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10. TROUBLESHOOTING
10-4
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Tooth of gears are damaged and/or worn. Replace respective gears.
Symptom: GEAR INDICATION FAILS.
1.
Check contact screws on gear housing center.
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Check contact screw outside for contamination and wetness. Clean contact screw and
screw for wiring harness.
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Contact(s) is (are) corroded and/or contact screw for wiring harness got loose. Clean
contact surface and retighten contact screw(s) with recommended torque.
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Wiring harness has broken cables. Replace wiring harness.
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Shifting indicator switch(es) pin(s) is (are) worn and/or damaged. Replace shifting
indicator switch(es).
Symptom: GEAR(S) IS (ARE) HARD TO SHIFT
1.
Check shift shaft splines and/or shift forks for wear and/or damages.
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Shift shaft is worn out and/or shows damaged splines. Replace shift shaft.
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Shift drum track(s) and/or splines is (are) worn out or damaged. Replace shift drum and
damaged part(s).
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Shift fork(s) is (are) worn out and/or engagement pins are damaged. Replace shift fork(s).
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Shift fork(s) is (are) worn out and/or fork(s) is (are) damaged. Replace shift fork(s).
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Shift gear(s) is (are) worn out. Replace shift gear(s).
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Shifting indicator switch(es) pin(s) is (are) worn out (no rounding on top of pin). Replace
shifting indicator switch(es).
2.
Check engine idle speed.
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Check throttle cable and throttle adjustment.
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Check bypass idle valve and connectors.
3.
Check CVT one way clutch on drive pulley.
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CVT one way clutch was not lubricated correctly. Lubricate CVT one way clutch (refer to
CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)).
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CVT one way clutch is worn out or damaged. Replace defective part(s) (refer to
CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)).
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Check if friction washer at one way clutch is worn. Replace friction washer (refer to
CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)).
4.
Check transmission lever and connecting rod.
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Ball joint and/or ball joint nut is (are ) loose. Retighten or replace the ball joint.
5.
Check spring on shift shaft in gearbox.
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Broken spring. Replace the spring (refer to GEARBOX).
6.
Check for any mud intrusions.
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CVT parts dirty. Clean all CVT parts.
COUPLING UNIT
Symptom: 4 WHEEL DRIVE INDICATION FAILS
1.
Check contact screw on gear housing right side for damage and/or wear.
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Shifting indicator switch pin is worn and/or damaged. Replace shifting indicator switch.
◼
Contact is corroded and/or contact screw for wiring harness got loose. Clean contact
surface and retighten contact screw with recommended torque.
◼
Wiring harness has broken cable. Replace wiring harness.
Symptom: 4 WHEEL DRIVE DOES NOT ENGAGE OR DISENGAGE
1.
Check actuator and/or actuator shifting fork for wear and/or damages.
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Check if selector works properly. If so, check actuator.
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If selector is out of specifications, check wires, connectors and/or replace selector.
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Actuator shifting fork is worn out and/or damaged. Replace shifting fork of actuator.
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Check function of actuator. Replace if actuator is not turning, refer to GEARBOX.
2.
Check shifting sleeve splines and/or shifting fork for wear and/or damages.
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Check sleeve shows damaged splines. Replace shifting sleeve (refer to GEARBOX).
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Shifting fork is worn out and/or engagement pin is damaged. Replace shifting fork.
CVT
Symptom: UNUSUAL ACCELERATION BEHAVIOR
1.
Check drive belt condition.
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Belt is too narrow (drive belt engagement is higher in drive pulley).replace belt if width is
less than specified.
2.
Check lever condition on drive pulley sliding sheave and/or roller(s) on governor cup.
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Lever(s) on drive pulley sliding sheave is (are) worn and/or damaged. Replace all levers