspection 4 10 Steering System 5 4 Installation 4 11 Steering Wheel Assembly 5 5 Cylinder and Piston 4 12 Disassembly...

Страница 6: ...5 33 5 34 5 37 5 37 5 38 5 39 5 39 5 40 5 41 5 42 5 45 5 46 5 47 5 49 5 50 5 51 5 52 5 53 5 55 5 56 5 58 5 59 5 60 5 62 5 66 6 1 6 3 6 4 6 6 6 7 6 8 6 9 6 10 6 11 6 12 6 15 Brake Master Cylinder Insp...

Страница 7: ...MH Manufacturer UV below 750 cc UV above 750 cc SZ TZ 500cc YZ 700cc 44 DOT Check Digits A 2010 Model Year B 2011 Model year C 2012 Model Year D 2013 Model Year E 2014 Model Year A Manufacturing Plan...

Страница 8: ...on the UV for the first time Warnings Cautions and Notes The terms Warning Caution and Note have specific meanings in this manual Warning Emphasizes areas where injury or even death could result from...

Страница 9: ...go bed 10 Tail brake lights 11 Rear shock absorber adjusting ring 12 Cargo bed release lever 13 Spark arrester 14 Passenger seat belt 15 Passenger seat 16 Oil filter 17 Engine oil dipstick 18 Battery...

Страница 10: ...ion 1 3 Identification Code Vehicle Identification Number Vehicle Identification number is stamped in the lower right side of the frame Engine Number Engine number is printed on a white tag on top of...

Страница 11: ...s 8 When replacing fasteners make sure the new fasteners are the same size and strength as the original ones 9 Keep your work area clean and organized 10 Wear eye protection anytime the safety of the...

Страница 12: ...until they can be properly disposed of or washed 7 Do not pour water onto a gasoline fire Water spreads the fire and makes it more difficult to put out Use a class B BC or ABC fire extinguisher to ex...

Страница 13: ...numbers available when ordering parts Fasteners Proper fastener selection and installation is important to ensure the UV operates as designed and can be serviced efficiently The choice of original equ...

Страница 14: ...ertain applications such as the rear axle on an UV or motorcycle the fastener must be secured in this way For these applications a cotter pin and castellated slotted nut is used To use a cotter pin fi...

Страница 15: ...ear eye protection when removing and installing snap rings E clips are used when it is not practical to use a snap ring Remove E clips with a flat blade screwdriver by prying between the shaft and E c...

Страница 16: ...he first number which indicates the low temperature viscosity Engine oils are most commonly mineral petroleum based but synthetic and semi synthetic types are used more frequently When selecting engin...

Страница 17: ...luble Local ordinances may restrict types of cleaning chemicals Refer to Safety in this chapter Use brake parts cleaner for brake system components Brake parts cleaner leaves no residue Electrical con...

Страница 18: ...to use Quality tools are a good investment Some of the procedures in this manual specify special tools In many cases the tools is illustrated in use Those with a large tool kit may be able to perform...

Страница 19: ...sening or tightening the screw clean the screw recess to prevent engine oil contamination Wrenches Open end box end and combination wrenches Figure 5 are available in a variety of types and sizes The...

Страница 20: ...e socket Sockets combined with any number of drivers make them the most convenient tool for fastener removal and installation Impact Drivers An impact driver provides extra force for removing fastener...

Страница 21: ...ket Wrenches Ratchets and Handles Sockets that attach to a ratchet handle Figure 7 are available with 6 point or 12 point openings Figure 8 and different drive sizes The drive size indicates the size...

Страница 22: ...beam the dial indicator and the audible click Figure 12 A torque wrench is a precision tool that must be properly cared for to remain accurate Store torque wrenches in their case or separate padded d...

Страница 23: ...ng from holding two parts together to gripping the end of a broken stud Use caution when using locking pliers as the sharp jaws will damage the objects they hold Snap Ring Pliers Snap ring pliers are...

Страница 24: ...ion Measuring Tools The ability to accurately measure components is essential to perform many of the procedures described in this manual Equipment is manufactured to close tolerances and obtaining con...

Страница 25: ...onvenient reading Vernier calipers have marked scales that must be compared to determine the measurement The digital caliper uses a liquid crystal display LCD to show the measurement Properly maintain...

Страница 26: ...a part that it can measure The usual sizes Figure 23 are 0 25mm 0 1 in 25 50 mm 1 2 in 50 75 mm 2 3 in and 75 100mm 3 4 in Micrometers that cover a wider range of measurements are available These use...

Страница 27: ...s do not align the micrometer is out of adjustment Follow the manufacturer s instructions to adjust the micrometer Care Micrometers are precision instruments They must be used and maintained with grea...

Страница 28: ...ith the sleeve line Each thimble mark equals 0 01mm Add the readings from steps 1 3 Standard Inch Micrometer The standard inch micrometer Figure 26 is accurate to one thousandth of an inch or 0 001 Th...

Страница 29: ...ost and carefully insert the gauge into the bore Carefully move the gauge in the bore to make sure it is centered Tighten the knurled end of the gauge to hold the movable post in position Remove the g...

Страница 30: ...ure 33 measures combustion chamber cylinder pressure usually in PSI or kg 2 cm The gauge adapter is either A cylinder bore gauge is similar to a dial indicator The gauge set shown in Figure 32 consist...

Страница 31: ...edle must align with the 0 mark to obtain accurate measurements 4 If necessary rotate the meter ohms adjust knob until the needle and 0 mark align Electrical System Fundamentals A thorough study of th...

Страница 32: ...he amount of current within a circuit Current is the actual flow of electricity The higher the current the more work can be performed up to a given point If the current flow exceeds the circuit it wil...

Страница 33: ...mbly 12 Some operations require using a hydraulic press If a press is not available have these operations performed by a shop equipped with the necessary equipment Do not use makeshift equipment that...

Страница 34: ...ply penetrating fluid as described the insert a screwdriver in the slot and tap the top of the screwdriver with a hammer This loosens the rust so the screw can be removed in the normal way If the scre...

Страница 35: ...the fitting of any corrosion or rubber hose material with a wire brush Clean the inside of the hose thoroughly Do not use any lubricant when installing the hose Lubricant may allow the hose to come of...

Страница 36: ...trike the hammer directly against the shaft Instead use a brass or aluminum rod between the hammer and shaft Figure 41 and make sure to support both bearing races with wooden blocks as shown 3 The ide...

Страница 37: ...ce Figure 44 3 When installing a bearing use a piece of pipe or a driver with a diameter that matches the bearing inner race Figure 45 shows the correct way to use a driver and hammer to install a bea...

Страница 38: ...on Do not heat the housing with a propane or acetylene torch Never bring a flame into contact with the bearing or housing The direct heat will destroy the case will cause hardening of the bearing and...

Страница 39: ...rely into the housing until it is to the correct depth or flush as noted during removal Never install a seal by hitting against the seal with a hammer Storage Several months of non use can cause a gen...

Страница 40: ...in the coolant in the coolant reserve tank and all tank lines 6 Cover the exhaust and intake opening 7 Apply a protective substance to the plastic and rubber components Make sure to follow the manufac...

Страница 41: ...ype or Grade Engine Oil API Service SG or higher Final Gear oil SAE 80 API GL 4 Hypoid Gear oil or 80W90 Gear oil Differential Gear oil SAE 80 API GL 5 Hypoid Gear oil or 80W90 Gear oil Type Liquid Co...

Страница 42: ...Transmission L H N R Chassis Frame Type Steel Tube Frame Toe In 0 10mm 0 0 39 in Tires Front Tubeless 25X8 12 Radial Rear Tubeless 25X10 12 Radial Tire Air Pressure Max 10 psi Cold Brakes Front Dual...

Страница 43: ...Krypton Bulb 12V10w Neutral Reverse LED Coolant Temp LED Parking Brake LED Four Wheel Drive Light LED Differential gear lock LED 700 UV Engine Specifications Item Metric Standard Service wear Limit C...

Страница 44: ...01 mm 1 1815 in B 36 50 36 60 mm 1 4370 1 4409 in 36 40 mm 1 4331 in Camshaft Runout limit 03 mm 0 0012 in Cam Chain Number of links Adjustment Method 126 Automatic Rocker arm Inside diameter 12 000 1...

Страница 45: ...453 in 0 2341 in Stem Outside Diameter IN EX 5 975 5 990 mm 0 2352 0 2358 in 5 930 mm 5 960 5 975 mm 0 2346 0 2352 in 0 2335 in Guide Inside Diameter 6 000 6 012 mm 0 2362 0 2367 in 6 050 MM IN EX 6 0...

Страница 46: ...gth Valve Closed IN EX Compressed pressure Installed IN EX Tilt limit IN EX Direction of winding 32 63 mm 1 28 in 31 0 mm 1 22in 36 46 mm 1 44 in 34 6 mm 1 36 in 27 5 mm 1 08 in 31 0 mm 1 22 in 100 0...

Страница 47: ...ton off set 1 0 mm 0 0394 in Off set direction Intake side Piston pin bore inside diameter 22 004 22 015 mm 0 8663 0 8667 in 22 045 mm 0 8679 in Piston pin outside diameter 21 991 22 000 mm 0 8658 0 8...

Страница 48: ...0 03 0 07 mm 0 0012 0 0028 in 0 13 mm 0 0051 in Oil ring Dimensions B T 2 5 3 4 mm 0 0984 0 1339 in End gap installed 0 20 0 70 mm 0 0079 0 0276 in Side clearance 0 06 0 15 mm 0 0024 0 0059 in Cranks...

Страница 49: ...ool Engine type Cylinder arrangement Forward inclined single cylinder Displacement 471cm3 Borexstroke 84 5X84 0mm 3 33X3 31in Compression ratio 9 4 1 Startingsystem E l ectri c starter Lubri cation sy...

Страница 50: ...500 UV Engine Specifications 2 10...

Страница 51: ...500 UV Engine Specifications 2 1 1...

Страница 52: ...500 UV Engine Specifications 2 12...

Страница 53: ...500 UV Engine Specifications 2 13...

Страница 54: ...mm 0 06 mm 0 0024 in 0 0024 in Shifter Shifter type Shift drum and guide bar Air filter oil grade Engine Oil Fuel Delivery Electronic Fuel Injection Oil pump Oil Filter Type Oil Pump Type Tip clearanc...

Страница 55: ...ll routes Coolant reservoir capacity From low to full level 380 mm 14 96 in 238 mm 9 37 in 24 mm 0 94 in 107 9 137 3 Kpa 15 35 19 53 psi 2 5 L 2 64 US qt 0 35 L 0 37 US qt 0 20 L 0 21 US qt Steering s...

Страница 56: ...m 0 08 in 0 08 in Brake lever and brake pedal Accelerator pedal free play Brake pedal free play Parking brake cable free play 0 mm 0 mm 2 3 mm 0 0 in 0 0 in 0 079 0 118 in Front disc brake Dual Ventil...

Страница 57: ...draulic Disc 1 5 mm 1 5 mm 0 06 in 0 06 in Type Disc outside diameter X thickness 165 5 0 mm 6 50 0 20 in Pad thickness inner Pad thickness outer 5 6 mm 5 6mm 0 22 in 0 22 in Master cylinder inside di...

Страница 58: ...lt 7 mm 2 20 14 Rocker arm shaft stopper Bolt 6 mm 2 10 7 2 Valve adjusting locknut 6 mm 5 14 10 Engine oil drain bolt 14 mm 1 30 22 Oil filter cartridge union bolt 20 mm 1 63 4 6 Oil filter cartridge...

Страница 59: ...m 2 10 7 2 A C magneto cover Bolt 6 mm 12 10 7 2 Starter clutch Bolt 8 mm 3 30 22 Clutch carrier assembly Nut 22 mm 1 160 115 stake Clutch housing assembly Bolt 6 mm 9 10 7 2 Bearing Retainer middle d...

Страница 60: ...t reservoir Bolt 6 mm 2 7 5 1 Radiator bracket and frame Bolt 6 mm 4 7 5 1 Fuel pump Bolt 6 mm 2 7 5 1 Fuel tank Bolt 8 mm 2 30 22 Muffler stay Bolt 6 mm 2 11 8 Muffler and exhaust pipe Bolt 8 mm 1 20...

Страница 61: ...0 7 2 Universal joint yoke and drive pinion gear 14 mm 62 45 Differential motor and differential gear case cover 8 mm 13 9 4 Differential gear case cover and differential gear case 8 mm 25 18 Rear dri...

Страница 62: ...ub 8 mm 30 22 Front brake caliper bleed screw 6 mm 6 4 3 Rear wheel and rear wheel hub 10 mm 55 40 Rear wheel hub and constant velocity joint of half shaft 20 mm 260 190 Rear brake hose and frame 6 mm...

Страница 63: ...a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies in a...

Страница 64: ...ase Joint of front brake cable Light lithium base grease Front brake lever axle and rear brake lever axle Light lithium base grease Adjusting nut and pin of front brake cable Light lithium base grease...

Страница 65: ...n Replace if necessary Every 20 40 hours More often if in dusty or wet environments Axle Boots Check Operation Replace if Damaged X X X X X Crankcase Breather System Check Breather Hose for Cracks or...

Страница 66: ...just if Necessary X X X Cooling System Check for coolant leaks Repair if Necessary Replace coolant every 24 months X X X X X Accelerator Pedal Check Operation and Free Play X X X X X Drive Shaft U Joi...

Страница 67: ...the fluid level and add brake fluid as needed Replace oil seals inside master cylinder and calipers every 2 years Replace Brake Hoses every 4 years or if cracked or damaged Maintenance and Adjustments...

Страница 68: ...rclockwise until the timing mark for TDC is aligned in the window 2 Remove the cooling fan 1 Fan cover 2 Fan impeller 3 Timing plug cover Note When aligning the timing mark for TDC there should be cle...

Страница 69: ...the adjuster steady lock down the locknut 4 Note The adjuster cannot move or your adjustment will not be correct 5 It is always a good idea to rotate the crankshaft 2 full revolutions and recheck your...

Страница 70: ...a loss of performance 1 Start the engine and let it warm up for several minutes 2 Stop the engine and remove the spark plug 3 Assemble the compression pressure tester and adapter and screw it into the...

Страница 71: ...cargo bed Checking the engine oil level 1 Place the vehicle on a level surface 2 Remove the driver s seat passenger s seat center console and heat shield 3 Unscrew the dipstick and check the oil leve...

Страница 72: ...m the crankcase 6 It is always recommended to change the oil filter when doing an oil change Remove the oil filter With an oil filter wrench Lubricate the O ring of the new oil filter with a thin coat...

Страница 73: ...engine oil passages the oil filter and the oil pump for damage or leakage Start the engine after solving the problem s and check the engine oil pressure again Tighten the oil galley bolt to specificat...

Страница 74: ...damp but not soaked or dripping Install Air filter element Air filter case cover Console Passenger s seat Driver s seat Note Never operate the engine with the air filter element removed This will all...

Страница 75: ...p 1 2 Disconnect coolant reservoir hose 2 3 Drain coolant from the reservoir 4 Reconnect coolant reservoir hose 5 Remove the coolant drain bolt 1 along with the copper washer 6 Remove the radiator cap...

Страница 76: ...or cap 16 Fill the coolant reservoir with the recommended coolant to the max level mark a Note Adding water instead of coolant lowers the antifreeze content of the coolant 17 Install coolant reservoir...

Страница 77: ...Passenger s seat Console Drive belt cover 2 Check the V belt for cracks wear scaling or chipping Replace if necessary 3 Check for oil or grease inside V belt housing If found see cleaning instructions...

Страница 78: ...facing the direction shown in figure 3 Remove the bolts used to widen the gap on the secondary sheaves 4 Install the following Drive belt cover Console Passenger s seat Driver s seat Cleaning the Spa...

Страница 79: ...cylinder Tighten the locknut to correct torque 3 Make sure there is no drag on the front or rear wheels when trying to move the UV Adjusting the Parking Brake 1 Shift the drive select lever into Low...

Страница 80: ...hen the brake pads wear indicator grooves a have almost disappeared replace the brake pads as a set 5 Install the console passenger s seat and driver s seat Checking the Brake fluid Level 1 Place the...

Страница 81: ...n very low The brake operation has been faulty 1 Locate the brake fluid reservoir 2 Add the proper brake fluid to the reservoir 3 Install the diaphragm Be careful not to spill any fluid or allow the r...

Страница 82: ...ing to prevent damage to the transmission 1 Adjustment of the shift lever rod Make sure the select lever is in the neutral position Loosen both locknuts 1 Adjust the rod Tighten the locknuts Adjusting...

Страница 83: ...all the filler plug 23 Nm 2 3 m kg 17 ft lb Changing the Final Gear Oil 1 Place the vehicle on a level surface 2 Place a container under the final gear case to collect the drained oil 1 Install the dr...

Страница 84: ...rement to find toe in measurement Adjust by the following Mark both tie rods ends This reference point will be needed during adjustment Loosen the locknut tie rod end 1 on each tie rod The same number...

Страница 85: ...ystem Check the steering wheel for excessive play up or down and side to side Check the tie rod ends Inspect for vertical play if any then replace the tie rod end in question Replacement is found in C...

Страница 86: ...eplace with manufacturer recommended tire combinations Tire wear limit a Front and rear 3 0 mm 0 12 in 2 Check tire air pressure Minimum tire pressure 9 psi Maximum tire pressure 22 psi Note These are...

Страница 87: ...der cover Close the hood Changing the Tail Brake Light Bulb Remove Cargo bed panel 1 Install New bulb into the tail brake light bulb holder Tail brake light bulb holder with bulb Cargo bed panel Tail...

Страница 88: ...ning order should always start with the smallest diameter bolt working up to the largest diameter bolt in a cross pattern from outside to inside 6 Bolt and nut tightening order should always start wit...

Страница 89: ...ke assembly Fig 1 Drain Plug Fig 2 Qty Remarks Remove the parts in the order 1 listed For installation reverse the order listed After removal of the intake system cover the opening so that no foreign...

Страница 90: ...per washer 3 Oil Line 3 4 Oil Line 2 5 Spark plug 6 Tappet Cover Intake 7 Tappet Cover Exhaust 8 Timing Chain Tensioner Cap Bolt 9 Timing Chain Tensioner Gasket 10 Timing Chain Guide Exhaust Side 11 T...

Страница 91: ...ing or scratching the spark plug threads or valve seats Look for cracks or damage Look at the cylinder head water jackets clean out any mineral deposits or rust 3 Inspect the Tappet covers Tappet cove...

Страница 92: ...the illustration in 2 stages Timing chain guide exhaust side Timing chain tensioner Lightly press the timing chain tensioner rod into the housing by hand While pressing wind it clockwise with a thin s...

Страница 93: ...2 Rocker arm shaft stopper 2 3 Rocker arm shaft 2 1 4 Rocker arm 3 1 5 Rocker arm shaft 3 O ring 1 1 6 Rocker arm 4 1 7 Rocker arm shaft 1 O ring 1 1 8 Rocker arm 1 1 9 Rocker arm 2 1 10 Wave washer...

Страница 94: ...t 11 96mm Subtract the rocker arm shaft outer diameter from the rocker arm inside diameter to determine the clearance Clearance limit 0 05mm Inspect the Camshaft Cam Lobes look for discoloration scrat...

Страница 95: ...ad Center Caution Do not turn the crankshaft during the camshaft installation Temporarily install the camshaft sprocket on the camshaft Do not install the bolts Install the timing chain on the sprocke...

Страница 96: ...Valves and Valve springs 1 Valve keeper 2 Valve spring collar 3 Intake valve spring 4 Exhaust valve spring 5 Intake valve 6 Exhaust valve 7 Valve stem seal 8 Valve spring seat Remove the parts in the...

Страница 97: ...0 12mm Exhaust 0 14mm Measure the margin thickness Both Intake and Exhaust 0 85 1 15 mm Measure valve stem runout Runout Limit 0 01 mm Whenever a valve is removed always replace the valve guide seal I...

Страница 98: ...the face of the valve Turn the valve until the valve face and the valve seat are evenly polished Clean off all of the lapping compound and install a new valve guide seal Install valve spring seats val...

Страница 99: ...inder and piston Water Pump outlet Hose Cylinder Head 1 Coolant inlet joint 2 Cylinder O ring 3 Cylinder gasket 4 Dowel pin 5 Wrist pin clip 6 Wrist pin 7 Piston 8 Piston ring set 1 1 1 1 2 2 1 1 1 Re...

Страница 100: ...der and measure with a feeler gauge Top ring 2nd ring limit 0 5mm 3 Measure piston outer diameter at 10 mm above the skirt Piston to cylinder clearance limit 0 15mm 4 Measure piston ring side clearanc...

Страница 101: ...piston pin 2 through piston wall rod piston wall Install piston pin clips 3 3 Cylinder O ring 10mm bolts 42Nm or 31 ft lbs 6mm bolts 10Nm or 7 ft lbs Install the cylinder with one hand while compress...

Страница 102: ...g fan air duct assembly 1 2 Air shroud 1 1 3 Engine cooling fan 1 4 Air shroud 2 1 5 A C Magneto coupler 2 6 Engine cooling fan pulley base 1 7 A C Magneto cover gasket 1 1 8 Dowel pin 2 9 Stator lead...

Страница 103: ...on Install the starter wheel gear onto the starter clutch and hold the starter clutch Note Install the starter wheel gear with the groove a facing the A C Magneto rotor Turn the starter wheel gear cou...

Страница 104: ...C Magneto cover use a long rod to hold the A C Magneto rotor in position from the outside This will make assembly easier Be careful not to damage the oil seal Apply Note Install the air shroud 1 10 Nm...

Страница 105: ...pump gears 1 Nut Lock washer 2 Balancer driven oil pump drive gear 3 Chain 4 Straight key 5 Oil pump driven gear 6 Plate 7 Balancer drive gear 8 Spring 9 Pin 10 Timing chain guide intake side 11 Timin...

Страница 106: ...r if it is necessary to replace either one replace them both as a set Note Balancer driven gear Timing chain Timing chain guides Look for cracks and stiffness in the links If necessary replace the tim...

Страница 107: ...aves Engine assembly 1 Drive Belt cover 2 Rubber gasket 3 Bearing Housing 4 Dowel pin 5 Primary sheave assembly 6 V belt 7 Primary fixed sheave 8 Secondary sheave assembly 9 Drive belt case 10 Rubber...

Страница 108: ...Primary Sheave 1 Primary pulley sheave cap 2 Primary pulley slider 3 Spacer 4 Primary pulley cam 5 Primary pulley weight 6 Collar 7 Oil seal 8 Primary sliding sheave 9 O ring Remove the parts in the o...

Страница 109: ...he Secondary Sheave 1 Nut 2 Spring seat 3 Compression spring 4 Spring seat 5 Guide pin 6 Secondary sliding sheave 7 O ring 8 Secondary fixed sheave 9 Oil seal 10 Oil seal Remove the parts in the order...

Страница 110: ...k for cracks or damage Primary sliding sheave Primary fixed sheave Look for cracks or damage 2 Inspect the Secondary sheave Secondary fixed sheave Secondary sliding sheave Look for smooth operation sc...

Страница 111: ...ing sheave Spacer Sliders 1 Primary pulley cam 2 Primary sliding sheave cap 3 Nm or 25 in lbs 3 Assembling the secondary Sheave Apply assembly lube to The secondary sliding sheave 1 inner surface and...

Страница 112: ...ents Chapter 3 will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen Install the V belt with the arrow facing the direction in the illust...

Страница 113: ...Removing the clutch Primary and secondary sheaves 1 Clutch housing assembly 2 Gasket dowel pin 3 One way clutch bearing 4 Nut 5 Clutch carrier assembly 1 1 2 1 1 1 Remove the parts in the order liste...

Страница 114: ...emarks Disassembling the clutch housing 1 Oil seal 2 Circlip 3 Bearing housing 4 Circlip 5 Bearing 6 Circlip 7 Bearing 8 Clutch housing Remove the parts in the order listed 1 1 1 1 1 1 1 For installat...

Страница 115: ...e way clutch bearing Install the one way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly When turning the clutch housing clockwise A the clutch ho...

Страница 116: ...Dowel pins Gasket Clutch housing assembly 10 Nm or 7 ft lbs Tighten the bolts in stages using a cross pattern After tightening check the operation of the clutch housing assembly that it rotates counte...

Страница 117: ...C magneto rotor Primary and secondary sheaves Clutch carrier assembly 1 Starter Motor O ring 2 Oil Filter O ring 3 Oil Line assembly O ring 4 Oil Line adapter O ring 5 Relief valve assembly 6 Speed se...

Страница 118: ...case Remove the parts in the order listed 1 Shift lever cover gasket 2 Dowel pin 3 Shift lever 1 4 Shift lever 2 assembly 5 Right crankcase half 6 Dowel pin 7 Left crankcase half 8 Spacer 9 Crankshaft...

Страница 119: ...Remarks Removing the crankcase bearings Crankshaft and oil pump Transmission Middle drive driven shaft 1 O ring collar 2 Oil seal 3 Bearing retainer 4 Bearing 1 1 1 1 9 Remove the parts in the order l...

Страница 120: ...all the dowel pins 2 Fit the left crankcase half onto the right crankcase half Tap lightly on the case with a soft hammer Crankcase Thoroughly wash the case halves in a mild solvent Clean all the gask...

Страница 121: ...t Crankcase Right Crankcase Installing the shift levers Shift lever 2 assembly 1 14 Nm or 10 ft lbs Shift lever 1 2 Note When installing the shift lever 1 align the punch mark a on the shift lever 1 w...

Страница 122: ...s Removing the Crankshaft and Oil Pump Remove the parts in the order listed 1 Crankcase separation 2 Oil Strainer O ring 3 Oil pump assembly gasket 4 Balancer 5 Plate 6 Relief valve assembly Crankshaf...

Страница 123: ...Part Name Qty Remarks Disassembling the Oil Pump 1 Rotor cover 2 Pin 3 Shaft 4 Pin 5 Inner rotor 6 Outer rotor 7 Oil Pump housing Remove the parts in the order listed 1 2 1 1 1 1 For installation rev...

Страница 124: ...ween the outer rotor 2 and the pump housing 3 Body clearance c between the outer rotor 2 and the pump housing 3 Tip clearance Limit 0 23 mm Side clearance Limit 0 17 mm Body clearance Limit 0 24 mm Me...

Страница 125: ...hould be replaced whenever removed from the crankshaft Install Assemble the oil pump Inner rotor outer rotor and oil pump shaft with the recommended lubricant Install the crankshaft and balancer Note...

Страница 126: ...the order listed Crankcase separation Middle driven gear 1 Low wheel gear 2 Shift drum 3 Shift fork assembly 4 Short spring 5 Shift fork 1 6 Long spring 7 Shift fork 2 8 Guide bar 9 Secondary shaft 1...

Страница 127: ...bly No Part Name Qty Remarks Disassembling the Drive Axle 1 Clutch dog 2 High wheel gear 3 Middle drive gear 4 Driven sprocket 5 Drive axle Remove the parts in the order listed 1 1 1 1 For installatio...

Страница 128: ...movement on the guide bar Look for smooth movement If replacement is necessary replace as a set Springs Look for cracks or damage Shift drum Inspect the grooves Look for scratches wear or damage High...

Страница 129: ...the shaft runout Use a truing stand and a dial gauge Shaft runout limit 0 06 mm Install Assembling the shift fork Guide bar 1 Shift fork 2 Long Spring 3 Shift fork 4 Short Spring 5 Installing the tra...

Страница 130: ...s Removing the Middle Drive Shaft Crankcase separation 1 Bearing housing 2 Middle drive gear 3 Nut 4 Middle drive pinion gear 5 Shim 6 Middle drive shaft 7 Bearing retainer Remove the parts in the ord...

Страница 131: ...the order listed Crankcase separation 1 Drive shaft coupling 2 Circlip 3 Bearing 4 Universal joint 5 Universal joint yoke 6 Bearing housing O ring 7 Shim 8 Middle driven pinion gear 9 Bearing retainer...

Страница 132: ...0 3 mm Measure gear lash Temporarily install the left crankcase half Wrap a rag around a screwdriver and insert it into the right crankcase speed sensor hole to hold the middle driven gear Attach a d...

Страница 133: ...yoke nut 150 Nm or 110 ft lbs Universal joint Install the opposite yoke onto the universal joint Apply wheel bearing grease to the bearings Install the bearing 1 onto the yoke Caution Check each bear...

Страница 134: ...t 1 Note Use the coupling gear middle shaft tool 2 to hold the drive shaft coupling Nut Torque 97 Nm or 71 ft lbs Install the middle drive shaft Tighten the middle pinion gear nut 1 to 145 Nm or 107 f...

Страница 135: ...on the Mechanical Compression Release gear to be parallel to the sealing sur face of the cylinder head Figure A If the MCR bump is not visible as in Figure B the timing is 180 degrees off The MCR bump...

Страница 136: ...ake calipers and brake levers for damage corrosion or deformity 2 Loss of Brake performance Check for brake rotor wear Has it exceeded the wear limit Check for brake pad wear Is the master cylinder lo...

Страница 137: ...driving Check for damage to the steering knuckle bearing Check if the king pin ball joint is damaged Check if the front wheel axle nut is loose or damaged Check the front wheel splines for damage or w...

Страница 138: ...ntial for wear or damage Check the gears of the rear gearbox for wear or damage Check the universal joint rubber boot for damage Check the universal joint for damage or wear 12 Failure to shift into f...

Страница 139: ...embly 1 2 Pinion 1 3 Circlip 1 4 Bearing 1 5 Adjuster 1 6 Spring 1 7 Pressure pad 1 8 Circlip 1 9 Oil seal 1 10 Zip tie L 200 2 11 Dust Boots 2 12 Flange bolt 10mm X 30mm 4 13 Tie rod end 2 14 Locknut...

Страница 140: ...Steering Wheel assembly No Part Name Qty Remarks Removing the Steering Wheel Assembly 1 Flange bolt 8mm X 16mm 4 2 Steering shaft 1 3 Steering wheel 1 4 Washer 1 5 Flange nut 12mm X 1 25 1 6 Plastic c...

Страница 141: ...is a safety area and any damage or wear needs to be repaired immediately Warning This is a safety area and any damage or wear needs to be repaired immediately Do not let vehicle leave without proper...

Страница 142: ...aft assembly 1 Checking and servicing the Universal joints on the steering shaft Bearing 1 Circlip 2 Oil seal 3 Cross axis 4 Inspect for smooth operation Replace any parts with wear or damage 2 Inspec...

Страница 143: ...g wheel nut torque 48 Nm 4 8m kg 35 ft lb The Brake System The brake system is crucial to the life of the operator and passengers and therefore must be periodically inspected and maintained This vehic...

Страница 144: ...brake disc 1 for thickness 2 Brake discs wear as well as brake pads therefore a periodic inspection may reveal scoring or wear to a disc Replacement is necessary if this is found 5 Check the brake li...

Страница 145: ...Qty Remarks Removing the Front Brake Line Attachment Hardware 1 Belt 3 L 150 2 2 Belt 4 L 200 4 3 Belt 6 L 150 4 4 Bolt 6mm X 30mm 1 5 Bolt 6mm X 20mm 1 6 Disc brake line clip 3 7 Flange bolt 6mm X 20...

Страница 146: ...Chassis 5 11 Front Disc Brakes No 1 2 3 4 5 6 Part Name Removing the Brake Discs Brake caliper assembly Brake disc Bolt Axle housing Bolt Brake disc guard Qty Remarks 1 1 4 4 4 1...

Страница 147: ...Inspect for galling or damage Measure brake disc deflection in 4 spots approximately 90 degrees from each other Brake disc maximum deflection 0 10 mm 0 004 in Brake disc thickness 1 Wheel hub 2 Rim 3...

Страница 148: ...Pads No Part Name Qty Remarks Removing the Front Brake Pads 1 Brake caliper mounting bolt 2 Brake pad holding bolt 3 Brake pad 4 Pad spring Remove parts in the order listed 2 2 2 For installation rev...

Страница 149: ...ck into the caliper Watch the brake fluid level in the reservoir so you don t overflow the reservoir After the pads have been installed be sure to fill the reservoir with the proper brake fluid so tha...

Страница 150: ...ving the Front Brake Caliper Brake fluid Union bolt Copper washer Brake hose Brake pad holding bolt Qty Remarks Remove the parts in the order listed 1 2 1 2 5 Brake caliper mounting bolt 6 Brake calip...

Страница 151: ...embling the Front Brake Caliper Qty Remarks Remove the parts in the order listed 1 Brake pad holding bolt 2 Brake pad 3 Pad spring 4 Brake caliper piston 5 Dust seal 6 Caliper piston seal 7 Bleed scre...

Страница 152: ...dure injury can occur when the piston is expelled from the caliper 2 Remove the dust seals 1 and caliper piston seals 2 All internal brake components should be cleaned with new brake fluid only Do not...

Страница 153: ...s 2 Union bolt 3 Note When installing the brake hose be sure that the brake fitting touches the stop a on the brake caliper 2 Fill the brake fluid reservoir Must use DOT 3 Brake Fluid 3 Bleed the air...

Страница 154: ...9 Rear Brake Disc No Part Name Qty Remarks Removing the Rear Brake Disc Brake caliper assembly Final drive gear 1 Rear brake disc 1 Remove the parts in the order listed For installation reverse the or...

Страница 155: ...ear Brake Disc 1 Inspect the disc Look for galling or damage 2 Measure the rear brake disc deflection Brake disc maximum deflection 0 10 mm 0 004 in 3 Measure the brake disc thickness a Brake disc min...

Страница 156: ...te Brake fluid Parking Brake switch coupler Spring Parking brake cable Parking brake lever assembly mounting bolt Parking brake lever assembly Union bolt Copper washer Brake hose Brake caliper mountin...

Страница 157: ...Brake caliper bracket 1 17 Parking brake arm nut 1 18 Parking brake arm 1 19 Set bolt 1 20 Parking brake arm shaft 1 21 Parking brake case bolt 2 22 Parking brake case 1 23 Gasket 1 24 Brake caliper...

Страница 158: ...ke caliper piston counterclockwise to remove it Warning All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort 2 Insp...

Страница 159: ...unterclockwise completely so that the punch mark a on the parking Align an end b of the groove in the brake piston with the punch mark c on the caliper body 3 Install the gasket 1 the parking brake ca...

Страница 160: ...7 m kg 12 ft lb Installing the Rear Brake Caliper 1 Install the brake caliper with the mounting bolts 40Nm 4 0m kg 29 ft lb Brake hose 1 Copper washers Union bolt 2 48Nm 4 8m kg 35 ft lb 2 Tighten the...

Страница 161: ...emarks Remove the parts in the order listed Drain 1 Brake fluid reservoir cap 2 Brake fluid reservoir diaphragm brake 3 Fluid reservoir float 4 Union bolt 5 Copper washer 6 Brake hose 7 Brake line 8 B...

Страница 162: ...fluid reservoir diaphragm 2 Look for cracks or damage Installing the Brake Master Cylinder 1 Install the brake master cylinder 16Nm 1 6 m kg 11 ft lb 2 Install the brake line 19Nm 1 9 m kg 13 ft lb 3...

Страница 163: ...paper 1 5 Sheathing film 1 6 Self locking flange nut 6mm 2 7 Clip 6mm 9 8 Right footrest cover 1 9 Dust guard plate 1 10 Screw 6mm X 16mm 11 11 Brake pedal mount 1 12 Flange bolt 8mm x 16mm 2 13 Accel...

Страница 164: ...ver assembly 1 22 Micro switch 1 23 Screw 4mm X 12mm 1 24 Parking brake dust cover 1 25 Parking brake cable 1 26 Flange bolt 6mm X 16mm 1 27 Cable clip 2 28 Choke cable 1 29 Anchor 4 30 Brake pedal mu...

Страница 165: ...Chassis 5 30 Front Wheel and Tire No Part Name Qty Removing the Front Wheel 1 Rim 2 2 Tire 2 3 Valve cap 2 4 Nut 8 5 Center cap 2 6 Axle nut 2 7 Front wheel hub 2...

Страница 166: ...Chassis 5 31 Rear wheel No Part Name Qty Removing the rear wheel 1 Rear wheel 2 2 Center cap 2 3 Axle nut 2 4 Rear wheel hub 2...

Страница 167: ...0 ft lb Installing the Wheel Assembly 1 Install the wheel with the arrow on the tire pointing toward the front of the UV 2 Install the tapered lug nuts Torque 55 Nm or 40 ft lbs Warning Wheels and tir...

Страница 168: ...Chassis 5 33 Transmission System Front Bridge No Part Name Qty 1 Circlip 1 2 CV joint 2 3 Circlip 1 4 Circlip 2 5 Boot band 2 6 Dust boot 2 7 Boot band 2 8 Joint shaft 1 9 Half axle assembly 1...

Страница 169: ...al gear case cover 1 4 Drive pinion gear 1 5 Universal joint yoke 1 6 Nut 14mm X 1 25 1 7 O ring 1 8 Oil seal 1 9 Oil seal front box input shaft 2 10 Shim 0 1T 1 Shim 0 2T 1 Shim 0 5T 1 11 Bolt 8mm X...

Страница 170: ...ack 1 21 O ring 2 X 81 1 22 O ring 2 4 X 140 4 23 Bearing 6007 1 24 Bearing 6912 1 25 Bearing 16007 1 26 Bearing 152112 1 27 Bolt M14X15X10 1 28 Washer 14 X 2 1 29 Nut 10mm 1 30 Washer 10 2 31 Shaft f...

Страница 171: ...Chassis 5 36 No Part Name Qty 37 Clamp 2 38 Intermediate shaft 2 39 Circlip 2 40 Cushion 1 41 Spring 25 X 2 3 X 28 1 42 Dust boot 1 43 Dust boot 1 44 Bolt 10mm X 25mm 1 45 Washer 2 46 Screw 2...

Страница 172: ...ansmission shaft from the differential Disassembling the Universal joint 1 Remove the universal joint 2 Remove the circlips 1 3 Place a pipe 2 of the correct size to collect outside diameter of the be...

Страница 173: ...g or damage 3 Inspect the oil seals and O rings Look for damage 4 Inspect the drive shaft splines universal joints and the drive pinion gear splines Look for wear or damage 5 Inspect the spring Look f...

Страница 174: ...o the grooves in each bearing Assembly of the Differential Gear 1 Slide the differential gear all the way to the right to put it into the 2 WD mode 2 Connect two C size batteries to the gear motor ter...

Страница 175: ...n shafts into the front bridge differential 2 Fill with 0 32L 80w90 gear lube and tighten the filler bolt 23 Nm 2 3m kg 17 ft lb 3 Install the front bridge differential onto the frame 2 Bolts 10mm X 1...

Страница 176: ...No Part Name Qty Remarks 1 Circlip 2 2 Boot band 2 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint assembly 1 7 Circlip 1 8 Circlip 1 9 Double off set joint assembly 1 10 Joint shaft 1...

Страница 177: ...ve pinion gear 1 6 Bearing 6305 1 7 Drive shaft coupling 1 8 Oil seal 61 X 35 X 9 1 9 Bearing 65BM6720 1 10 O ring 3 1 X 63 8 1 11 Flat gasket 12 X 4 X 30 1 12 Flange nut 12mm X 1 25 1 13 Pinion gear...

Страница 178: ...20 Vent rear speed reducer 1 21 Ring gear bearing housing 1 22 Ring gear stopper 8mm 1 23 Washer 8 5 4 24 Flange nut 8mm 2 25 Oil seal 65 X 90 X 9 2 26 Bearing 16017 1 27 O ring 3 1 X 150 2 28 Washer...

Страница 179: ...r bridge 1 36 Circlip 2 37 Cover 1 38 Circlip 1 39 Self locking flange nut 1 40 Dust cover 2 1 41 Dust cover 1 1 42 Oil line 1 43 Oil line clip 1 44 Washer 1 45 Clip 1 46 Clip 1 47 Driven gear 1 48 Bo...

Страница 180: ...Lever sheath of gearshift 1 3 Gearshift dust boot 1 4 Gearshift assembly 1 5 Gearshift rod 1 6 Heim joint 1 7 Lever 1 8 Washer 1 9 Bolt 8mm X 12mm 1 10 Bolt 8mm X 16mm 3 11 Plastic bolt 1 12 Clip cla...

Страница 181: ...Before shifting you must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be damaged 1 Adjustment Make sure the shift lever is in the neutral position Loos...

Страница 182: ...pper ball joint 1 3 Elasticity block ring 1 4 Upper right A arm 1 5 Front upper ball joint 1 6 Block ring shaft 1 7 Front lower left A arm 1 8 Front lower right A arm 1 9 Middle bushing 8 10 Flange bo...

Страница 183: ...No 15 16 17 18 19 20 21 Part Name Front shock absorber left and right Locknut 10mm X 1 25 Flange bolt 10mm X 1 25 X 52 Rocker baffle Flange nut 6mm Flange bolt 6mm X 12mm Front upper ball joint Qty 2...

Страница 184: ...r damage 2 Inspect the shock absorber body Look for oil leaks 3 Inspect the spring Look for fatigue Installing the front A arms and shock absorbers 1 Install both the upper arm 1 and the lower arm 2 N...

Страница 185: ...ber left and right 2 2 Flange bolt 12mm X 1 25 X 70 2 3 Flange bolt 12mm X 1 25 X 65 2 4 Nut 12mm X 1 25 4 5 Stabilizer 1 6 Left idler arm 1 7 Right idler arm 1 8 Locknut 8mm 4 9 Rubber isolator 2 10...

Страница 186: ...er A arm assembly 1 2 Rear Lower right A arm assembly 1 3 Rear Lower left A arm assembly 1 4 Bushing 8 5 Flange bolt 10mm X 1 25 X 70 8 6 Locknut 10mm X 1 25 8 7 Rear upper A arm 1 8 Bushing gasket 16...

Страница 187: ...Inspect the shock absorber body Look for oil leaks Inspect the spring Look for cracks or fatigue Installing the Rear A Arms and Shock Absorbers 1 Install the rear upper arm 1 and rear lower arm 2 temp...

Страница 188: ...e After left rubber hose Right rubber hose Right metal hose Formed right rubber hose Bolt clip Clip Bolt 6mm Radiator assembly Radiator fan assembly Phillips screw 6mm X 25 Quad seal Nut clip 5mm Radi...

Страница 189: ...diator 1 19 Radiator cover 3 20 Oil cooler 1 21 Bolt 6mm X 20mm 4 22 Quad seal 4 23 Bolt 6mm X 20mm 2 24 Quad seal 2 25 Bushing 2 26 Grommet 2 27 Radiator fill reservoir 1 28 Oil cooler shield 1 29 Ho...

Страница 190: ...the drain plug and top off the radiator with the new coolant 7 Add new coolant to the reservoir to be above the minimum level mark 8 Shut the UV off and allow the unit to cool off 9 After unit has coo...

Страница 191: ...p assembly Bolt 6mm X 45mm Bolt 6mm X 65mm Bolt 6mm X 10mm Water pipe 2 O ring 20 7 X 2 6 Water pipe 3 Hose clamp Cylinder inlet water joint Bolt 6mm X 20mm O ring 33 4 X 2 4 Water pipe 1 Clamp Pipe c...

Страница 192: ...Chassis 5 57 No Part Name Qty 18 Water pump housing cover 1 19 Gasket 1 20 Circlip 1 21 Impeller assembly 1 22 Water pump seal 1 23 Oil seal 1 24 Bearing 1 25 Water pump housing 1 26 O ring 1...

Страница 193: ...rom the water pump housing 3 by tapping them out from the outside of the water pump housing Inspecting the Water pump 1 Inspect the water pump housing cover 1 the water pump housing 2 the impeller 3 t...

Страница 194: ...on 2 Install the water pump seal 1 into the housing 2 using a mechanical seal installer 3 and water pump seal installer 4 Do not lubricate this seal with oil or grease Use the special tool 3 Install t...

Страница 195: ...4 Flange bolt 8mm X 30mm 8 5 Flange locknut 8mm X 1 25 8 6 Flange bolt 8mm X 30mm 1 7 Seat latch 2 8 Bolt 6mm X 38mm 4 9 Nut 6mm 4 10 Seat latch stud 2 11 Grommet 1 4 12 Grommet 2 4 13 Bushing 10 5 2...

Страница 196: ...Seat No Part Name Qty 18 Nut 10mm X 1 25 1 19 Bolt 2 20 Flange locknut 2 21 Cover 2 22 Seat belt latch 2 23 Seat belt 2 24 Nut 2 25 Bolt 10mm X 1 25 X 22mm 2 26 Bolt 10mm X 1 25 X 25mm 2 27 Washer 6...

Страница 197: ...e Fuel tank Insulation paper Shock absorber cushion Binder plate Fuel pump cover Rubber tube Fuel outlet plug Clip 10 Clip Three way pipe High pressure pipe Fuel pipe Fuel pump assembly fuel inlet plu...

Страница 198: ...r 2 Place a container under the end of the fuel hose 1 3 Turn the ignition switch to the run position Do not start the engine 4 Fuel should start running out the hose 5 Turn the key to the off positio...

Страница 199: ...itch 2 2 Radiator fan 3 Gear motor 4 Brake light switch 5 Parking brake switch 6 Pickup coil stator assembly 7 Speed sensor 8 Diode 1 9 Circuit breaker radiator fan motor 10 Thermo switch 1 11 Ignitio...

Страница 200: ...rive relay 3 5 Differential gear lock indicator light relay 6 Four wheel drive indicator light relay 7 Fuse box 8 C D I unit 9 Battery 10 Regulator Rectifier 11 Indicator light assembly 1 12 Indicator...

Страница 201: ...ives The typical lifespan of a lead acid battery is 1 to 2 years but if maintained with a battery tender they can survive longer Maintenance Free Battery The maintenance free battery is a sealed batte...

Страница 202: ...burns and or permanent eye damage First Aid in Case of Bodily Contact Skin Wash thoroughly with water Eyes Flush with water for 15 minutes and seek immediate medical attention When installing a batter...

Страница 203: ...tart charging Make sure the setting is at 1 10 the amp hour rating of the battery This is typically 2 amp 12 Volts Charge the battery until the charging amperage drops all the way down usually 1 amp T...

Страница 204: ...e open circuit voltage Monitor the amperage for 3 5 minutes Is the standard charging amperage exceeded Adjust the voltage to obtain the standard charging amperage Adjust the charging voltage to 20 25...

Страница 205: ...box Inside the centralized relay box on the fire wall After testing and replacement of the fuse turn on the main switch to energize and check the circuit that was affected If the fuse blows immediate...

Страница 206: ...tch for continuity Turn the switch on and off a few times when checking it The terminal connections for switches main switch light switch etc are shown in a chart similar to the one on the right This...

Страница 207: ...between lead terminals Poor connection no continuity correct or replace The coupler locations are circled 1 Fuse 2 Brake light switch 3 On Command four wheel drive switch and differential gear lock sw...

Страница 208: ...lb socket for damage or wear proper connections and also for continuity between the terminals Caution Avoid touching the glass part of the bulb as the oils in your skin transfer to the bulb This cause...

Страница 209: ...Electrical 6 11 Ignition System Circuit Diagram 1 High tension coil 2 C D I 3 Magneto...

Страница 210: ...lug cap resistance 6 Ignition coil resistance 7 Main switch 8 Pickup coil resistance 9 Rotor pickup coil resistance 10 Wiring connections the entire Ignition circuit No Continuity Continuity Incorrect...

Страница 211: ...il Replace the main switch Test the main switch for continuity Out of Specification Both Tests meet specification correct Incorrect Test the A C magneto coupling resistance Connect multimeter as shown...

Страница 212: ...Electrical 6 14 Check the wiring of the entire ignition circuit Repair wiring or replace connectors as necessary incorrect Replace the C D I unit...

Страница 213: ...Electrical 6 15 Electric Starting System...

Страница 214: ...ack terminal 2 Connect the multimeter positive lead to the red terminal 3 Connect the multimeter negative lead to the black terminal 4 Check for continuity 5 Main switch for continuity 6 Gear position...

Страница 215: ...Removing the starter motor 1 Remove the parts in the order Starter motor lead listed 2 Starter motor O ring 1 1 Disassembling the starter motor 1 Bracket 1 1 2 Washer kit 1 3 Bracket 2 1 4 Shims 5 Br...

Страница 216: ...Electrical 6 18 Charging System...

Страница 217: ...ernal short 2nd test in ohms 1 white wire to 2 white wire 2 white wire to 3 white wire 3 white wire to 1 white wire We should have continuity or small numbers 0 32 0 43 ohms Now perform the 2nd test a...

Страница 218: ...Electrical 6 20 Lighting System...

Страница 219: ...Electrical 6 21 Signaling System...

Страница 220: ...Electrical 6 22 Cooling System...

Страница 221: ...Electrical 6 23 2WD 4WD Selecting System...

Страница 222: ...ine speed load and temperature then providing the ignition spark at the right time for the prevailing conditions and metering the fuel to the engine in the exact quantity required Typical Components o...

Страница 223: ...conditions The ECU also provides diagnosis when system malfunctions occur Handling This is the electrical brain for the UV Because of this it requires special handling Do not subject this unit to exce...

Страница 224: ...fuel injector Do not reuse injector seal rings dip injector tips into lubricants cycle injectors repeatedly without fuel pressure pulse a high leak rate injector allow water into the fuel system cont...

Страница 225: ...r wiring harness Relieve fuel pressure Remove the retaining clip from the fuel injector Remove the fuel line connection from the injector Carefully clean debris from the interface surfaces Do not dama...

Страница 226: ...tall the retaining clip after connecting the fuel line Tighten the injector mounting to the desired torque as mentioned in the manufacturer manual Tighten the fuel line Re install the injector electri...

Страница 227: ...to injector Start and idle the vehicle for an additional 2 minutes to ensure the residual injector cleaner is flushed from system Throttle Body Assembly with stepper motor The Throttle Body Assembly i...

Страница 228: ...rticles Throttle Body Installation Reverse the removal procedure for installation noting the following Adjust accelerator cable play Check to ensure that all removed parts are back in place Precaution...

Страница 229: ...to the spark plug and keep the plug wire short in length 6 inches or less if possible Mount the coil away from any pickup type devices especially the crank cam sensor and route wiring away from these...

Страница 230: ...es No 1 Switch on ignition key Fuel pump primes for 3 seconds when the ignition key is ON Check for fuel pump running noise for 3 seconds after ignition key is ON Do you hear the pump running Go to st...

Страница 231: ...everse the removal process Fill with at least 3 liters of fuel Install the fuel filler cap Turn on the ignition key to prime the pump and fuel lines Fuel Leakage Check Procedure After performing any s...

Страница 232: ...ke Air Temperature Sensor IAT 0113 IAT circuit high voltage IAT short high Coolant Temperature Sensor 0117 Coolant temp sensor circuit low voltage Coolant short low Coolant Temperature Sensor 0118 Coo...

Страница 233: ...system is working correctly Perform this test on the engine when it is both cold and hot if possible If the test results are positive for each test the ignition system is working correctly Caution Af...

Страница 234: ...ng to the fuel tank Two wires go to the back of the unit and two wires go to the front of the unit Find the white 2 pin connector that goes towards the throttle body and connect 12v Do you hear the pu...

Страница 235: ...coolant hose immediately after or during engine operation Scalding fluid and steam may be blown out under pressure and cause serious injury When the engine has been operated the coolant is very hot an...

Страница 236: ...ossibility of more extensive damage Use a mechanic s stethoscope to isolate the location Determining the exact cause of a noise can be difficult If this is the case consult with a professional mechani...

Страница 237: ...tic engine compression is in preventing the piston from moving as the combustion chamber starts to pressurize Any piston movement will force the crankshaft to turn away from TDC and allow air to escap...

Страница 238: ...shaft movement can throw the tool away from the engine under considerable force attempting to hold the tool can cause serious injury Engine damage may also occur to the crankshaft or right crankcase c...

Страница 239: ...component and connector identification Use the wiring diagrams to determine how the circuit should work by tracing the current paths from the power source through the circuit components to ground Als...

Страница 240: ...repair the problem or replace the part Check for wires with cracked or broken insulation Heat This is another common problem with connectors or plugs that have loose or poor connections As these conn...

Страница 241: ...V The ECU controls all the electrical and motor systems on the UV It sends out voltage to the sensors which use the voltage to measure something In their processing of the measurement they use up some...

Страница 242: ...Gray Water Temp Switch Black Wire Colors Listed In Black Font 4 Regular Above Wire Or To The Right Of Wire Wire Function Listed In Red Font 5 Semi Bold Above Wire A The EPS Power Assist Steering Is O...

Страница 243: ...ow Black White Black Orange Black Red Blue Gray Green Black Red Blue Yellow Black Green Black Red Black Red Blue Brown Black Light Green Green Black Green Black Purple White Black Black White Blue Gre...

Страница 244: ...MTD Products Inc Product Training and Education Department FORM NUMBER 769 10856 05 2015...

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