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CHAPTER 7 BRAKES

BUCK 450 SERVICE MANUAL 20.0

CHAPTER 7

BRAKES PAGE. 7-

13

remove the caliper mounting bolts and remove
caliper.

4.

Remove brake pad as described above.

5.

Inspect surface of caliper for nicks, scratches or
damage and replace if necessary.

6.

Install brake pads in caliper body with friction
material facing each other, with the spacer
between the pads. Install retaining pin through
outer pad, pad spacer and inner pad.

7.

Install caliper and torque mounting bolts to 18
ft.lbs. (25 Nm).

8.

Install brake hose and tighten to specified
torque.

Banjo Bolt Torque: 15 ft. lbs. (21 Nm)

9.

Bleed.

10.

Field test unit for proper braking action before
putting into service. Inspect for fluid leaks and
firm brakes. Make sure the brake is not dragging
when lever is released. If the brake drags,
recheck assembly and installation.

11.

Install the rear wheel and wheel nuts. Carefully
lower the vehicle.

NOTE:

If new brake pads are installed, it is

recommended that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise.

7.14 REAR BRAKE DISC INSPECTION /

REMOVAL / REPLACEMENT

INSPECTION

1.

Visually inspect the brake disc for nicks,
scratches, or damage.

2.

Measure the disc thickness at 8 different points
around the pad contact surface using a 0-1"
micrometer and a dial indicator. Replace disc if
worn beyond service limit.

Brake Disc Thickness

New 0.291-0.299"/7.4-7.6mm

Service Limit 0.281"/7.146mm

Brake Disc Thickness Variance

Service Limit 0.002 " (0.051 mm)

difference between measurements

3.

Mount dial indicator as shown to measure disc

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Содержание ARCHON 400

Страница 1: ...SERVICE MANUAL ARCHON 400...

Страница 2: ...ig nificant changes in specifications or procedures will be forwarded to all authorized Linhai dealers and will appear in future editions of this manual where applicable NOTE Designs and specification...

Страница 3: ...CONTENTS CHAPTER1 General Information CHAPTER2 Maintenance CHAPTER3 Engine CHAPTER4 Chassis CHAPTER5 Final Drive CHAPTER6 Transmission CHAPTER7 Brakes CHAPTER8 Electrical...

Страница 4: ...ains sulfuric acid Serious burns can result from contact with skin eyes or clothing Always keep alert and wear protection Exhaust system components are very hot during and after use of UTV Never servi...

Страница 5: ...GENERAL INFORMATION The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each UTV model for spare parts i...

Страница 6: ...cements Use recommended oil and grease for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality GASKETS OIL SEALS AND O RINGS 1 Replace all gaskets seals...

Страница 7: ...lick together 7 Check for continuity with a tester NOTE If there is no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness Use the tester on...

Страница 8: ...CONVERSION TABLE METRIC TO IMP Known Multiplier Result Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb In lb ft lb In lb Weight kg g 2 205 0 03527 lb oz Distance km h km m m cm mm 0 621...

Страница 9: ...ICE MANUAL 20 0 CHAPTER 1 GENERAL INFORMATION PAGE 1 5 1 2 V I N AND ENGINE SERIAL NUMBER The vehicle identification number 1 is stamped into the front of the frame tube The engine serial number 1 is...

Страница 10: ...CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 1 GENERAL INFORMATION PAGE 1 6 1 3 VEHICLE DIMENSIONS...

Страница 11: ...CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 1 GENERAL INFORMATION PAGE 1 7 NOTES...

Страница 12: ...ve almost same appearance Always refer to Parts Manual of each UTV model for spare parts information and service 2 1 PERIODIC MAINTENANCE 2 2 THROTTLE PEDAL INSPECTION 2 3 FUEL SYSTEM 2 4 TOE ALIGNMEN...

Страница 13: ...ed Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust or replace parts as necessary NOTE Inspectio...

Страница 14: ...se Oil 100 hrs Monthly Check monthly and change annually Front Gear case Oil 100 hrs Monthly Check monthly and change annually Engine Cylinder Head and Cylinder Base Fasteners 25 hrs 3 months Inspect...

Страница 15: ...sion 50 hrs 6 months Inspect lubricate tighten fasteners Rear Suspension 50 hrs 6 months Inspect tighten fasteners Spark Plug 100 hrs 12 months Inspect replace if necessary D Ignition Timing 100 hrs 1...

Страница 16: ...k Check level daily 2 Brake Fluid DOT 3 Only Add to proper level above the minimum level mark and replenish if necessary As require change every two years or 200 hours 3 Transmission Oil SAE GL 4 85W...

Страница 17: ...te fitting and Grease Semi annually 12 Front Rear A arm pivot Shaft Grease Locate fitting on pivot shaft and grease with grease gun Every 3 months or 50 hours 13 Throttle Cable Grease M Grease inspect...

Страница 18: ...ith the Periodic Maintenance Chart and adjust the play if necessary THROTTLE FREEPLAY INSPECTION 1 Apply the parking brake 2 Put the gear shift lever in the N Neutral position 3 Start the engine and w...

Страница 19: ...it run in an enclosed area Fuel powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Never drain the float bowl when the engine is hot Severe burns...

Страница 20: ...ends must screw in same and enough threads length 2 5 BRAKING SYSTEM INSPECTION The following checks are recommended to keep the braking system in good operating condition Service life of braking syst...

Страница 21: ...ked for proper operation The mechanical brake must be maintained to be full functional 1 With the engine off apply the parking brake lever and attempt to move the UTV 2 If the rear wheels are locked i...

Страница 22: ...Always do the procedure 1 to 8 when necessary 2 6 SUSPENSION SPRING RPELOAD ADJUSTMENT Operator weight and vehicle loading affect suspen sion spring preload requirements Adjust if necessary FRONT SUSP...

Страница 23: ...e the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION 1 With the transmission in gear and the parking Brake loc...

Страница 24: ...cause machine damage especially in 4X4 model TIRE TREAD DEPTH Always replace tires when tread depth is worn to 1 8 3mm or less Operating an UTV with worn tires will increase the possibility of the veh...

Страница 25: ...CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20 0 NOTES CHAPTER 2 MAINTENANCE PAGE 2 14...

Страница 26: ...3 COMPRESSION PRESSURE 3 2 4 ENGINE OIL LEVEL INSPECTION 3 2 5 COOLANT LEVEL INSPECTION 3 3 CYLINDER HEAD 3 4 CAMSHAFT AND ROCKER ARMS 3 5 VALVES AND VALVE SPRINGS 3 6 CYLINDER AND PISTON 3 7 V BELT C...

Страница 27: ...SC A 0404ASDH 108 Rocker arm rocker armshaft Rocker arm inside diameter Rocker shaft outside diameter Rocker arm to rocker arm shaft clearance 12 000 12 018 mm 11 981 11 991 mm 0 009 0 012 mm 12 03 m...

Страница 28: ...22 42 83 kg 36 1 mm 35 0 mm 2 5 1 7mm 2 5 1 7mm Piston Piston to cylinder clearance Piston size D Measuring point H Piston pin bore inside diameter 0 02 0 049mm 79 965 79 980 mm 5mm 18 004 18 015 mm 1...

Страница 29: ...6 mm 21 0 mm Oil pump Type Tip clearance Side clearance Housing and rotor clearance Trochoid type 0 1 0 34 mm 0 013 0 036 mm 0 04 0 09 mm 0 4 mm 0 15 mm 0 15 mm Item Standard Limit Radiator Type Widt...

Страница 30: ...alve cover Filer neck supporting Oil pump Oil pump cover Drain plug Exhaust pipe assembly Crankcase left and right Drain bolt Oil filer Crankcase cover left Magnet cover _ _ Bolt Nut Bolt Bolt Nut Nut...

Страница 31: ...1 2 Timing check plug Plug M16 1 8 0 8 One way clutch _ M 8 3 30 3 0 Clutch housing Bolt M14 1 60 6 0 Grease stopper Primary sheave _ M 4 4 3 0 3 Primary fixed sheave _ M14 1 60 6 0 Clutch carrier as...

Страница 32: ...cification Adjust Valve clearance cold Intake valve 0 08 0 12m m Exhaust valve 0 13 0 16mm Measurement steps Rotate the primary fixed sheave counterclockwise to align the slit aE A on the rotor with t...

Страница 33: ...rew Crankcase cover 3 2 2 SPARK PLUG INSPECTION 1 Remove Spark plug cap Spark plug CAUTION Before removing the spark plug use compressed air to blow away any dirt accumulated in the spark plug wells t...

Страница 34: ...ASUREMENT NOTE Insufficient compression pressure will result in performance loss 1 Check Valve clearance Out of specification Adjust Refer to CALCE CLEARANCE ADJUSTMENT section 2 Start the engine and...

Страница 35: ...plied into cylinder Reading Diagnosis Higher than without oil Worn or damaged pistons Same as without oil Possible defective ring s valves cylinder head gasket or Piston Repair Compression pressure at...

Страница 36: ...grade CAUTION Do not put in any chemical additives or use oils with a grade of CD or higher Be sure not to use oils labeled ENERGY CONSERVING I or higher Engine oil also lubricates the clutch and add...

Страница 37: ...loosen the oil check bolt Start the engine and keep it idling until the oil begins to seep from the oil check bolt If no oil comes out after one minute turn the engine off so it will not seize Check...

Страница 38: ...ew minutes until the coolant settles before inspecting the coolant level COOLANTRE PLACE MENT 1 Remove Front cover of UTV plastic body work Seat 2 Remove Hose reservoir tank Drain the reservoir tank o...

Страница 39: ...n Hose 7 Connect Hose reservoir tank 8 Fill Radiator to specified level Fill the coolant slowly until the coolant comes out from the head hose Reservoir tank to maximum level A aE A Recommended coolan...

Страница 40: ...o coolant splashes onto painted surfaces If it does wash them immediately with water Do not mix different types of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines 9 Tig...

Страница 41: ...CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20 0 3 3 CYLINDER HEAD CHAPTER 3 ENGINE PAGE 3 16...

Страница 42: ...e Injector seat Joint O ring Crankcase cover Plug O ring Cam sprocket cover O ring Valve cover intake side O ring Valve cover exhaust side O ring Timing chain tensioner assembly Timing chain tensioner...

Страница 43: ...n Bolt 3 Remove Timing chain tensioner assembly Timing chain tensioner gasket 4 Remove Breather plate Cam sprocket Timing chain NOTE Fasten a safety w ire to the timing chain to prevent it from fallin...

Страница 44: ...urface plate and resurface the head using a figure eight sanding patten NOTE Rotate the cylinder head several times for an even resurfacement CYINDER HEAD INSTALLATION 1 Install Gasket cylinder head N...

Страница 45: ...slot in the cam sprocket CAUTION Do not turn the crankshaft during installation of the cam shaft Dam age or improper valve timing will result While holding the camshaft temporarily tighten the bolts...

Страница 46: ...50 SERVICE MANUAL 20 0 6 Tighten Bolt cam sprocket 7 Check Valve timing Out of alignment Adjust 8 Check Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJUSTMENT section CHAP...

Страница 47: ...1 Remove the parts in order Refer to CYLINDER HEAD section 2 Plate 1 Refer to ROCKER ARM AND ROCKER 3 Rocker arm shaft intake 1 SHAFT REMOVAL AND INSTALLATION section 4 Rocker arm shaft exhaust 1 5 R...

Страница 48: ...place 2 Measure Cam lobes length A aE A and A bE Out of specification Replace Cam lobes length Intake A aE A 36 545 36 645 mm Lim it 36 45 mm A bE A 30 021 30 121 mm Lim it 29 92 mm Exhaust A aE A 36...

Страница 49: ...les Out of specification Replace Inside diameter rocker arm 12 000 12 018mm Lim it 12 030 mm Measure the outside diameter B of the rocker arm shafts Out of specification Replace Outside diameter rocke...

Страница 50: ...haust completely pushed in 5 Install Rocker arm Rocker arm shaft intake NOTE Intake Insert the guide shaft 8 mm into the stud bolt hole in the cylinder head to the rocker arm shaft intake CAUTION Do n...

Страница 51: ...pring retainer Valve spring inner Valve spring Outer Valve intake Valve exhaust Valve guide Spring seat 4 2 2 2 1 1 2 2 Remove the parts in order Refer to CYLINDER HEAD section Refer to ROCKER ARM SHA...

Страница 52: ...id damage to the valve spring VALVE AND VALVE SPRINGS INSPECTION 1 Measure Valve stem diameter Out of specification Replace Valve stem diameter Intake 5 975 5 990mm Limit 5 94mm Exhaust 5 960 5 975mm...

Страница 53: ...lve guide inside diameter Intake 6 000 6 012 mm Limit 6 05mm Exhaust 6 000 6 012 mm Limit 6 05 mm 7 Measure Stem to guide clearance Valve guide inside diameter Valve stem diameter Out of specification...

Страница 54: ...e valve seat is too wide too narrow or the seat is not centered the valve seat must be replaced 4 Lap Valve face Valve seat NOTE After replacing the valve seat valve and valve guide the valve seat and...

Страница 55: ...the valve guide and onto the valve seat to make a clear pattern Measure the valve seat with A cE A again VALVES AND VALVE SPRINGS INSTALLATION 1 Deburr Valve stem end Use an oilstone to smooth the st...

Страница 56: ...Install the valve cotters while com pressing the valve spring with a valve spring compressor and attachment 5 Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood CAUT...

Страница 57: ...chain guide exhaust side 1 Refer to PISTON RINGS 4 Cylinder 1 PISTON AND CYLINDER INSTALLATION section 5 Dowel pin 2 6 Cylinder gasket 1 7 Piston pin circlip 2 Refer to PISTON AND 8 Piston pin 1 PISTO...

Страница 58: ...piston ring open the end gap of the ring by fingers and push up the other side of the ring CYLINDER INSPECTION 1 Measure Cylinder bore Out of specification Rebore or replace NOTE Measure the cylinder...

Страница 59: ...kirt diameter Refer to CYLINDER section for cylinder bore measurement Out of specification Replace the piston and piston rings as a set Piston to cylinder clearance 0 02 0 04mm 3 Measure Piston pin bo...

Страница 60: ...tion Piston ring into the cylinder NOTE Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore A 1E A 5 0mm 3 Measure End gap Out of specification Replace N...

Страница 61: ...iston pins The mark A aE A on the piston must face the exhaust side of the cylinder Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip fr...

Страница 62: ...Piston ring Cylinder inner surface Engine oil 6 Install Cylinder NOTE Install the cylinder with one hand while com pressing the piston rings with the other hand Pass the timing chain and timing chain...

Страница 63: ...LEFT Order Job name Part name Q ty Remarks Crankcase cover left removal Remove the parts in order 1 Crankcase cover left 1 2 Front cover 1 3 Hose clamp B 1 4 Joint B 1 5 Air strainer B 1 6 Hose clamp...

Страница 64: ...condary primary sheave removal Remove the parts in order 1 Nut Plain washer 1 1 2 Primary fixed sheave 1 3 Nut 1 4 Clutch housing 1 5 Clutch assembly 1 6 V belt 1 7 Primary sliding sheave 1 8 Collar 1...

Страница 65: ...er 1 Nut 1 2 Clutch carrier 1 Refer to SECONDARY SHEAVE 3 Clutch shoe spring 3 DISASSEMBLY section 4 Compression spring 1 5 Spring seat 1 Refer to SECONDARY SHEAVE 6 Guide pin 4 INSTALLATION section 7...

Страница 66: ...Remove Nut secondary sheave Clutch housing NOTE Loosen the nut secondary sheave while holding the clutch housing with the sheave holder 2 Remove Nut clutch carrier CAUTION Do not remove the nut clutc...

Страница 67: ...CLUTCH INSPECTION 1 Measure Clutch shoe thickness Scratches Glaze using coarse sandpaper Wear Damage Replace Clutch shoe thickness 5 5mm Limit 4 0mm NOTE After using the sandpaper clean off the polis...

Страница 68: ...VE INSPECTION 1 Inspect Secondary fixed sheave smooth operation Secondary sliding sheave smooth operation 2 Inspect Torque cam groove Wear Damage Replace 3 Inspect Guide pin Wear Damage Replace PRIMAR...

Страница 69: ...econdary fixed sheave 2 Install Secondary sliding sheave NOTE Install the secondary sliding sheave using the oil seal guide to the secondary fixed sheave 3 Install Guide pin 4 Apply Lightweight lithiu...

Страница 70: ...ary sheave and clutch 7 Install Nut clutch carrier NOTE Tighten the nut clutch carrier using the locknut wrench while holding the clutch carrier with the rotor holder 8 Install Clutch housing Nut clut...

Страница 71: ...ator coil removal Drain the engine oil Remove the parts in order Refer to ENGINE OIL REPLACEMENT section NOTE Disconnect the couplers Reverse the removal procedure for installation 1 Couplers A C magn...

Страница 72: ...gneto and starter clutch removal Rotor Shaft idle gear Idler gear Starter one way clutch assembly Woodruff key Starter wheel gear 1 1 1 1 1 1 Remove the parts in order Refer to A C MAGNETO ROTOR REMOV...

Страница 73: ...turned out slightly to adjust the flywheel puller s position CAUTION Cover the crankshaft end with the box wrench for protection STARTER DRIVE GEAR INSPECTION 1 Inspect Starter idle gear teeth Starter...

Страница 74: ...install the woodruff key 2 Install Plain washer Rotor NOTE Clean the tapered portion of the crankshaft and the rotor hub When installing the magneto rotor make sure the woodruff key is properly seated...

Страница 75: ...pump removal Remove the parts in order A C magneto Refer to A C MAGNETO AND STARTER 1 Cover 1 CLUTCH section 2 Pump driven gear 1 3 Dowel pin 1 4 Oil pump assembly 1 5 Gasket 1 6 Impeller shaft gear...

Страница 76: ...ner rotor and the outer rotor Side clearance between the outer rotor and the pump housing Housing and rotor clearance between the pump housing and the rotors Out of specification Replace the oil pump...

Страница 77: ...ndary primary sheave A C magneto and starter clutch Oil pump Water pump Rear wheel Bolt O ring 1 1 Remove the parts in the order Refer to ENGINE REMOVAL section Refer to CYLINDER HEAD section Refer to...

Страница 78: ...me Q ty Remarks 3 4 5 6 7 8 9 10 11 Timing chain Crankcase right Dowel pin Crankshaft assembly Balancer assembly Crankcase left Timing chain guide intake Bracket shift Oil seal 1 1 2 1 1 1 1 1 1 Rever...

Страница 79: ...nkshaft cannot be removed CRANKSHAFT INSPECTION 1 Measure Crankshaft runout Out of specification Replace crankshaft and or bearing NOTE Measure the crankshaft runout with the crankshaft assembly runni...

Страница 80: ...ut the journal with compressed air BALANCER INSPECTION Inspect Balancer driven gear Wear Damage Replace balancer CRANKCASE INSTALLATION 1 Clean all the gasket mating surface and crankcase mating surfa...

Страница 81: ...ty Remarks Radiator removal Drain the coolant Remove the parts in order Refer to COOLANT REPLACEMENT section 1 Fan motor leads 1 2 Thermo switch leads 1 3 Outlet hose radiator 1 4 Inlet hose radiator...

Страница 82: ...adiator pipes Cracks damage Replace 3 Measure Radiator cap opening pressure Radiator cap opens at a pressure below the specified pressure Replace Radiator cap opening pressure 110 140kPa 1 1 1 4kg cm2...

Страница 83: ...der Drain the coolant Refer to COOLANT REPLACEMENT section A C magneto Refer to A C MAGNETO AND STARTER CLUTCH section 1 lmpeller shaft gear 1 2 Dowel pin plain washer 1 1 3 Shaft 1 Refer to WATER PUM...

Страница 84: ...K 450 SERVICE MANUAL 20 0 Order Job name Part name Q ty Remarks 8 9 10 Impeller shaft O ring O ring 1 1 1 Refer to WATER PUMPINSTALLATION section Reverse the removal procedure for installation CHAPTER...

Страница 85: ...ur deposits Clean 2 Inspect Impeller shaft gear Wear damage Replace 3 Inspect Mechanical seal Damage worn wear Replace WATER PUMP INSTALLATION 1 Install Mechanical seal NEW Installation steps Apply th...

Страница 86: ...ps Apply a small amount of grease to the impeller shaft tip Install the impeller shaft while turning it Use care so that the oil seal is not damaged or the spring does not slip off its position NOTE A...

Страница 87: ...at removal Drain the coolant Remove the parts in order Refer to COOLANT REPLACEMENT section 1 Clip 1 2 Hose 1 3 Hose clamp 1 4 Inlet hose radiator 1 5 Thermostatic cover 1 Refer to THERMOSTAT INSTALLA...

Страница 88: ...the thermometer while continually stirring the water Thermostatic valve Vessel Thermometer Water A CLOSE B OPEN NOTE The thermostatic valve is sealed and its setting requires specialized work If its...

Страница 89: ...Description and Working Principle 3 12 3 2Throttle Body Removal 3 12 3 3 Cleaning Procedure 3 12 3 4 Throttle Body Installation 3 12 4 Engine Coolant Temperature Sensor 3 12 4 1 Description and Workin...

Страница 90: ...ANUAL 20 0 3 12 7 7 Fuel Leakage Check Procedure 3 12 8 Motor Scanner for MT05 EMS 3 12 8 1 Precautions 3 12 8 2 Configurations 3 12 8 3 Preparations Connection 3 12 8 4 Functions 3 12 8 5 MT05 ECU Ma...

Страница 91: ...pipe or Engine when removed High temperature might reduce the life of the ECU and also can damage the ECU DO NOT Place the ECU close to or pour water oil or any other liquids ECU is susceptible to wa...

Страница 92: ...vive with no permanent damage Battery and or Ignition voltage 13V DC for 1 minute But the fuse will fuse 3 12 1 6 Operating Temperature The controller shall operate in the ambient temperature from 20...

Страница 93: ...me Operating Temperature Range some performance degradation 40 to 150 3 12 2 3 Fuel Contamination The injector fuel inlet filter protects the fuel injector from initial build fuel contamination as wel...

Страница 94: ...ns of damage Even minor defects in the seal ring can lead to leakage Take extra care in installing seal ring over flange of injector inlet Carefully installing the harness connector will prevent termi...

Страница 95: ...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 damage seal mating surfaces Remove...

Страница 96: ...ttle Body Assembly 3 12 3 1 Description and Working Principle The Throttle Body Assembly is an interactive system comprised of the following subsystems the main casting body bearing system shaft and v...

Страница 97: ...h that are present Do not let the bye pass holes be blocked by dirt or foreign particles 3 12 3 4 Throttle Body Installation Reverse the procedure for installation noting the following Adjust accelera...

Страница 98: ...tioned above 3 12 5 Oxygen Sensor 3 12 5 1 Description and Working Principle This sensor is a device for monitoring the residual oxygen in the exhaust of an internal combustion engine It is the feedba...

Страница 99: ...tes an electrical path to outside the system permitting improper system operation misfire or even possible personal injury if arcing occurs DO NOT Use parts that have been dropped or display physical...

Страница 100: ...nd the power applied unwanted secondary output might occur possibly resulting in injury damage the ignition component and test equipment DO Take care when working around the ignition system The high v...

Страница 101: ...clear of moving parts belts fan etc must be protected from or kept at least 125 mm away from radiant heat source exceeding 400 F must be protected from environmental damage dirt splash oils fluids et...

Страница 102: ...ltage Too narrow of a gap could affect idle stability A flat gauge can t accurately measure the spark plug on used plugs DO When replacing spark plugs with new ones always use equivalent plugs with sa...

Страница 103: ...regulator regulates the fuel pressure at a set pressure by releasing the excessive fuel flow to fuel tank 3 12 7 2 Operating Conditions Fuel Pump needs to be mounted on Fuel Tank Top according to the...

Страница 104: ...cing make sure that the fuel hoses and clamps are connected according to the hose fitment instructions given in vehicle instruction manual After servicing please follow the Fuel Leakage Check Procedur...

Страница 105: ...oints 2 Check Fuel Pump 3 Check Pressure Regulator 1 Clogged Filter 2 Kink Blockage in Fuel Hoses 3 Check Regulator 3 12 7 4 Fuel Pump Removal Relieve fuel pressure in fuel lines referring to the Fuel...

Страница 106: ...Procedure to check any leakage before the engine is started 3 12 7 6 Fuel Pressure Relief Procedure Caution This work must not be done when engine is hot After making sure that engine is cold relieve...

Страница 107: ...med by the person who is driving the car This unit should be used and stored in the following conditions Ambient temperature 0 50 Relative humidity 90 Note This instruction is only applicable to Delph...

Страница 108: ...be used to diagnose Delphi Engine Management System with functions Read DTC Clear DTC Data Stream Status Stream and Record Data Operations When the unit is powered up the screen will display the inter...

Страница 109: ...t Press with accessing system fleeting on the screen then it will display as right Available functions are as follows Read DTC Clear DTC Data Stream Status Stream Record Data Press or key to select fu...

Страница 110: ...ight 3 Data Stream Select Data Stream and press it will display as right Press or key for page up down to view more Press key to exit 4 Status Stream Select Status Stream and press the interface will...

Страница 111: ...Circuit Low Voltage P0132 O2A Circuit High Voltage P0031 O2A Heater Circuit High Voltage P0032 O2A Heater Circuit Low Voltage P0201 Injector 1 Circuit Malfunction P0202 Injector 2 Circuit Malfunction...

Страница 112: ...CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20 0 NOTES CHAPTER 3 ENGINE PAGE 3 87...

Страница 113: ...versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 4 1 FRONT A ARM REPLACEMENT 4 2 RE...

Страница 114: ...rt Lh 17 Screw M5X10 18 Grease Fitting M6 19 Front Shock Absorber Assy 20 Bolt M10X1 25X57 21 Arm Upper Frt Lh Assy 22 Arm Lwr Frt Lh Assy 23 Carrier Bearing Wheel Lh Assy 1 Elevate and safely support...

Страница 115: ...cle is on the ground DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 10 Attach A arm to strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If...

Страница 116: ...16 Arm Lwr Rear Lh 17 Plug 18 Shaft Rear Lwr Arm 19 Cover Arm Lwr Rear Lh 20 Screw M5X10 21 Rear Shock Absorber Assy 22 Bolt M10X1 25X62 5 23 Bolt M10X1 25X57 24 Stabilizer Bar 25 Ball Pin Lh 26 Ball...

Страница 117: ...move the spindle nut and washer Remove the hub assy by sliding it off of the shaft 5 Loosen two bolts that secure the rear knuckle to the A arm Remove the rear knuckle assembly by sliding it off of th...

Страница 118: ...njury or death could result if fasteners come loose during operation 13 Attach A arm to rear knuckle Tighten upper and lower bolts to 44 ft lbs 60 Nm 14 Install the shock and tighten shock bolt to 44...

Страница 119: ...ss to the stabilizer bar each side 3 Remove the stabilizer bar nut from the lower A arm each side 4 Remove the two bolts that secure the stabilizer bar to the main frame each side 5 Remove the stabili...

Страница 120: ...during the rest of the removal process The box is not as stable with the hinge pin removed 6 With the hinge pins removed remove the box from the frame Two people maybe needed to remove the bed from th...

Страница 121: ...20 Shoulder Bolt M10 1 25 30 21 Bushing For Adjustable Steering Wheel 22 Nut M10 23 Shaft Steering 24 Adjustment Cylinder 25 Shoulder Bolt M8 1 25 30 26 Washer 6 27 Bolt M6X12 1 With the steering whe...

Страница 122: ...CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20 0 CHAPTER 4 CHASSIS PAGE 4 10 NOTES...

Страница 123: ...REMOVAL INSPECTION 5 4 FRONT HUB INSTALLATION 5 5 FRONT HUB BEARING REPLACEMENT 5 6 FRONT DRIVE AXLE REMOVAL INSPECTION 5 7 FRONT DRIVE AXLE INSTALLATION 5 8 FRONT DRIVE AXLE DISASSEMBLY INSPECTION 5...

Страница 124: ...ION Locking nuts and bolts with pre applied locking agent should be replaced if removed The self locking properties of the nut or bolt are reduced or destroyed during removal 5 2 FRONT HUB EXPLODED VI...

Страница 125: ...isture dirt or corrosion or roughness is evident 5 4 FRONT HUB INSTALLATION 1 Inspect the hub strut bearing surface for wear or damage 2 Apply grease to drive axle spindle 3 Install spindle through th...

Страница 126: ...pport casting on outer edges so bearing can be removed 4 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bear...

Страница 127: ...er and Chapter 4 CAUTION To avoid damage to the front gearcase oil seal hold the front drive shaft horizontal and straight out from the front differential during removal 3 Hold the drive shaft straigh...

Страница 128: ...ront differential 2 Push the drive shaft straight into the front differential and push it in all the way until it bottoms out If necessary carefully tap on the outer end of the drive shaft with a rubb...

Страница 129: ...be reused b Slide the outboard boot off the drive axle and discard the boot band A it cannot be reused 9 Inspect the drive axle as described in this chapter INNER CV JOINT INSPECTION 1 Clean the beari...

Страница 130: ...er end splines and the front hub cotter pin hole for wear or damage If any of these areas are worn or damaged replace the drive axle Check the movement of the joint NOTE Inner CV joint must be replace...

Страница 131: ...mbly Work the grease in between the balls the race and the case Make sure all voids are filled with grease 9 Apply a liberal amount of molybdenum disulfide grease to the inner surfaces of the inboard...

Страница 132: ...e stopper ring and make sure it is seated correctly in the drive axle groove 18 Apply molybdenum disulfide grease to the end splines 5 10 REAR HUB EXPLODED VIEW 5 11 REAR HUB AND KNUCKLE REMOVAL INSPE...

Страница 133: ...b and knuckle assembly onto the drive shaft 2 Align the bottom of knuckle and lower control arm Secure with the lower control arm bolt 3 With the driveshaft placed in the knuckle align the knuckle wit...

Страница 134: ...of the frame Use short sharp jerks to free the circlip from the gearcase The circlip holds the axle in the gearcase 4 Inspect the axle splines and CV boots for any damage 5 14 REAR DRIVE SHAFT INSTAL...

Страница 135: ...d install bolt to upper and lower control arm Torque bolt to 45 ft lbs 60 Nm 5 Install the washer and the new spindle nut 6 Lower the vehicle Torque the spindle retaining nut to 103 ft lbs 140 Nm 7 Kn...

Страница 136: ...CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20 0 CHAPTER 5 FINAL DRIVE 5 14 5 15 REAR GEARCASE EXPLODED VIEW REAR GEARCASE EXPLODED VIEW...

Страница 137: ...PLER REAR AXLE 4 7 BOLT M18x1 5 1 31 WASHER 12 5 30 4 1 8 OIL SEAL30x60x15 1 32 NUT M12 1 25 1 9 BEARING 6008 1 10 ADJUST SHIM48x40 3 AR 11 HEXAGON HEAD BOLT 1 12 WASHER 1 13 DRIVEN BEVEL GEAR ASSEMBL...

Страница 138: ...igh pressure water jet 1 Remove the oil drain plug A and let the oil drain from the gearbox Important Clean the plug carefully Replace the sealing washer B before it s assembled Fig 1 Fig 1 Fig 2 2 Re...

Страница 139: ...ner L with the special tool Remove the bearing M and the oil seal P from the bevel gear bearing housing N Fig 4 Fig 4 2 Remove the six bolts M8 25 Q and the two bolts M10 1 25 25 R Remove the ring gea...

Страница 140: ...st shim Y from the bevel gear comp driven X Fig 7 Fig 7 5 Remove the O ring Z the oil seal 65 90 9 a and the bearing b from the ring gear bearing housing T Fig 8 Fig 8 5 17 REAR GEAR CASE ASSEMBLY Imp...

Страница 141: ...ar comp driven E in the bore of bearing A Mount the adjust shim F in the other neck of the bevel gear comp driven E Fig 2 Fig 2 3 Mount the needle bearing H and the needle bearing into the suited hole...

Страница 142: ...rear gear case G together Fig 6 Fig 6 7 Tighten the six bolts M8 25 Q to a torque of 20 25N m Tighten the two bolts M10 1 25 25 P to a torque of 35 40N m 8 Mount the axle sleeve U of the inner outer...

Страница 143: ...shaft neck of the bevel gear bearing housing Z Make the rear gear case G and the bevel gear bearing housing Z together Fig 11 Fig 11 12 Apply some Loctite 242 threadlocker on screw thread Tighten the...

Страница 144: ...22 Fig 13 14 Mount the oil seal 65 90 9 j in the ring gear bearing housing C on the right Fig 14 Fig 14 15 Mount the oil seal k in the ring gear bearing housing G on the left Make the O ring m on the...

Страница 145: ...CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20 0 CHAPTER 5 FINAL DRIVE 5 23 5 18 FRONT GEARCASE EXPLODED VIEW FRONT GEARCASE EXPLODED VIEW...

Страница 146: ...Vent Pipe 1 10 Oil Seal 24 38 8 2 35 O Ring 81 2 1 9 1 11 Fill Plug 1 36 Gear Motor 1 12 O Ring 30 5 3 1 37 Screw M8 20 4 13 Drain Bolt 1 38 Pin Shaft 1 14 Washer 10 1 39 Shift Fork 1 15 Front Axle Bo...

Страница 147: ...36 is protected if mounted Never clean the gearbox with a high pressure water jet Fig 0 Fig 0 1 Remove the DRAIN BOLT NO 13 and let the oil drain from the gearbox Important Clean the plug carefully an...

Страница 148: ...ove the OIL SEAL NO 5 and repalce with a new seal Fig 5 Fig 5 6 Remove the four SCREW NO 37 Fig 6 Fig 6 7 Remove the GEAR MOTOR NO 36 Fig 7 Fig 7 8 Remove the six bolts M8 X L28 NO 29 Fig 8 Fig 8 9 Re...

Страница 149: ...eth NOTE The DIFFERENTIAL GEAR ASSY A is NOT intended to be disassembled as it requires special tooling in order to properly reassemble If there is any damage to the gear bearings or others the assemb...

Страница 150: ...38 SHIFT FORK NO 39 Fig 14 Fig 14 14 Remove the DRIVE CLUTCH NO 23 Fig 15 Fig 15 15 Inspect the bearing NO 26 If the bearing was damaged remove the RETAINER NO 25 first and then remove the bearing NO...

Страница 151: ...ecial tool Fig 19 Fig 19 20 Remove the DRIVE PINION GEAR B Fig 20 Fig 20 NOTE The DIFFERENTIAL GEAR ASSY A AND THE DRIVE PINION GEAR B MUST BE REPLACED SIMULTANEOUSLY NOT SEPARAT 5 20 FRONT GEARCASE A...

Страница 152: ...5 30 2 Mount the retainer 62 NO 25 Fig 2 Fig 2 3 Mount the drive clutch NO 23 Fig3 Fig 3 4 Mount the pin shaft NO 38 and the shift fork NO 39 Fig 4 Fig 4 5 Install the screw NO 30 and washer NO 29 th...

Страница 153: ...E 5 31 Fig 6 7 Install the DIFFERENTIAL GEAR ASSY A into the carrier housing Fig 7 Fig 7 8 Install the DRIVE PINION GEAR B and install the BEARING RETAINER NO 6 with special tool Fig 8 Fig 8 9 Install...

Страница 154: ...l the bolts NO 29 that secure the cover to the housing Torque the bolts in a criss cross pattern to 20 25Nm Fig 11 Fig 11 12 Mount the gear motor A Important Before assemble the gear motor NO 36 make...

Страница 155: ...ER 5 FINAL DRIVE 5 33 14 Mount the coupler NO 4 Fig 14 Fig 14 15 Mount the O ring NO 3 Fig 15 Fig 15 16 Apply some Loctite 263 thread locker on screw thread mount the nut NO 3 tighten it to a torque o...

Страница 156: ...CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20 0 CHAPTER 5 FINAL DRIVE 5 34 NOTES...

Страница 157: ...me parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 6 1 GEAR SHIFTER REMOVAL 6 2 SHIFTER DISASSEMBLY 6 3 SHIFTER INSTALLATION 6...

Страница 158: ...20 0 CHAPTER 6 TRANSMISSION PAGE 6 2 6 1 GEAR SHIFTER REMOVAL 1 Remove parts that interfere with access to shift selector seat cover etc 2 Disconnect the two linkage rods from transmission slides 3 Re...

Страница 159: ...CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 6 TRANSMISSION PAGE 6 3 4 Remove the screw from the shifter 5 Remove the three bolts from the frame 6 Remove shift support assembly...

Страница 160: ...SMISSION PAGE 6 4 6 2 SHIFTER DISASSEMBLY Disassemble the gear shift mechanism as shown NOTE Pay attention to the falling springs and steel balls 6 3 SHIFTER INSTALL ATION The assembly process is the...

Страница 161: ...erosol lubricant or grease 2 Loosen all rod end adjuster jam nuts 3 Note orientation of tie rod end studs with stud up or down Remove both rod end studs from transmission bell cranks 4 Be sure idle sp...

Страница 162: ...feed and return hoses refer to Engine chapters 3 Remove throttle cable wire connected to carburetor 4 Disconnect engine from wiring harness completely 5 Disconnect gear position indicator switches 6 R...

Страница 163: ...bolt M10X1 25X120 and right mount bolt M10x1 25x70 11 Remove engine and transmission from engine mount bracket 6 6 ENGINE AND TRANSMISSION INSTALLATION 1 Reverse the procedure of chapter 6 5 ENGINE AN...

Страница 164: ...on shaft retainer plate and pinion shaft 8 Remove front drive output housing cover screws Carefully remove the cover with a soft face hammer tap on the cover bosses 9 Note position of shim washers and...

Страница 165: ...ocket on front output shaft with sprocket step side inward as shown only for 4X4 2 Assemble front only for 4X4 and rear output shafts 3 a 4X4 Install front and rear output shafts with chain as an asse...

Страница 166: ...ble shafts with chain and shift forks 11 Carefully install high reverse shaft assembly and gear cluster as a unit into their respective bearing case areas Tap with a soft face hammer to seat shaft ass...

Страница 167: ...eed adjustment Transmission oil type quality Driven clutch CVT deflection Loose fasteners on rod ends Loose fasteners on gear shift box Worn rod ends clevis pins or pivot arm bushings Linkage rod adju...

Страница 168: ...CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 6 TRANSMISSION PAGE 6 12 4X4 TRANSMISSION EXPLODED VIEW...

Страница 169: ...CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20 0 CHAPTER 6 TRANSMISSION PAGE 6 13 NOTES...

Страница 170: ...rmation 7 1 SPECIFICATIONS 7 2 TORQUE 7 3 BRAKE SYSTEM SERVICE NOTES 7 4 BURNISHING PROCEDURE 7 5 BRAKE BLEEDING FLUID CHANGE 7 6 PARKING BRAKE AND BRAKE LINE INSPECTION 7 7 PARKING BRAKE ADJUSTMENT 7...

Страница 171: ...Brake Disc Thickness 0 291 0 299 7 4 7 6mm 0 281 7 146mm Brake Disc Thickness Variance Between Measurements 0 002 0 051mm Brake Disc Run out 0 005 0 127mm 7 2 TORQUE Item Torque ft lbs except where no...

Страница 172: ...raking effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the brake pads use the following procedure 1 Choose an area large enough to safely ac...

Страница 173: ...n clear hose to the fitting and place the other end in a clean container Be sure the hose fits tightly on the fitting 6 Slowly pump foot pedal until pressure builds and holds 7 Hold brake pedal on to...

Страница 174: ...reservoir cover 13 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve should be no less than 1 2 13m...

Страница 175: ...vehicle should not roll while parked 3 If the vehicle moves adjustment is necessary 4 Adjust the parking brake where the cable attaches to the lever assembly on the rear brake caliper Parking Brake A...

Страница 176: ...the bracket and lift park brake assembly out 2 Measure the thickness of the caliper parking brake pads Replace pads if worn beyond the service limit Service Limit 0 3 64 1 mm Park Brake Caliper Insta...

Страница 177: ...ly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove e...

Страница 178: ...er clockwise 6 Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install wheels and torque wheel nut...

Страница 179: ...lean mating surface of disc and hub 4 Install new disc on hub and tighten to specified CAUTION Always use new brake disc mounting bolts Front Brake Disc Mounting Bolt Torque 18 ft lbs 25 Nm 7 11 FRONT...

Страница 180: ...p machine Repeat procedure 10 times 7 12 REAR BRAKE PAD REMOVAL INSPECTION INSTALLATION NOTE The brake pads should be replaced as a set REMOVAL 1 Remove the cargobox CAUTION Use care when remove the c...

Страница 181: ...brake fluid in the reservoir to prevent air from entering the brake system 5 Install wheels burnishing procedure should be performed 7 13 REAR CALIPER REMOVAL INSPECTION INSTALLATION CAUTION The cali...

Страница 182: ...and firm brakes Make sure the brake is not dragging when lever is released If the brake drags recheck assembly and installation 11 Install the rear wheel and wheel nuts Carefully lower the vehicle NOT...

Страница 183: ...ifications Brake Disc Runout Service Limit 0 005 0 127 mm REMOVAL REPLACEMENT 1 Remove the cargobox 2 Remove calipers 3 Remove bolts and disc from the flange 4 Clean mating surface of disc 5 Install n...

Страница 184: ...CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20 0 CHAPTER 7 BRAKES PAGE 7 15 NOTES...

Страница 185: ...CE 8 2 BATTERY 8 3 IGNITION SYSTEM 8 4 CHARGING SYSTEM 8 5 ELECTRICS STARTING SYSTEM 8 6 COOLING SYSTEM 8 7 LIGHTING SYSTEM 8 8 GEAR POSITION INDICATOR SWITCH TEST 8 9 SPEEDOMETER SYSTEM 8 10 MAIN SWI...

Страница 186: ...light beam can be adjusted vertically 2 Place the vehicle on a level surface with the headlight approximately 9 8 3m from a wall 3 Measure the distance from the floor to the center of the headlight an...

Страница 187: ...PAGE 8 3 TAILLIGHT BRAKELIGHT LAMP REPLACEMENT 1 Pull the Taillight plug off the wire harness remove the screw 2 Turn and remove the lamp base or Remove bulb and replace it with recommended bulb 3 Rei...

Страница 188: ...ol water and seek immediate medical attention Battery Maintenance 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If...

Страница 189: ...he storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perf...

Страница 190: ...erminal board or connections wet corroded Poor ignition coil ground e g coil mount loose or corroded Faulty stator measure resistance of all ignition related windings Incorrect wiring inspect color co...

Страница 191: ...system 5 Spark plug cap resistance 6 Ignition coil 1 Fuse NO CONTINUITY Check switches Replace the fuse CONTINUITY 2 Battery INCORRECT Clean battery terminals Recharge or replace the battery Check the...

Страница 192: ...ion system is not faulty Minimum spark gap 0 6mm 0 24 in OUT OF SPECIFICATION OR NO SPARK 5 Resistive cable with Spark plug cap resistance Tester lead Spark plug side Tester lead High tension cord sid...

Страница 193: ...tester 1 to the ignition coil Check if the primary coil has the specified resistance Primary coil resistance 0 58 0 058 20 Tester lead Right Terminal Tester lead Left Terminal Remover the resistive c...

Страница 194: ...coil coupler Tester lead BI Terminal Tester lead G Terminal Check the pickup coil has the specified resistance Primary coil resistance 120 160 20 OUT OF SPECIFICATION Replace the pickup coil 8 Main sw...

Страница 195: ...tery cable or ammeter with the engine running Damage will occur to light bulbs and speed limiter Connect an ammeter in series with the negative battery cable Check for current draw with the key off if...

Страница 196: ...ORRECT Clean battery terminals Recharge or replace the battery 3 Charging voltage Connect the engine tachometer to the spark plug lead Connect the pocket tester DC20V to the battery Test lead Battery...

Страница 197: ...ester X1 to the stator coil Tester lead yellow terminal Tester lead yellow terminal Measure the stator coil resistance Stator coil resistance 0 3 1 1 20 OUT OF SPECITICATION Replace the stator coil ME...

Страница 198: ...TRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 14 8 5 ELECTRICS STARTING SYSTEM DIAGRAM TROUBLESHOOTING THE STARTER MOTOR OPERATES WHEN THE BRAKE SWITCH IS ON IF THE STARTER MOTOR FAI...

Страница 199: ...attery 3 Starter motor Connect the battery positive terminal and starter motor cable using a jumper lead Check the starter motor operation DOES NOT MOVE Repair or replace the starter motor 4 Starter r...

Страница 200: ...NDUCTION CONTINUITY Replace the starter replay 4 Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 1 Brake switch CHECKING SWITCHES NO CONTINUITY Replace the brake switch 7 Starter swit...

Страница 201: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 17 8 6 COOLING SYSTEM...

Страница 202: ...ystem 1 Fuse CHECK SWITCHES NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section INCORRECT Clean battery terminals Recharge or replace the battery 3...

Страница 203: ...the thermo switch from the radiator Connect the pocket tester X1 to the thermo switch Immerse the thermo switch in the water Check the thermo switch for continuity NOTE Measure temperatures while hea...

Страница 204: ...EAT ALARM UNIT WORKING When the main switch is turned on the temperature of the engine begins to go up As it comes to 88 3 the thermostat is connected and the fan starts to work cooling the coolant if...

Страница 205: ...or allow it to be dropped Should it be dropped it must be replaced Do not touch the thermo unit to the bottom of the heated vessel Coolant temperature Resistance 80 47 5 56 8 100 26 2 29 3 OUT OF SPEC...

Страница 206: ...450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 22 6 Wiring connection check the connections of the entire cooling system Refer to CIRCUIT DIAGRAM POOR CONNECTION CORRECT Replace the temperature...

Страница 207: ...tem 1 fuse refer to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section INCORRECT Clean battery terminals Recharge or rep...

Страница 208: ...am light and direction indicator light couplers A When the High low beam switch is on high beam High beam light Tester lead Blue lead Tester negative lead Green lead B When the High low beam switch on...

Страница 209: ...ITY NO CONTINUITY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC20V to the taillight couplers 2 1 position light Tester lead Black terminal Tester lead Green terminal Turn...

Страница 210: ...CTRICAL PAGE 8 26 8 8 GEAR POSITION INDICATOR SWITCH TEST Switch table This sensor is used to provide the gear position signal for meter display When the gearbox is in one gear position there is conti...

Страница 211: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 27 Switch schematic...

Страница 212: ...tio of black metal gear or gear rack B Main Technical Parameter for sensor Item Code Vol value Unit Operating voltage Vcc 5 20 V Operating current Icc 15 mA Low voltage output Vol 0 4 V Hight voltage...

Страница 213: ...dicator 11 Km Mile Selector 3 High Beam Indicator Light 12 Gear Position Indicator 4 Parking Brake Indicate Lamp 13 2WD 4WD Indicator 5 Safety Belt Lamp 14 Front Differential Lock Indicator 6 Turn Rig...

Страница 214: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 30 8 10 MAIN SWITCH AND HANDLE SWITCH Optional...

Страница 215: ...e fuel sensor attached to fuel tank Hold fuel sensor in an upright position after removing it It is normal if indicator shows E otherwise circuitry connection fuel sensor or instrument should be inspe...

Страница 216: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 32 Fuel sensor resistance range FLOAT POSITION RESISTANCE 20 68 F TOP FULL 16 BOTTOM RESERVE 100...

Страница 217: ...OF THE ELECTRIC 4WD SHIFT 1 The rider shifts 2WD to 4WD by the Switch on panel 2 When shift 2WD 4WD or Diff Lock the mechanics in the front gear box maybe still engaged disengaged the mechanics would...

Страница 218: ...CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20 0 CHAPTER 8 ELECTRICAL PAGE 8 34 8 13 WIRING DIAGRAM...

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