HS1000UTV-2

FOREWORD

Brief introduction to maintenance handbook of HS1000UTV-2

The handbook is edited by Technical Center of Chongqing Huansong Science And

Technology Industrial Co.,Ltd, and is supplied to dealers and technicians as document of

technique.Mainly, the handbook gives methods to check, maintain and repair utility terrain

vehicles （UTV）, and supplies some relevant technique and performance data. Some

techniques and method inside may be used to check, maintain and repair other models of

UTV, although it is mainly for HS1000UTV-2.

Please read the handbook through and fully understand it; otherwise, any improper

repairing and amounting would bring you problems, and accident may occur in your use.

Proper use and maintenance can guarantee UTV being driven safely, reduce its

malfunction, and help the vehicle remain its best performance.

The standards, performances and specifications mentioned in interpretation are

based on the sample in design, and they are subject to changes according to the

product’s improvement without prior notice.

First version ,December, 2014

Published by Chongqing Huansong Science And Technology Industrial Co.,Ltd

Chongqing Huansong Science And Technology Industrial Co.,Ltd holds the copy right.

No publishing and reprinting without permission.

 CONTENT

CHAPTER 1
GENERAL INFORMATION

GENERAL INFORMATION……………………………………………………………………1
WATNINGS, CAUTIONS AND NOTES……………………………………………………1
DESCRIPTION……………………………………………………………………………………2
IDENTIFICATION CODE……………………………………………………………………… 4
Frame No. ………………………………………………………………………………… 4
Engine No. ………………………………………………………………………………… 4
SAFETY ………………………………………………………………………………………… 5
Handing gasoline safely…………………………………………………………………… 5
Cleaning parts……………………………………………………………………………… 6
Warning labels……………………………………………………………………………… 6
SERIAL NUMBERS…………………………………………………………………………… 7
FASTENERS…………………………………………………………………………………… 7
Torque specifications ……………………………………………………………………… 7
Self-locking fasteners……………………………………………………………………… 7
Washers…………………………………………………………………………………… 7
Cotter pins…………………………………………………………………………………… 8
Snap rings and E-clips …………………………………………………………………… 8
SHOP SUPPLIES……………………………………………………………………………… 9
Lubricants and Fluids……………………………………………………………………… 9
Engine oils…………………………………………………………………………………… 9
Greases……………………………………………………………………………………… 9
Brake fluid………………………………………………………………………………… 10
Coolant…………………………………………………………………………………… 10
Cleaners, Degreasers and solvents …………………………………………………… 10
Gasket sealant…………………………………………………………………………… 10
Gasket remover ………………………………………………………………………… 11
Thread locking compound……………………………………………………………… 11
BASIC TOOLS ………………………………………………………………………………… 11
Screwdrivers……………………………………………………………………………… 12

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 Wrenches ………………………………………………………………………………… 12
Adjustable wrenches …………………………………………………………………… 13
Socket wrenches, ratchets and handles ……………………………………………… 13
Impact drivers …………………………………………………………………………… 14
Allen wrenches…………………………………………………………………………… 14
Torque wrenches………………………………………………………………………… 14
Torque adapters ………………………………………………………………………… 15
Pliers……………………………………………………………………………………… 16
Snap ring pliers…………………………………………………………………………… 16
Hammers ………………………………………………………………………………… 17
Ignition grounding tool…………………………………………………………………… 17
PRECISION MEASURING TOOLS ………………………………………………………… 17
Feeler gauge ……………………………………………………………………………… 17
Calipers…………………………………………………………………………………… 18
Micrometers……………………………………………………………………………… 19
Adjustment ……………………………………………………………………………… 19
Care ……………………………………………………………………………………… 20
Metric micrometer………………………………………………………………………… 20
Standard inch micrometer……………………………………………………………… 21
Telescoping and small bore gauges…………………………………………………… 22
Dial Indicator……………………………………………………………………………… 22
Compression gauge……………………………………………………………………… 23
Multimeter………………………………………………………………………………… 23
Cltp-on ammeter………………………………………………………………………… 23
Magneto puller………………………………………………………………………………24
ELECTRICAL SYSTEM FUNDAMENTALS……………………………………………… 24
Voltage …………………………………………………………………………………… 24
Resistance………………………………………………………………………………… 24
Amperage………………………………………………………………………………… 24
BASIC SERVICE METHODS……………………………………………………………… 25
Removing frozen fasteners……………………………………………………………… 26
Removing broken fasteners …………………………………………………………… 26
Repairing damaged threads …………………………………………………………… 27
Stud Removal/Installation ……………………………………………………………… 27

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 Removing hoses ………………………………………………………………………… 27
Bearings…………………………………………………………………………………… 28
Removal…………………………………………………………………………………… 28
Installation………………………………………………………………………………… 29
Interference fit …………………………………………………………………………… 29
Seal replacement………………………………………………………………………… 31
STORAGE……………………………………………………………………………………… 31
Storage area selection…………………………………………………………………… 31
Preparing the motorcycle for storage …………………………………………………… 31
Returning the UTV to service…………………………………………………… 32
TROVBLESHOOTING……………………………………………………………………… 32
ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 33
STARTING THE ENGINE ………………………………………………………………… 33
Engine is cold …………………………………………………………………………… 34
Engine is warm…………………………………………………………………………… 34
Flooded engine……………………………………………………………………………34
ENGINE WILL NOT START ……………………………………………………………… 35
Identifying the problem ………………………………………………………………… 35
Spark test………………………………………………………………………………… 36
The starter cannot work repeatedly or can only work slowly………………… 37
POOR ENGINE PERFORMANCE………………………………………………………… 37
The engine starts slowly or difficultly…………………………………………… 37
Engine backfires, cuts out or misfires during acceleration…………………………… 37
The engine is not idling or cannot idle stably…………………………………………… 38
Poor fuel mileage………………………………………………………………………… 38
Engine will not idle or idles roughly …………………………………………………… 38
Low engine power ………………………………………………………………………… 38
Poor idle or low speed performance…………………………………………………… 40
Poor high speed performance ………………………………………………………… 40
FUEL SYSTEM……………………………………………………………………………… 40
Rich mixture……………………………………………………………………………… 41
Lean mixture……………………………………………………………………………… 41
ENGINE………………………………………………………………………………………… 41
Engine smoke……………………………………………………………………………… 41

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 Black smoke ……………………………………………………………………………… 41
Blue smoke………………………………………………………………………………… 41
White smoke or steam…………………………………………………………………… 42
Low engine compression ………………………………………………………………… 42
High engine compression ……………………………………………………………… 42
Engine overheating (cooling system) ………………………………………………… 42
Engine overheating (engine)…………………………………………………………… 43
The ignition advance angle is too large………………………………………………… 43
Detonation………………………………………………………………………………… 43
Power loss ……………………………………………………………………………… 43
engine noises……………………………………………………………………………… 44
ENGLNE LUBRICATION…………………………………………………………………… 45
HIGH OIL CONSUMPTION OR EXCESSIVE……………………………………………… 45
Exhaust smoke…………………………………………………………………………… 45
Low oil pressure ………………………………………………………………………… 45
High oil pressure ………………………………………………………………………… 45
No oil pressure…………………………………………………………………………… 45
Oil level too low…………………………………………………………………………… 45
Oil contamination………………………………………………………………………… 46
CYLINDER LEAK DOWN TEST…………………………………………………………… 46
ELECTRICAL TESTING…………………………………………………………………… 48
Preliminary checks and precautions …………………………………………………… 48
Intermittent problems…………………………………………………………………… 49
Electrical component replacement ……………………………………………………… 50
Test equipment …………………………………………………………………………… 50
Ammeter …………………………………………………………………………………… 50
Self-powered test light …………………………………………………………………… 50
Ohmmeter ………………………………………………………………………………… 50
Jumper wire……………………………………………………………………………… 51
TEST PROCEDURES………………………………………………………………………… 52
Voltage test……………………………………………………………………………… 52
Voltage drop test………………………………………………………………………… 52
Peak voltage test………………………………………………………………………… 53
Continuity test……………………………………………………………………………… 53

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 Testing for a short with a self-powered test light or ohmmeter……………………… 53
Testing for a short with a test light or voltmeter………………………………………… 54
BRAKE SYSTEM……………………………………………………………………………… 54
Soft or spongy brake lever or pedal…………………………………………………… 54
Brake drag………………………………………………………………………………… 55
Hard brake lever or pedal operation…………………………………………………… 56
Brake Grabs……………………………………………………………………………… 56
Brake squeal or chatter ………………………………………………………………… 56
Leaking brake caliper …………………………………………………………………… 56
Leaking master cylinder………………………………………………………………… 56

CHAPTER 2
SPECIFICATIONS

HOW TO USE CONVERSION TABLE OF UNIT…………………………………………… 58

How to use conversion table…………………………………………………………… 58
Definition of unit ………………………………………………………………………… 58
GEBERAR SPECIFICATIONS ……………………………………………………………… 59
ENGINE SPECIFICATIONS ………………………………………………………………… 62
CHASSIS SPECIFICATIONS………………………………………………………………… 68
ELECTRICAL SPECIFICATIONS…………………………………………………………… 70
LUBRICATION PIONTS AND LUBRICANT TYPES……………………………………… 72
Engine……………………………………………………………………………………… 72
Chassis……………………………………………………………………………………… 73
HYDROGRAPHIC CHART…………………………………………………………………… 74
LUBRICATION OIL WAY…………………………………………………………………… 75

CHAPTER 3
MAINTENCE AND ADJUSTMENT OF THE UTV

MAINTENANCE SCHEDULE……………………………………………………………… 77
ENGINE

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 Adjusting the valve clearance…………………………………………………………… 79
Checking the spark plug………………………………………………………………… 82
Checking the ignition timing……………………………………………………………… 83
Measuring the compression pressure………………………………………………… 84
Checking the engine oil leve l………………………………………………… 85
Changing the engine oil……………………………………………………………… 86
CHASSIS
Cleaning the air filter………………………………………………………………… 88
Checking the coolant level …………………………………………………………… 89
Changing the coolant…………………………………………………………………… 90
Checking the coolant temperature warning light …………………………………… 93
Checking the v-belt……………………………………………………………………… 94
Cleaning the spark arrester …………………………………………………………… 95
Adjusting the brake pedal……………………………………………………………… 96
Checking the brake fluid level ………………………………………………………… 97
Checking the front brake pads………………………………………………………… 98
Checking the rear brake pads………………………………………………………… 98
Checking the brake hoses and brake pipes ………………………………………… 99
Bleeding the hydraulic brake system ………………………………………………… 99
Adjusting the select lever shift rod …………………………………………………… 101
Checking the final gear oil level…………………………………………………… 102
Changing the final gear oil…………………………………………………… 103
Checking the differential gear oil…………………………………………………… 104
Checking the constant velocity joint dust boots……………………………………… 105
Checking the steering system………………………………………………………… 106
Adjusting the toe-in …………………………………………………………………… 107
Adjusting the front and rear shock absorbers………………………………………… 108
Checking the tires ……………………………………………………………………… 110
Checking the wheels…………………………………………………………………… 111
Checking and lubricating the cables ………………………………………………… 112
ELECTRICAL
Checking and charging the battery…………………………………………………… 113
Checking the fuses …………………………………………………………………… 118
Adjusting the headlight beam………………………………………………………… 120
Changing the headlight bulb………………………………………………………… 120

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 Changing the tail/brake light bulb …………………………………………………… 121

CHAPTER 4
ENGINE

ENGINE NOTE……………………………………………………………………………… 122

ENGINE REMOVAL………………………………………………………………………… 123
CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 125
ROCKER ARMS VALES AND CAMSHAFT……………………………………………… 130
VALVES AND VALVE SPRINGS…………………………………………………………… 133
CYLINDER AND PISTON………………………………………………………………… 138
ENGINE LEFT CRANKCASE COVER AND A.C. MAGNETO…………………………142
STARTER MOTOR AND WATER PUMP…………………………………………………146
PRIMARY AND SECONDARY SHEAVES…………………………………………………149
CRANKCASE COVER AND OIL PUMP……………………………………………………153
CRAKCASE AND MIDDLE DRIVEN SHAFT………………………………………………157
GEARCASE SHIFT LEVER AND OIL PUMP……………………………………………165
GEARCASE TRANSMISSION………………………………………………………………169

CHAPTER 5
CHASSIS

MALFUNCTION INSPECTION…………………………………………………………… 175

PANEL AND CARGO BED
Front panel………………………………………………………………………………… 178
Side cover………………………………………………………………………………… 181
Middle cover……………………………………………………………………………… 182
Cargo bed 1……………………………………………………………………………… 186
Cargo bed 2……………………………………………………………………………… 189
Head shed frame………………………………………………………………………… 191
DIRECTION SYSTEM
Steering wheel part……………………………………………………………………… 196

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 Steering mechanism part……………………………………………………………… 199
BRAKE SYSTEM…………………………………………………………………………… 204
Disk brake components………………………………………………………… 205
FOOTREST PART ………………………………………………………………… 225
WHEEL AND TYRE PARTS ……………………………………………………………… 229
Front wheels……………………………………………………………………………… 229
Rear wheels……………………………………………………………………………… 230
TRANSMISSION SYSTEM……………………………………………………………… 234
C.V axle, front axle……………………………………………………………………… 235
Front bridge……………………………………………………………………… 235
C.V axle, rear axle……………………………………………………………………… 243
Rear bridge reducer…………………………………………………………… 244
SHIFT OPERATING SYSTEM …………………………………………………………… 249
SUSPENSION……………………………………………………………………………… 255
Front suspension……………………………………………………………………… 255
Rear suspension……………………………………………………………………… 261
COOLING SYSTEM………………………………………………………………………… 266
Water and oil radiator…………………………………………………………………… 266
SEAT ………………………………………………………………………………………… 272
FUEL TANK………………………………………………………………………………… 279

CHAPTER 6
ELECTRICAL COMPONENTS

ELECTRICAL SYSTEM MALFUNCTION INSPECTION ……………………………… 282

ELECTRICAL………………………………………………………………………………… 283
ELECTRICAL COMPONENTS…………………………………………………………… 283
Checking the switch…………………………………………………………………… 287
Checking the switch continuity………………………………………………………… 288
Checking the bulbs and bulb sockets ……………………………………… 290
IGNITION SYSTEM…………………………………………………………………………290
Circuit diagram…………………………………………………………………………… 290
Troubleshooting……………………………………………………………………… 291

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ELECTRIC STARTING SYSTEM…………………………………………………………294
Circuit diagram………………………………………………………………………… 294
Troubleshooting……………………………………………………………………… 295
STARTER MOTOR………………………………………………………………………… 298
CHARGING SYSTEM……………………………………………………………………… 299
Circuit diagram………………………………………………………………………… 299
Troubleshooting……………………………………………………………………… 300
LIGHTING SYSTEM………………………………………………………………………… 301
Circuit diagram………………………………………………………………………… 301
Troubleshooting……………………………………………………………………… 302
Checking the lighting system…………………………………………………… 303
SIGNALING SYSTEM……………………………………………………………………… 304
Circuit diagram………………………………………………………………………… 304
Troubleshooting……………………………………………………………………… 305
Checking the signal system……………………………………………………… 306
COOLING SYSTEM………………………………………………………………………… 312
Circuit diagram………………………………………………………………………… 312
Troubleshooting……………………………………………………………………… 313
2WD/4WDSELECTINGSYSTEM………………………………………………………… 315
Circuit diagram………………………………………………………………………… 315
Troubleshooting……………………………………………………………………… 316

CHAPTER 7
ENGINE MANAGEMENT SYSTEM

INTRODUCTION
Ems (engine management system) …………………………………………………… 318
Typical components of EMS………………………………………………………………318
Layout of EMS components………………………………………………………………320
COMPONENTS OF EMS
Electronic control unit …………………………………………………………………… 320
Multec 3.5 injectors ……………………………………………………………………… 321
Throttle body assembly(with stepper motor) …………………………………………325

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 Engine coolant temperature sensor ……………………………………………………327
Intake air pressure and temperature sensor …………………………………………327
Oxygen sensor ………………………………………………………………………… 328
Ignition coil………………………………………………………………………..……… 328
Fuel pump module…………………………………………………………………………332
EMS FAULT DIAGNOSIS
EME fault diagnosis ………………………………………………………………………338
Fault code list………………………………………………………………………………338

CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING………………………………………………… 340
Fuel system ………………………………………………………………………………340
Electrical system ………………………………………………………………………… 340
Compression system …………………………………………………………………… 341
POOR IDLE SPEED PERFORMANCE ………………………………………………… 341
Poor idle speed performance…………………………………………………………… 341
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ……………………………… 342
Poor medium and high-speed performance………………………………………… 342
FAULTY GEAR SHIFTING…………………………………………………………………342
Shift lever does not move ………………………………………………………………342
Jumps out of gear……………………………………………………………………… 343
ENGING OVERHEATING…………………………………………………………………… 343
Overheating………………………………………………………………………………343
FAULTY BRAKE……………………………………………………………………………343
Poor braking effect………………………………………………………………………343
SHOCK ABSORBER MALFUNCTION………………………………………………… 344
Loss of damping function……………………………………………………………… 344
UNSTABLE HANDLING…………………………………………………………………… 344
Unstable handling……………………………………………………………………… 344
LIGHTING SYSTEM………………………………………………………………………… 344
Head light is out of work………………………………………………………………… 344
Bulb burnt out…………………………………………………………………………… 345

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 Error display of meter…………………………………………………………………… 345

CHAPTER 9
WIRING DIAGRAM
WIRING DIAGRAM…………………………………………………………………… 346

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 GENERAL INFORMATION
GENERAL INFORMATION
The text provides complete information on maintenance，tune-up repair and overhaul，Hundreds of
photographs and illustrations created during the complete disassembly of four wheel utility terrain
venires (UTV) guide the reader through every job，All procedures are in step-by-step format and
designed for the reader who may be working on the UTV for the first time.

WARNINGS, CAUTIONS AND NOTES

The terms WARNING, CAUTION and NOTE have specific meaning in this manual.

WARNING: emphasizes areas where injury or even death could result from negligence.
Mechanical damage may also occur. WARNINGS are to be taken seriously
CAUTION: emphasizes areas where equipment damage could result. Disregarding a
CAUTION could cause permanent mechanical damage. though injury is unlikely.
NOTE: provides additional information to make a step or procedure easier or clearer.
Disregarding a NOTE could cause inconvenience. but would not cause
equipment damage or injury.

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GENERAL INFORMATION
DESCRIPTION
1. Front bumper assy.
2. Front wheel
3. Air filter case (engine and air
intake duct)
4. Steering wheel
5. Driver seat
6. Driver seat belt
7. Engine
8. Muffler
9. Rear wheel
10. Tail lights
11. Cargo bed
12. Rear shock absorber
13. Fuel tank cap
14. Passenger seat belt
15. Passenger seat
16. Drive select lever
17. Ceiling
18. Front shock absorber
19. Headlights
20. Front turning lights
21. High/low beam lights
22. 4WD button
23. Front axle differential
24. Rear axle differential
25. Multi-function meter unit
26. Switch box
27. Brake pedal
28. Accelerator pedal
29. Light switch
30. Turn signals
31. DC socket
32. Emergency light
33. USB

NOTE:
The vehicle you have purchased may
differ slightly from those in the figures of
this manual.

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GENERAL INFORMATION
DESCRIPTION
1. Front bumper assy.
2. Front wheel
3. Air filter case (engine and air
intake duct)
4. Steering wheel
5. Driver seat
6. Driver seat belt
7. Engine
8. Muffler
9. Rear wheel
10. Tail lights
11. Cargo bed
12. Rear shock absorber
13. Fuel tank cap
14. Passenger seat belt
15. Ceiling
16. Passenger seat
17. Drive select lever
18. Front shock absorber
19. Headlights
20. Front turning lights
21. High/low beam lights
22. 4WD button
23. Front axle differential
24. Rear axle differential
25. Multi-function meter unit
26. Switch box
27. Brake pedal
28. Accelerator pedal
29. Light switch
30. Turn signals
31. DC socket
32. Emergency light
33. USB

NOTE:
The vehicle you have purchased may
differ slightly from those in the figures of
this manual.

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GENERAL INFORMATION
IDENTIFICATION CODE

Frame No.
Frame No. is carved on the right side of front
main frame

Engine No.
Engine NO. Is carved on the right side of the
engine, Figure.

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 GENERAL INFORMATION
SAFETY

Professional mechanics can work for years and never sustain a serous injury or mishap. Follow
these guidelines and practice common sense to safely service the utility terrain venires
1. Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain
carbon monoxide. an odorless, colorless and tasteless poisonous gas. Carbon monoxide levels
build quickly in small enclosed areas and can cause unconsciousness and death in a short time.
Make sure to properly ventilate the work area or operate the UTV side
2. Never use gasoline or any extremely flammable liquid to clean parts. Refer to cleaning parts and
handling Gasoline Safely in this section
3. Never smoke or use a torch in the vicinity of flammable liquids, such as gasoline or cleaning
solvent.
4. If welding or brazing on the UTV the fuel tank to a safe distance at least 50ft.(15m) away.
5. Use the correct type and size of tools to avoid damaging fasteners.
6. Keep tools clean and in good condition. Replace or repair worn or damaged equipment.
7. When loosening a tight fastener, be guided by what would happen if the tool slips.
8. When replacing fasteners, make sure the new fasteners are the same size and strength as the
original ones.
9. Keep the work area clean and organized.
10. Wear eye protection anytime the safety of the eyes is in question. This includes procedures that
involve drilling, grinding, hammering, compressed air and chemicals.
11. Wear the correct clothing for the job. Tie up or cover long hair so it does not get caught in moving
equipment.
12. Do not carry sharp tools in clothing pockets.
13. Always have an approved fire extinguisher available. Make sure it is rated for gasoline (Class B)
and electrical (Class C) fires.
14. Do not use compressed air to clean clothes, the UTV or the work area. Debris may be blown into
the eyes or skin. Never direct compressed air at anyone. Do not allow children to use or play with
any compressed air equipment.
15. When using compressed air to dry rotating parts, hold the part so it does not rotate. Do not allow
the force of the air to spin the part. The air jet is capable of rotating parts at extreme speed. The
part may disintegrate of become damaged, causing serious injury.
16. Do not inhale the dust created by brake pad and clutch wear. These particles may contain
asbestos. In addition, some types of insulating materials and gaskets may contain asbestos.
Inhaling asbestos particles is hazardous to one’s health.
17. Never work on the UTV while someone is working under it.

Handling Gasoline Safely

Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop.
Because gasoline is used so often, many people forget it is hazardous. Only use gasoline as fuel
for gasoline internal combustion engines. Keep in mind when working on the machine, gasoline is
always present in the fuel tank fuel line throttle. To avoid a disastrous accident when working
around the fuel system, carefully observe the following precautions:
1. Never use gasoline to clean parts. Refer to Cleaning Parts in this section.
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 GENERAL INFORMATION
2. When working of the fuel system, work outside or in a well-ventilated area.
3. Do not add fuel to the fuel tank or service the fuel system while the UTV is near open flames,
sparks or where someone is smoking .Gasoline vapor is heavier than air, it collects in low areas
and is more easily ignited than liquid gasoline.
4. Allow the engine to cool completely before working on any fuel system component.
5. Do not store gasoline in glass containers. If the glass breaks, a serious explosion of fire may
occur.
6. Immediately wipe up spilled gasoline with rags. Store the rags in a metal container with a lid until
they can be properly disposed of, or place them outside in a safe place for the fuel to evaporate.
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 which are dedicated to extinguish the gasoline fire.
8. Always turn off the engine before refueling. Do not spill fuel onto the engine or exhaust system.
Do not overfill the fuel tank. Leave an air space at the top of the tank to allow room for the fuel to
expand due to temperature fluctuations.

Cleaning Parts
Cleaning parts is one of the more tedious and difficult service jobs performed in the home garage.
Many types of chemical cleaners and solvents are available for shop use. Most are poisonous and
extremely flammable. To prevent chemical exposure, vapor buildup, fire and serious injury, observe
each product warning label and note the following:
1. Read and observe the entire product label before using any chemical. Always know what type of
chemical is being used and whether it is poisonous and/or flammable.
2. Do not use more than one type of cleaning solvent at a time. If mixing chemicals is required,
measure the proper amounts according to the manufacturer.
3. Work in a well-ventilated area.
4. Wear chemical-resistant gloves.
5. Wear safety glasses.
6. Wear a vapor respirator if the instructions call for it.
7. Wash hands and arms thoroughly after cleaning parts.
8. Keep chemical products away from children and pets.
9. Thoroughly clean all oil, grease and cleaner residue from any part that must be heated.
10. Use a nylon brush when cleaning parts. Metal brushes may cause a spark.
11. When using a parts washer, only use the solvent recommended by the manufacturer. Make sure
the parts washer is equipped with a metal lid that will lower in case of fire.

Warning Labels
Most manufacturers attach information and warning labels to the UTV. These labels contain
instructions that are important to personal safety when operating, servicing, transporting and storing
the UTV. Refer to the owner’s manual for the description and location of labels. Order replacement
labels from the dealers or manufacturer if they are missing or damaged.

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 GENERAL INFORMATION
SERIAL NUMBERS
Serial and identification numbers are stamped on various locations on the frame engine throttle
body. Record these numbers in the Quick Reference Data section in the front of the manual. Have
these numbers available when ordering parts.

FASTENERS
Proper fastener selection and installation is important to ensure the motorcycle operates as
designed and can be serviced efficiently. The choice of original equipment fasteners is not arrived at
by chance. Make sure replacement fasteners meet all the same requirements as the originals
Many screws. Bolts and studs are combined with nuts to secure particular components. to indicate
the size of a nut. Manufactures specify the internal diameter and the thread pitch
The measurement across two flats on a nut or bolt indicates the wrench size

WARNING
Do not install fasteners with a strength
classification lower than what was originally
installed by the manufacturer doing so may cause
equipment failure and or damage

Torque Specifications
The material used in the manufacturing of the UTV may be subjected to uneven stresses if the
fasteners of the various subassemblies are not installed and tightened correctly. Fasteners that are
improperly installed or work loose can cause extensive damage. it is essential to use an accurate
torque wrench as described in this chapter

Self-Locking Fasteners
Several types of bolts. Screws and nuts incorporate a system that creates interference between
the two fasteners. Interference is achieved in various ways. The most common types are the nylon
insert nut and a dry adhesive coating on the threads of a blot.
Self-locking fasteners offer greater holding strength than standard fasteners, which improves their
resistance to vibration. All self-locking fasteners cannot be reused. The materials used to from the lock
become distorted after the initial installation and removal. Discard and replace self-locking fasteners
after removing them. Do not replace self-locking fasteners with standard fasteners.

Washers
The two basic types of washers are flat washers and lock washers. Flat washers are simple discs
with a hole to fit a screw or bolt. Lock washers are used to prevent a fastener from working loose.
Washers can be used as spacers and seals. Or can help distribute fastener load and prevent the
fastener from damaging the component
As with fasteners. When replacing washers make sure the replacement washers are of the same
design and quality

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 GENERAL INFORMATION
Cotter Pins
A cotter pin is a split metal pin inserted into a hole or slot to prevent a fastener from loosening. In
certain applications, such as the rear axle on an UTV 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, first make sure the diameter is correct for the hole in the fastener. Aster
correctly tightening the fastener and aligning the holes, insert the cotter pin through the hole and bend
the ends over the fastener, Unless instructed to do so, never loosen a tightened fastener to align the
holes. If the holes do not align. Tighten the fastener enough to achieve alignment
Cotter pins are available in various diameters and lengths. Measure the length from the bottom of
the head to the tip of the shortest pin

Snap Rings and E-clips

Snap rings (Figure 1) are circular-shaped metal
retaining clips. They secure parts in place on parts
such as shafts. External type snap rings are used to
retain items on shafts. Internal type snap rings secure
parts within housing bores. In some applications. in
addition to securing the component(s). snap rings of
varying thicknesses also determine endplay. These
are usually called selective snap rings.
The two basic types of snap rings are machined
and stamped snap rings. Machined snap rings (Figure
2) can be installed in either direction. Because both
faces have sharp edges. Stamped snap rings (Figure
3) are manufactured with a sharp and a round edge.
When installing a stamped snap ring in a thrust
application, install the sharp edge facing away from
the part producing the thrust.
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-clip. To
install an E-clip. Center it over the shaft groove and
push or tap it into place
Observe the following when installing snap rings:
1. Remove and install snap rings with snap rings
pliers. Refer to Basic Tools in this chapter
2. In some applications. it may be necessary to
replace snap rings after removing them
3. Compress or expand snap rings only enough to
install them. If overly expanded. Lose their
retaining ability
4. After installing a snap ring. Make sure it seats completely
5. Wear eye protection when removing and installing snap rings

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 GENERAL INFORMATION
SHOP SIPPLIES
Lubricants and Fluids
Periodic lubrication help ensure a long service life for any type of equipment. Using the correct
type of lubricant is as important as performing the lubrication service. Although in an emergency the
wrong type is better than not using one, The following section describes the types of lubricants most
often required. Make sure to follow the manufacturer’s recommendations for lubricant types

Engine oils
Engine oil for four-stroke the UTV engine use is classified by two standards: the American
Petroleum Institute (API) service classification. The Society of Automotive Engineers (SAE) viscosity
rating Standard classification
The API and SAE information is on all oil container labels. Two letters indicate the API service
classification. The number or sequence of numbers and letter (10W-40SG for example) is the oil’s
viscosity rating. The API service classification and the SAE viscosity index are not indications of oil
quality.
The APL service classification standards, The first letter in the classification S indicates that the oil
is for gasoline engines. The second letter indicates the standard the oil satisfies .
The classifications are: MA (high friction applications) and MB( low frication applications).

NOTE
Refer to Engine Oil and Filter in
Chapter Three for further information
on API, SAE classifications.

Always use an oil with a classification recommended by the manufacturer, Using an oil with a
different classification can cause engine damage.
Viscosity is an indication of the oil’s thickness. Thin oils have a lower number while thick oil have a
higher number. Engine oils fall into the 5-to50-weight range for single-grade oils.
Most manufactures recommend multi-grade oil. These oils perform efficiently across a wide
range of operating conditions. Multi-grade oils are identified by a W after the 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 engine oil, follow the manufacturer’s recommendation for
type, classification and viscosity.

Greases
Grease is lubricating oil with thickening agents added to it. The National Lubricating Grease
Institute (NLGI) grades grease. Grades range from No.000 to No.6, with No.6 being the thickest.
Typical multipurpose grease is NLGI No.2. For specific applications, manufacturers may recommend
water-resistant type grease or one with an additive such as molybdenum disulfide (MoS2).

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 GENERAL INFORMATION
Brake fluid
Brake fluid is the hydraulic fluid used to transmit hydraulic pressure (force) to the wheel brakes.
Brake fluid is classified by the Department of Transportation (DOT). Current designations for brake
fluid are DOT 3, DOT 4 and DOT 5, this classification appears on the fluid container.
Each type of brake fluid has its own definite characteristics. Do not intermix different types of brake
fluid as this may cause brake system failure. DOT 5 brake fluid is silicone based. DOT 5 is not
compatible with other brake fluids may cause brake system failure. When adding brake fluid, only use
the fluid recommended by the manufacturer.
Brake fluid will damage any plastic, painted or plated surface it contacts. Use extreme care when
working with brake fluid and remove any spills immediately with soap and water.
Hydraulic brake systems require clean and moisture free brake fluid. Never reuse brake fluid.
Keep containers and reservoirs properly sealed.

WARNING
Never put a mineral-based (Petroleum) oil into the
brake system. Mineral oil causes rubber parts in
the system to causing complete brake failure.

Coolant
Coolant is a mixture of water and antifreeze used to dissipate engine heat. Ethylene glycol is the
most common from of antifreeze. Check the UTV Manufacturer’s recommendations when selecting
antifreeze. Most require one specifically designed for aluminum engines. There types of antifreeze
have additives that inhibit corrosion.
Only mix antifreeze with distilled water. Impurities in tap water may damage internal cooling
system passages.

Cleaners, Degreasers and Solvents

Many chemicals are available to remove oil, grease and other residue from the UTV. Before using
cleaning solvents, consider how they will be used and disposed of , particularly if they are not
water-soluble. Local ordinances may types of cleaning chemicals. Refer to Safer in this chapter.
Use brake parts cleaner to brake system components. Brake parts cleaner leaves no residue. Use
electrical contact cleaner is a powerful solvent used to remove fuel deposits and varnish from fuel
system components. Use this cleaner carefully, as it may damage finishes.
Most solvents are designed to be used with a parts washing cabinet for individual component
cleaning. For safety, use only nonflammable or high flash point solvents.

Gasket Sealant
Sealant is used in combination with a gasket or seal. In other applications, such as between
crankcase halves, only a sealant is used. Follow the manufacturer’s recommendation when using a
sealant. Use extreme care when choosing a sealant different sealant based on its resistance to heat,
various fluids and its sealing capabilities.

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 GENERAL INFORMATION
Gasket Remover
Aerosol gaskets remover can help remove stubborn gasket. This product can speed up the
removal process and prevent damage to the mating surface that may be caused by using a scraping
tool. Most of these types of products are very caustic. Follow the gasket remover manufacturer’s
instructions for use.

Thread locking Compound

A thread locking compound is a fluid applied to the threads of fasteners. After tightening the
fastener, the fluid dries and becomes a solid filler between the threads. This makes it difficult for the
fastener to work loose from vibration or hear expansion and contraction. Some thread locking
compound sparingly. Excess fluid can run into adjoining parts.

CAUTION
Thread locking compounds are anaerobic and will
stress, crack and attack most plastics. Use caution
when using these products in areas where there are
plastic components.

Thread locking compounds are available in a wide range of compounds for various strength,
temperature and repair applications. Follow the manufacturer’s recommendations regarding
compound selection.

BASIC TOOLS
Most of the procedures in this manual can be carried out with basic hand tools and test equipment
familiar to the home mechanic. Always use the correct tools for the job. Keep tools organized and
clean. Store them in a tool chest with related tools organized together.
Quality tools are essential. The best are constructed of high-strength alloy steel. These tools are
light, easy to use and resistant to wear. Their working surface is devoid of sharp edges and carefully
polished. They have an easy-to-clean finish and are comfortable 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 replacement. However, in some cases, the
specialized equipment or expertise may make it impractical for the home mechanic to attempt the
procedure. When necessary, such operations are recommended to have a dealership or specialist
perform the task. It may be less expensive to have a professional perform these jobs, especially when
considering the cost of equipment.
When purchasing tools to perform the procedures covered in this manual, consider the tool’s
potential frequency of use. If a tool kit is just now being started. Consider purchasing a basic tool set
from a quality tool combinations and offer substantial savings when complicated, specialized tools can
be added.

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 GENERAL INFORMATION
Screwdrivers
Screwdrivers of various lengths and types are mandatory for the simplest tool kit. The two basic
types are the slotted tip (flat blade) and the Phillips tip. These are available in sets that often include an
assortment of tip size and shaft lengths.
As with all tools, use a screwdriver designed for the job. Make sure the size of the fastener. Use
them only for driving screws. Never use a screwdriver for
prying or chiseling metal. Repair or replace worn or
damaged screwdrivers. A worn tip may damage the
fastener, making it difficult to remove.
Phillips-head screws are often damaged by
incorrectly fitting screwdrivers. Quality Phillips
screwdrivers are manufactured with their crosshead tip
machined to Phillips Screw Company specifications.
Poor quality or damaged Phillips screwdrivers can back
out (cam out) and round over the screw head. In addition.
Weak or soft screw materials can make removal difficult.
The best type of screwdriver to use on Phillips
screw is the ACR Phillips II screwdriver, patented by the
horizontal anti-cam out ribs found on the driving faces or
flutes of the screwdriver’s tip (figure 4). ACR Phillips II
screwdrivers were designed as part of a manufacturing
drive system to be used with ACR Phillips II screws, but
they work of tool companies offer ACR Phillips II
screwdrivers in different Tip size and interchangeable
bits to fit screwdriver bit holders.

NOTE
Another way to prevent cam out and to increase
the grip of a Phillips screwdriver is to apply valve
grinding compound or permute screw ＆ socket
Gripper onto the screwdriver tip.After
loosening/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 number stamped on the wrench refers to the distance of the fastener head.
The box-end wrench is an excellent tool because it grips the fastener on all sides. This reduces
the chance of the tool slipping. The box-end wrench is designed with either a 6 or 12-point opening.
For stubborn or damaged fasteners, the 6-point provides superior holding because it contacts the
fastener across a wider area at all six edges. For general use, the 12-point works well. It allows the
wrench to be removed and reinstalled without moving the handle over such a wide are.

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 GENERAL INFORMATION
An open-end wrench is fast and works best in areas
with limited overhead access. It contacts the fastener at
only two points and is subject to slipping if under heavy
force, or if the tool or fastener is worn. A box-end wrench
is preferred in most instances, especially when braking
loose and applying the final tightness to a fastener.
The combination wrench has a box-end on one end
and an open-end on one end and an open-end on the
other. This combination makes it a convenient tool.

Adjustable wrenches
An adjustable wrench or Crescent wrench (Figure 6)
can fit nearly any nut or bolt head that has clear access
around its entire perimeter. An adjustable wrench is best
used as a backup wrench to keep a large nut or bolt from
turning while the other end is being loosened or
tightened with a box-end or socket wrench.
Adjustable wrenches contact the fastener at only
two points, which makes them more subject to slipping
off the fastener. Because one jaw is adjustable and may
become loose, this shortcoming is aggravated. Make
certain the solid jaw is the one transmitting the force.

Socket 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 of the square hole that accepts the ratchet handle.
The number stamped on the socket is the size of the
work area and must the fastener head
As with wrenches. a 6-point provides
superior-holding ability. While a 12-point socket needs to
be moved only half as for to reposition it on the fastener
Sockets are designated for either hand or impact use.
Impact sockets are made of thicker material for more
durability. Compare the size and wall thickness of a
19-mmhand socket (A, Figure 9) and the 19-mm impact
socket (B). Use impact sockets when using an impact
driver or air tools. Use hand sockets with hand-driven
attachments

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 GENERAL INFORMATION

WARNING
Do not use hand sockets with air or impact
tools because they may shatter and cause
injury. Always wear eye protection when
using impact or air tools

Various handles are available for sockets. Use the

speed handle for fast operation. Flexible ratchet heads in
varying length allow the socket to be turned with varying
force and at odd angles. Extension bars allow the socket
setup to reach difficult areas. The ratchet is the most
versatile. It allows the user to install or remove the nut without removing the socket
Sockets combined with any number of drivers make them undoubtedly the fastest. Safest and
most convenient tool for fastener removal and installation

Impact Drivers
An impact driver provides extra force for removing fasteners by converting the impact of a
hammer into a turning motion. This makes it possible to remove stubborn fasteners without damaging
them. Impact drivers and interchangeable bits (Figure 10) are available from most tool suppliers.
When using a socket with an impact driver. Make sure the socket is designed for impact use. Refer to
Socket Wrenches. Ratchets and handles in this section.

WARNING
Do not use hand sockets with air or
impact tools because they may shatter
and cause injury. Always wear eye
protection when using impact or air tools

Allen Wrenches
Use Allen or setscrew wrenches (Figure 11) on
fasteners with hexagonal recesses in the fastener
head. These wrenches are available in L-shaped bar.
Socket and T-handle types. A metric set is required
when working on most motorcycles. Allen bolts are
sometimes called socket bolts.

Torque Wrenches
Use a torque wrench with a socket, torque adapter or similar extension to tighten a fastener to a
measured torque. Torque wrenches come in several drive sizes (1/4, 3/8, 1/2 and 3/4) and have
various methods of reading the torque value. The drive size indicates the size of the square drive that

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 GENERAL INFORMATION
accepts the socket, adapter or extension. Common
methods of reading the torque value are the deflecting
beam, the dial indicator and the audible click (Figure
12).
When choosing a torque wrench, consider the
torque range, drive size and accuracy. The torque
specifications in this manual provide an indication of the
range required.
A torque wrench is a precision tool that must be
properly cared for to remain accurate. Store torque
wrenches in cases or separate padded drawers within a toolbox. Please refer to the followed
manufacturer’s instructions for their care and calibration.

Torque Adapters
Torque adapters or extensions
extend or reduce the reach of a
torque wrench. The torque adapter
shown in (Figure 13) is used to
tighten a fastener that cannot be
reached because of the size of the
torque wrench head, drive, and
socket. If a torque adapter changes
the effective lever length (Figure
14), the torque reading on the
wrench will not equal the actual
torque applied to the fastener. It is
necessary to recalibrate the torque
setting on the wrench to
compensate for the change of lever
length. When using a torque
adapter at a right angle to the drive
head, calibration is not required,
because the effective length has not
changed.
To recalculate a torque reading
when using a torque adapter, use
the following formula and refer to Figure 14:
TW = TA×L
L+A
TW is the torque setting or dial reading on the wrench.
TA is the torque specification and the actual amount of torque that is applied to the fastener.
A is the amount that the adapter increases (or in some cases reduces) the effective lever length as
measured along the centerline of the torque wrench.
L is the lever length of the wrench as measured from the center of the drive to the center of the grip.

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 GENERAL INFORMATION
The effective length is the sum of L and A.
Example:

TA=20 ft.-lb.
A=3in.
L=14in.
TW=20×14=280=16.5 ft. - lb.
14+3 = 17
In this example, the torque wrench would be set
to the recalculated torque value (TW = 16.5 ft. –lb.).
When using a beam-type wrench, tighten the fastener
until the pointer aligns with 16.5 ft. –lb. In this example,
although the torque wrench is pre set to 16.5 ft. –lb., the actual torque is 20 ft. –lb.

Pliers
Pliers come in a wide range of types and sizes.
Pliers are useful for holding, cutting, bending, and
crimping. Do not use them to turn fasteners. Figure 15
and Figure 16 show several types of useful pliers.
Each design has a specialized function. Slip-joint
pliers are general – purpose pliers used for gripping
and bending. Diagonal cutting pliers are needed to cut
wire and can be used to remove cotter pins. Use
needle nose pliers to hold or bend small objects.
Locking pliers (Figure 16), sometimes called Vise-
Grips, are used to hold objects very tightly. They have
many uses ranging 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 specialized pliers with tips that
fit into the ends of snap rings to remove and install them.
Snap ring pliers (Figure 17) are available with a fixed action (either internal or external ) or
convertible (one tool works on both internal and external snap rings). They may have fixed tips or
interchangeable ones of various sizes and angles. For general use, select a convertible type pliers
with interchangeable tips (Figure 17).

WARNING
Snap rings can slip and fly off when removing and
installing them. Also, the snap ring pliers tips may break.
- 16 -
 GENERAL INFORMATION
Always wear eye protection when using snap ring pliers.

Hammers
Various types of hammers are available to fit a number of applications. Use a ball-peen hammer to
strike another tool, such as a punch or chisel. Use soft-faced hammers when a metal object must be
struck without damaging it. Never use a metal-faced hammer on engine and suspension components
because damage occurs in most cases.
Always wear eye protection when using hammers. Make sure the hammer face is in good
condition and the handle is not cracked. Select the correct hammer for the job and make sure to strike
the object squarely. Do not use the handle or the side of the hammer to strike an object.

Ignition Grounding Tool

Some test procedures require turning the engine
over without starting it. To prevent damage to the
ignition system from excessive resistance or the
possibility of fuel vapor being ignited by an open spark,
remove the spark plug cap and ground it directly to a
good engine ground with the tool shown in (Figure
18).
Make the tool shown from a No.6 screw and nut,
two washers, length of tubing, alligator clip, electrical eyelet and a length of wire.

PRECISION 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 consistently
accurate measurements is essential to determine which components require replacement or further
service.
Each type of measuring instrument is designed to measure a dimension with a certain degree of
accuracy and within a certain range. When selecting the measuring tool, make sure it is applicable to
the task.
As with all tools, measuring tools provide the best results if cared for properly. Improper use can
damage the tool and cause inaccurate results. If any measurement is questionable, verify the
measurement using another tool. A standard gauge is usually provided with micrometers to check
accuracy and calibrate the tool if necessary.
Precision measurements can vary according to the experience of the person performing the
procedure. Accurate results are only possible if the mechanic possesses a feel for using the tool.
Heavy-handed use of measuring tools produces less accurate results. Hold the tool gently by the
fingertips to easily feel the point at which the tool contacts the object. This feel for the equipment
produces more accurate measurements and reduces the risk of damaging the tool or component.
Refer to the following sections for specific measuring tools.

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 GENERAL INFORMATION
Feeler Gauge
Use feeler or thickness gauges (Figure19) for measuring the distance between two surfaces.
A feeler gauge set consists of an assortment of
steel strips of graduated thickness. Each blade is
marked with its thickness. Blades can be of various
lengths and angles for different procedures.
A common use for a feeler gauge is to measure
valve clearance. Use wire (round) type gauges to
measure spark plug gap.

Calipers
Calipers (Figure 20) are excellent tools for
obtaining inside, outside and depth measurements.
Although not as precise as a micrometer, they allow
reasonable precision, typically to within 0.02mm or
0.05 mm (0.001 in.). Most calipers have a range up to
150 mm (6 in.).
Calipers are available in dial, venire or digital
versions. Dial calipers have a dial readout that
provides convenient reading. Venire 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 the measuring surfaces of the caliper. There must not be any dirt or burrs
between the tool and the object being measured. Never force the caliper to close around an object.
Close the caliper around the highest point so it can be removed with a slight drag. Some calipers
require calibration. Always refer to the manufacturer’s instructions when using a new or unfamiliar
caliper.
To read a vernire. Calipers refer to Figure 21. The
fixed scale is marked in l-mm increments. Ten
individual lines on the fixed scale equal 1 cm. The
movable scale is marked in 0.05 mm (hundredth)
increments. To obtain a reading, establish the first
number by the location of the 0 line on the movable
scale in relation to the first line to the left on the fixed
scale. In this example, the number is 10 mm. To
determine the next number, note which of the lines on
the movable scale align with a mark on the fixed scale.
A number of lines will seem close, but only one will align exactly. In this case, 0.50 mm is the reading to
add to the first number. Adding 10 mm and 0.50 mm equals a measurement of 10.50 mm.

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 GENERAL INFORMATION
Micrometers
A micrometer is an instrument designed for linear measurement using the decimal divisions of
the inch or meter (Figure 22). While there are many types and styles of micrometers, most of the

DECIMAL PLACE VALUES*

0.1 Indicates 1/10 (one tenth of an inch or
millimeter)
0.01 Indicates 1/100 (one one-hundredth of
an inch or millimeter)
0.001 Indicates 1/1000 (one one-thousandth
of an inch or millimeter)
*This chart represents the values of figures placed to the right of the decimal point. Use
it when reading decimals from one-tenth to one one-thousandth of an inch or millimeter.
It is not a conversion chart (for example: 0.001 in. is not equal to 0.001 mm).

procedures in this manual call for an outside

micrometer. Use the outside micrometer to measure
the outside diameter of cylindrical forms and the
thickness of materials.
A micrometer’s size indicates the minimum and
maximum size of 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 75-100 mm
(3-4 in.).
Micrometers that cover a wider range of
measurements are available. These use a large frame with interchangeable anvils of various lengths.
This type of micrometer offers a cost savings, but its overall size may make it less convenient.
When reading a micrometer, numbers are taken from different scales and added together. The
following sections describe how to adjust, care for and read the measurements of various types of
outside micrometers.
For accurate results, properly maintain the measuring surfaces of the micrometer. There cannot
be any dirt or burrs between the tool and the measured object. Never force the micrometer to close
around an object. Close the micrometer around the highest point so it can be removed with a slight
drag.

Adjustment
Before using a micrometer, check its adjustment as follows:
1. Clean the anvil and spindle faces.
2A. To check a 0-1 in. or 0-25 mm micrometer:
a. Turn the thimble until the spindle contacts the anvil. If the micrometer has a ratchet stop, use it to
ensure that the proper amount of pressure is applied.

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 GENERAL INFORMATION
b. If the adjustment is correct, the 0 mark on the thimble will align exactly with the 0 mark on the
sleeve line. If the marks do not align, the micrometer is out of adjustment.
c. Follow the manufacturer’s instructions to adjust the micrometer.
2B. To check a micrometer larger than 1 in. or 25 mm use the standard gauge supplied by the
manufacturer. A standard gauge is a steel block, disc or rod that is machined to an exact size.
a. Place the standard gauge between the spindle and anvil, and measure its outside diameter or
length. If the micrometer has a ratchet stop, use it to ensure that the proper amount of pressure is
applied.
b. If the adjustment is correct, the 0 mark on the thimble will align exactly with the 0 mark on the
sleeve line. If the marks do not align, the micrometer is out of adjustment.
c. Follow the manufacturer’s instructions to adjust the micrometer.

Care
Micrometers are precision instruments. They must be
used and maintained with great care. Note the following:
1. Store micrometers in protective cases or separate
padded drawers in a tool box.
2. When in storage, make sure the spindle and anvil faces
do not contact each other or another object. If they do,
temperature changes and corrosion may damage the
contact faces.
3. Do not clean a micrometer with compressed air. Dirt
forced into the tool will cause wear.
4. Lubricate micrometers with WD-40 to prevent corrosion.

Metric micrometer
The standard metric micrometer (Figure 24) is
accurate to one one-hundredth of a millimeter (0.01 mm).
The sleeve line is graduated in millimeter and half
millimeter increments. The marks on the upper half of the
sleeve line equal 1.00 mm. Each fifth mark above the
sleeve line is identified with a number. The number
sequence depends on the size of the micrometer. A 0-25
mm micrometer, for example, will have sleeve marks
numbered 0 through 25 in 5 mm increments. This
numbering sequence continues with larger micrometers.
On all metric micrometers, each mark on the lower half of
the sleeve equals 0.50 mm.
The tapered end of the thimble has 50 lines marked
around it. Each mark equals 0.01 mm. One completer turn
of the thimble aligns its 0 mark with the first line lower half of the sleeve line or 0.50mm.
When reading a metric micrometer, add the number of millimeters and half-millimeters on the
sleeve line to the number of one one-hundredth millimeters on the thimble. Perform the following steps
- 20 -
 GENERAL INFORMATION
while referring to Figure 25.
1. Read the upper half of the sleeve line and count the number of lines visible. Each upper line
equals 1mm.
2. See if the half –millimeter line is visible on the
lower sleeve line. If so, add 0.50mm to the reading
in Step 1.
3. Read the thimble mark that aligns with the sleeve
line. Each thimble mark equals 0.01mm.

NOTE
If a thimble mark does not align exactly
with the sleeve line. Estimate the amount
between the lines. For accurate readings in
two-thousandths of a millimeter (0.002mm), use a metric
vernier micrometer.

4. 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. The
sleeve is marked in 0.025 in. increments. Every fourth
sleeve mark is numbered 1,2,3,4,5,6,7,8,9. These
numbers indicate 0.100, 0.200, 0.300, and so on.
The tapered end of the thimble has 25 lines marked
around it. Each mark equals 0.001 in. One complete turn
of the thimble will align its zero mark with the first mark
on the sleeve or 0.025 in.
To read a standard inch micrometer, perform the
following steps and refer to Figure 27.
1. Read the sleeve and find the largest number
visible. Each sleeve number equals 0.100 in.
2. Count the number of lines between the numbered
sleeve mark and the edge of the thimble. Each
sleeve mark equals 0.025 in.
3. Read the thimble mark that aligns with the sleeve
line. Each thimble mark equals 0.01 in.

NOTE
If a thimble mark does not align exactly with the sleeve line, estimate the
amount between the lines. For accurate readings in ten-thousandths of an
inch (0.0001 in), use a vernier inch micrometer.
4. Add the readings from Steps 1-3.

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 GENERAL INFORMATION
Telescoping and Small Bore Gauges
Use telescoping gauges (Figure 28) and small
bore gauges (Figure 29) to measure bores. Neither
gauge has a scale for direct readings. Use an outside
micrometer to determine the reading.
To use a telescoping gauge, select the correct
size gauge for the bore. Compress the movable post
and. Care fully 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 gauge and
measure the length of the posts. Telescoping gauges
are typically used to measure cylinder bores.
To use a small bore gauge, select the correct size
gauge for the bore. Carefully insert the gauge into the
bore. Tighten the knurled end of the gauge to carefully
expand the gauge fingers to the limit within the bore.
Do not over tighten the gauge because there is no
built-in release. Excessive tightening can damage the
bore surface and damage the tool. Remove the gauge
and measure the outside dimension (Figure 30).
Small bore gauges are typically used to measure valve guides.

Dial Indicator:
A dial indicator (Figure 31) is a gauge with a dial
face and needle used to measure variations in
dimensions and movements. Measuring brake rotor
runout is a typical use for a dial indicator.
Dial indicators are available in various ranges and
graduations and with three basic types of mounting
bases: magnetic (B. Figure 31). Clamp, or screw-in
stud. When purchasing a dial indicator, select on with
a continuous dial (A, Figure 31).
Cylinder Bore Gauge
A cylinder bore gauge is similar to a dial indicator.
The gauge set shown in Figure 32 consists of a dial
indicator, handle, and different length adapters (anvils)
to fit the gauge to various bore sizes. The bore gauge
is used to measure bore size, taper and out-of-round.
When using a bore gauge, follow the manufacturer’s
instructions.

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 GENERAL INFORMATION
Compression Gauge
A compression gauge (Figure 33) measures combustion chamber (cylinder) pressure, usually in
PSI or kg/ cm2 . The gauge adapter is either inserted or screwed into the spark plug hole to obtain the
reading. Disable the engine so it does not start and hold the throttle in the wide-open position when
performing a compression test An engine that does
not have adequate compression cannot be properly
tuned. Refer to Chapter Three.

Multimeter
A multimeter (Figure 34) is an essential tool for
electrical system diagnosis. The voltage function
indicates the voltage applied or available to various
electrical components. The ohmmeter function tests
circuits for continuity, or lack of continuity, and measures the resistance of a circuit.
Some manufacturer’s specifications for electrical components are based on results using a specific
test meter. Results may vary if using a meter not recommended by the manufacturer. Such
requirements are noted when applicable.
Ohmmeter (analog) calibration
Each time an analog ohmmeter is used or if the
scale is changed, the ohmmeter must be calibrated.
Digital ohmmeters do not require calibration.
1. Make sure the meter battery is in good condition.
2. Make sure the meter probes are in good condition.
3. Touch the two probes together and observe the
needle location on the ohms scale. The needle
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.

Clip-on ammeter
1. Clip-on ammeter (Figure 35) is the basic tool for
electrical system diagnosis which is used to
measure the current of charging system and other
electrical components work current.
2. Clip-on ammeter can measure direct current and
alternating current. Please ensure that the
instrument battery capacity is sufficient when
work.
3. When measure the current, the calliper must
seize the positive pole of the power. If seize the
negative pole mistakenly, wrong result will appear.

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 GENERAL INFORMATION
Magneto puller
Magneto drawing (figure 36) is special tool to dismantle magneto rotor . firstly put the mandril into th
e inside of shaft hole ,Turn the magneto rotor accordingly, screw magneto drawing and push-out ma
gneto rotor

ELECTRICAL SYSTEM FUNDAMENTALS

A thorough study of the many types of electrical systems used in today’s motorcycles is beyond
the scope of this manual. However, a basic understanding of electrical basics is necessary to perform
simple diagnostic tests.
Refer to Electrical Testing in Chapter Two for typical test procedures and equipment. Refer to
Chapter Ten for specific system test procedures.

Voltage
Voltage is the electrical potential or pressure in an electrical circuit and is expressed in volts. The
more pressure (voltage) in a circuit the more work can be performed.
Direct current (DC) voltage means the electricity flows in one direction. All circuits powered by a
battery are DC circuits.
Alternating current (AC) means the electricity flows in one direction momentarily and then
switches to the opposite direction. Alternator output is an example of AC voltage. This voltage must be
changed or rectified to direct current to operate in a battery powered system.

Resistance
Resistance is the opposition to the flow of electricity within a circuit or component and is
measured in ohms. Resistance causes a reduction in available current and voltage
Resistance is measured in an inactive circuit with an ohmmeter. The ohmmeter sends a small
amount of current into the circuit and measures how difficult it is to push the current through the circuit.
An ohmmeter, although useful, is not always a good indicator of a circuit’s actual ability under
operating conditions. This is because of the low voltage (6-9 volts) the meter uses to test the circuit.
The voltage in an ignition coil secondary winding can be several thousand volts. Such high voltage can
cause the coil to malfunction, even though it tests acceptable during a resistance test.
Resistance generally. Increases with temperature. Perform all testing with the component or
circuit at room temperature. Resistance tests performed at high temperatures may indicate high
resistance readings and cause unnecessary replacement of a component.

Amperage
Amperage is the unit of measurement for the 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 or component capacity, it will damage the system.

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 GENERAL INFORMATION

Warning
If the current insulation damage, may cause short circuit fault which lead to short circuit or large
current in components. It may cause a fire.
Thus, if the current of circuit or components measured by amperage exceeds the standard level,
must check and repair electrical system at once.

BASIC SERVICE METHODS

Most of the procedures in this manual are straightforward and can be performed by anyone
reasonably competent with tools. However, consider personal capabilities carefully before attempting
any operation involving major disassembly.
1. Front, in this manual, riders to the front of the UTV, The front of any component is the end closest
to the front the UTV. The left and right sides refer to the position of the parts as viewed by the rider
sitting on the seat facing forward.
2. Whenever servicing an engine or suspension component, secure the UTV in a safe manner.
3. Tag all similar parts for location and mark all mating parts for position. Record the number and
thickness of any shims when removing them. Identify parts by placing them in sealed and labeled
plastic sandwich bags.
4. Tag disconnected wires and connectors with masking tape and a marking pen. Do not rely on
memory alone.
5. Protect finished surfaces from physical damage or corrosion. Keep gasoline and other chemicals
off painted surfaces.
6. Use penetrating oil on frozen or tight bolts. Avoid using heat where possible. Heat can warp, melt
or affect the temper of parts. Heat also damages the finish of paint and plastics.
7. When a part is a press fit or requires a special tool to remove, the information or type of tool is
identified in the text. Otherwise, if a part is difficult to remove or install, determine the cause before
proceeding.
8. To prevent objects or debris from falling into the engine, cover all openings.
9. Read each procedure thoroughly and compare the illustrations to the actual components before
starting the procedure. Perform the procedure in
10. Recommendations are occasionally made to refer service to a dealership or specialist. In these
cases, the work can be performed more economically by the specialist than by the home
mechanic.
11. The term replaces means to discard a defective part and replace it with a new part. Overhaul
means to remove, disassemble, inspect, measure, repair and/or replace parts as required to
recondition an assembly.
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 may damage the motorcycle.
13. Repairs are much faster and easier if the UTV is clean before starting work. Degrease the
motorcycle with a commercial degreaser; follow the directions on the container for the best results.
Clean all parts with cleaning solvent when removing them.

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 GENERAL INFORMATION
CAUTION
Do not direct high-pressure water at steering
bearings, fuel hoses, wheel bearings,
suspension and electrical components.
Water may force grease out of the bearings
and possibly damage the seals

14. If special tools are required, have them available before starting the procedure. When special
tools are required, they are described at the beginning of the procedure.
15. Make diagrams of similar-appearing parts. For instance, crankcase bolts are often not the same
lengths. Do not rely on memory alone. Carefully laid out parts can become disturbed, making it
difficult to reassemble the comports correctly.
16. Make sure all shims and washers are reinstalled in the same location and position.
17. Whenever rotating parts contact a stationary part, look for a shim or washer.
18. Use new gaskets if there is any doubt about the condition of old ones.
19. If using self-locking fasteners, replace them with new ones. Do not install standard fasteners in
place of self-locking ones.
20. Use grease to hold small parts in place if they tend to fall out during assembly. Do not apply
grease to electrical or brake components.

Removing Frozen Fasteners

If a fastener cannot be removed, several methods
may be used to loosen it. First, apply a penetrating
fluid. Apply it liberally and let it penetrate for 10-15
minutes. Rap the fastener several times with a small
hammer. Do not hit it hard enough to cause damage.
Reapply the penetrating fluid if necessary.
For frozen screws, apply penetrating fluid as
described, the insert a screwdriver in the slot and rap
the top of the screwdriver with a hammer. This loosens
the rust so the screw can be removed in the normal
way. If the screw head is too damaged to use this
method, grip the head with locking pliers and twist the
screw out.
Avoid applying heat unless specifically instructed.
Heat may melt, warp or remove the temper from parts.

Removing Broken Fasteners

If the head breaks off a screw or bolt, several methods are available for removing the remaining
portion. If a large portion of the remainder projects out, try gripping it with locking pliers. If the
projecting portion is too small, file it to fit a wrench of cut a slot in it to fit a screwdriver (Figure 37)
If the head breaks off flush, use a screw extractor. To do this, center punch the exact center of the

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 GENERAL INFORMATION
remaining portion of the screw or bolt. Drill a small hole in the screw and tap the extractor into the hole.
Back the screw out with a wrench on the extractor (Figure 38)

Repairing Damaged Threads

Occasionally, threads are stripped through
carelessness or impact damage. Often the threads
can be repaired by running a tap (for internal threads
on nuts) or die (for external threads on bolts) through
the threads (Figure 39). To clean or repair spark plug
threads, use a spark plug tap.
If an internal thread is damaged, it may be
necessary to install a Helical or some other type of
thread insert. Follow the manufacturer’s instructions when installing their insert.
If it is necessary to drill and tap a hole, refer to Table 8 for metric tap and drill sizes.

Stud Removal/Installation
A stud removal tool (Figure 40) is available from
most tool suppliers. This tool makes the removal and
installation of studs easier. If one is not available,
thread two must onto the stud and tighten them
against each other. Remove the stud by turning the
lower nut (Figure 41).
1. Measure the height of the stud above the
surface.
2. Thread the stud removal tool onto the stud and
tighten it, or thread two nuts onto the stud.
3. Remove the stud by turning the stud remover
or the lower nut.
4. Remove any thread locking compound from the
threaded hole. Clean the threads with an
aerosol parts cleaner.
5. Install the stud removal tool onto the new stud
or thread two nuts onto the stud.
6. Apply thread locking compound to the threads of the stud.
7. Install the stud and tighten with the stud
removal tool or the top nut.
8. Install the stud to the height noted in Step 1 or
its torque specification.
9. Remove the stud removal tool or the two nuts.

Removing Hoses
When removing stubborn hoses, do not exert
excessive force on the hose or fitting. Remove the

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 GENERAL INFORMATION
hose, do not exert excessive force on the hose or fitting. Remove the hose clamp and carefully insert a
small screwdriver or pick tool between the fitting and hose. Apply a spray lubricant under the hose and
carefully twist the hose off the fitting. Clean 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
(new or old). The lubricant may allow the hose to come off the fitting, even with the clamp secure.

Bearings
Bearings are used in the engine and
transmission assembly to reduce power loss, heat
and noise resulting from friction. Because bearings
are precision parts, they must be maintained with
proper lubrication and maintenance. If a bearing is
damaged, replace it immediately. When installing a
new bearing, take care to prevent damaging it.
Bearing replacement procedures are included in the individual chapters where applicable; however.
Use the following sections as a guideline.

NOTE
Unless otherwise specified, install bearings with the
manufacturer’s mark or number facing outward.

Removal
While bearing are normally removed only when
damaged, there may be times when it is necessary to
remove a bearing that is in good condition. However,
improper bearing removal will damage the bearing and
possibly the shaft or case. Note the following when
removing bearings:
1. When using a puller to remove a bearing from a
shaft, take care that the shaft is not damaged.
Always place a piece of metal between the end
of the shaft and the puller screw. In addition,
place the puller arms next to the inner bearing
race. See Figure 42.
2. When using a hammer to remove a bearing from
a shaft. do not strike the hammer directly against
the shaft. Instead, use a brass or aluminum rod
between the hammer and shaft (Figure 43) and
make sure to support both bearing races with wooden blocks as shown.
3. The ideal method of bearing removal is with a hydraulic press. Note the following when using a
press:
a. Always support the inner and outer bearing races with a suitable size wooden or aluminum
spacer (Figure 44). If only the outer race is supported, pressure applie against the balls

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 GENERAL INFORMATION
and/or the inner race will damage them.
b. Always make sure the press arm (Figure
44) aligns with the center of the shaft. If the
arm is not centered, it may damage the
bearing and/or shaft.
c. The moment the shaft is free of the bearing.
It drops to the floor. Secure or hold the
shaft to prevent it from falling.

Installation
1. When installing a bearing in a housing, apply
pressure to the outer bearing race (Figure 45).
When installing a bearing on a shaft, apply
pressure to the inner bearing race (Figure 46).
2. When installing a bearing as described in Step 1,
some type of driver is required. Never strike the
bearing directly with a hammer or it will damage
the bearing. When installing a bearing, use a
piece of pipe or a driver with a diameter that
matches the bearing inner race. Figure 47 Shows
the correct way to use a driver and hammer to
install a bearing.
3. Step 1 describes how to install a bearing in a
case half or over a shaft However, when installing
a bearing over a shaft and into the housing at the
same time, a tight fit is required for both outer and
inner bearing races. In this situation, install a
spacer underneath the driver tool so that pressure
is applied evenly across both races. See Figure
48. If the outer race is not supported as shown,
the balls will push against the outer bearing race and damage it

Interference fit
1. Follow this procedure when installing a bearing over a shaft. When a tight fit is required, the
bearing inside diameter is smaller than the shaft. In this case. Driving the bearing on the shaft
using normal methods may cause bearing damage. Instead, heat the bearing before installation.
Note the following:
a. Secure the shaft so it is ready for bearing installation.
b. Clean all residues from the bearing surface of the shaft. Remove burrs with a file or
sandpaper.
c. Fill a suitable pot or beaker with clean mineral oil. Place a thermometer rated above
120℃(248°F) in the oil. Support the thermometer so it does not rest on the bottom or side
of the pot.
d. Remove the bearing from its wrapper and secure it with a piece of heavy wire bent to hold it
in the pot. Hang the bearing in the pot so it does not touch the bottom or sides of the pot.

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 GENERAL INFORMATION
e. Turn the heat on and monitor the thermometer. When the oil temperature rises to
approximately 120℃(248°F), remove the bearing from the pot and quickly install it. If
necessary, place a socket on the inner bearing race and tap the bearing into place. As the
bearing chills, it will tighten on the shaft, so install it quickly. Make sure the bearing is
installed completely.
2. Follow this step when installing a bearing in a housing. Bearings are general installed in a housing
with a slight interference fit Driving the bearing into the housing using normal methods may
damage the housing or cause bearing damage. Instead, heat the housing before the bearing is
installed. Note the following:

CAUTION
Before heating the housing in this procedure, wash
the housing thoroughly with detergent and water.
Rinse and rewash the cases as required to remove
all traces of oil and other chemical deposits

a. Heat the housing to approximately 100℃ (212°F) in an oven or on a hot plate. An easy way to
check that it is the proper temperature is to place tiny drops of water on the housing; if they
sizzle and evaporate immediately, the temperature is correct. Heat only one housing at a time.

CAUTION
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 hardening of the bearing and will likely warp
the housing.

b. Remove the housing from the oven or hot plate, and hold onto the housing with welding gloves.
It is hot!

NOTE
Remove and install the bearings with a
suitable size socket and extension.
c. Hold the housing with the bearing side down and tap the bearing out. Repeat for all bearings in
the housing.
d. Before heating the bearing housing, place the new bearing in a freezer if possible. Chilling a
bearing slightly reduces its outside diameter while the heated bearing housing assembly is
slightly larger due to heat expansion. This makes bearing installation easier.

NOTE
Always install bearings with the manufacturer’s
mark or number facing outward.
e. While the housing is still hot. Install the new bearing(s) into the housing. Install the bearings by
hand. if possible. If necessary, lightly tap the bearing(s) into the housing with a driver placed on
the outer bearing race (Figure 45). Do not install new bearings by driving on the inner-bearing
race. Install the bearing(s) until it seats completely.

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 GENERAL INFORMATION
Seal Replacement
Seals (Figure 49) contain oil, water, grease
or combustion gasses in a housing or shaft.
Improperly removing a seal can damage the
housing or shaft. Improperly installing the seal
can damage the seat. Note the following:
1. Prying is generally the easiest and most
effective method of removing a seal from the
housing. However. Always place a rag
underneath the pry tool to prevent damage to
the housing. Note the seal’s installed depth or
if it is installed flush.
2. Pack waterproof grease in the seal lips before the seal is installed.
3. In most cases, install seals with the manufacturer’s numbers or marks facing out.
4. Install seals with a socket or driver placed on the outside of the seal as shown in. Drive the seal
squarely into the housing until it is to the correct depth or flush as noted during removal. Never
install a seal by hitting against the top of it with a hammer.

STORAGE
Several months of non-use can cause a general deterioration of the motorcycle, UTV This is
especially true in areas of extreme temperature variations. This deterioration can be minimized with
careful preparation for storage. A properly stored motorcycle is much easier to return to service.

Storage Area Selection

When selecting a storage area, consider the following:
1. The storage area must be dry. A heated area is best, but not necessary. It should be insulated to
minimize extreme temperature variations.
2. If the building has large window areas, mask them to keep sunlight off the UTV .
3. Avoid buildings in industrial areas where corrosive emissions may be present. Avoid areas close to
saltwater.
4. Consider the area’s risk of fire, theft or vandalism. Check with an insurer regarding UTV coverage
while in storage.

Preparing the Motorcycle for Storage

The amount of preparation a motorcycle should undergo before storage depends on the expected
length of non-use, storage area conditions and personal preference. Consider the following list the
minimum requirement:
1. Wash the UTV thoroughly. Make sure all dirt, mud and other debris are removed.
2. Lubricate the drive chain.
3. Start the engine and allow it to reach operating temperature. Drain the engine oil regardless of the
riding time since the last service. Fill the engine with the recommended type of oil.
4. Drain the fuel tank fuel lines throttle.
5. Remove the spark plug and ground the ignition system with a grounding tool as described in this
chapter. Then pour a teaspoon (15-20ml) of engine oil into the cylinder. Place a rag over the
opening and Start the engine over to distribute the oil. Remove the grounding tool and reinstall the
spark plug.
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 GENERAL INFORMATION
6. When the engine has cooled to room temperature, drain the cooling system drain the coolant in
the coolant reserve tank and all tank lines.
7. Cover the exhaust and intake opening.
8. Apply a protective substance to the plastic and rubber components. Make sure to follow the
manufacturer’s instructions for each type of product being used.
9. Place the UTV on a work stand with both wheels off the ground.
10. Cover the UTV with old bed sheets or something similar. Do not cover it with any plastic material
that will trap moisture.
Returning the UTV to Service
The amount of service required when returning a UTV to service after storage depends on the
length of non-use and storage conditions. In addition to performing the reverse of the procedure, note
the following:
1. Remove the covers from the intake and exhaust openings.
2. Service the air filter as described in Chapter Three.
3. Inspect the cooling system. Check the drain plug and hose connections for leaks.
4. Refill the fuel tank. Turn the fuel shutoff valve on and check for fuel leaks.
5. Make sure the brakes, clutch, throttle and engine stop switch work properly before operating the
UTV. Evaluate the service intervals to determine which areas require service.
6. If the UTV has been in storage for longer than four months, change the engine oil as and filter, and
the transmission oil as described

TROVBLESHOOTING
Diagnose electrical and mechanical problems by following an orderly procedure and remembering
the basic operating requirements

Define → Symptoms

→ Which areas could exhibit these

Determine
symptoms

↓
Test and →
The suspect areas
analyze

Is date → The problem

By following a systematic approach, the possibility of unnecessary parts replacement can be

avoid, always start with the simple and most obvious checks when troubleshooting, This would include

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 GENERAL INFORMATION
the engine stop switch, fuel quantity and condition, fuel vale position and spark plug cap tightness
Proper maintenance as described in Chapter Three reduces the necessity for troubleshooting.
Even with the best of care, however, the motorcycle may develop problems that require trouble
shooting.
If the problem cannot be solved. Stop and evaluate all conditions prior to the problem. If the
motorcycle must be taken to a repair facility, the mechanic will want to know as many details as
possible.
For removal, installation and test procedures for some components, refer to the specific chapter.
When applicable, tables at the end of each chapter also provide specifications and service limits.

ENGINE PRINCIPLES AND OPERATING REQUIREMENTS

An engine needs three basics to run properly:

Correct air/fuel mixture

Engine
Compression
runs

A spark at the right time

If one basic requirement is missing the engine will not run.

STARTING THE ENGINE

When experiencing engine-starting troubles, it is easy to work out of sequence and forget basic
starting procedures. The following sections describe the recommended starting procedures.

Several special faults and countermeasures of EFI engine system

1.Special fault：
Idle speed is too high at starting moment。
The engine start normally, the engine speed will be a little higher than normal idle speed
(1400rpm) within the first 10 seconds. According to different temperature of engine coolant, the
process will continue from several seconds to tens of seconds.
Finally, the engine speed will decrease to normal idle speed automatically.
Reason: The intelligent control function of EFI automatically forces to complete the engine
warm-up process and enhance the oil pressure to correct level at the same time.
Result: Ensure the engine can work with steady idle speed and conducive to complete the
engine warm-up process quickly after start engine in low temperature.

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 GENERAL INFORMATION
2.Special fault：
Idle instability, CH and CO of off-gas out of limits
Reason：Oxygen sensor loosing cause slight leakage or pipe slight leakage and makes the
oxygen sensor collect too much oxygen ion signal. The wrong signal transmits to the ECU which
result the increasing of oil supply. Finally, it causes the oil too thick.
3.Special fault:
In the vehicle driving process, there is no idle speed or too low idle speed when restart it after
storage battery power off abnormally.
Countermeasure: Step on the throttle slightly when start the engine and maintain for a few
seconds. And then let go of the throttle, remove the key and switch off the vehicle. After waiting for
ten minutes, switch on with the key that could restart the engine.

4.Special fault:
The engine can’t start normally after changing air filter or air throttle
Reason：The inner cleanness of old air filter and air throttle is poor after long running. The idle
speed step motor will revise the volume of air up automatically. If change to new air filter or air
throttle, idle speed step motor inside ECU need to match the volume of oil when in idle speed
automatically.
Countermeasure: When start the engine, run 2 to 3 minutes in idle speed. If it can’t run normally
in idle, turn off the engine and restart it repeatedly 10 seconds later until it can run normally in idle.
Or switch on and off the key 5 times in a row which can reset all saved data in ECU.

Engine is cold
1. Shift the transmission into neutral.
2. Turn the fuel valve on or confirm if the fuel is in upper or below retile in the fuel tank.
3. Start the engine and run in neutral for 1 minute to enhance the temperature of engine. If it runs
normally in neutral, you can drive the UTV.

NOTE
Race the engine with high power in low
temperature will cause damage to the engine.

Engine is warm
1. Shift the transmission into neutral.
2. Confirm if the fuel is in upper or below retied in the tank.
3. Start the engine. If the engine can run in idle speed steady and the engine speed is lower than
1600RPM, the UTV can shift driving forward.
4. NOTE
Shift operation must be after UTV has stopped and
the engine speed has reduced to idle speed (1450RPM).

Flooded engine
If the engine fails to start after several attempts, it is probably flooded. This occurs when too much
fuel is drawn into the engine and the spark plug fails to ignite it. The smell of gasoline is often evident

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 GENERAL INFORMATION
when the engine is flooded. Troubleshoot a flooded engine as follows:
1. Open the throttle fully and hold in this position. Then start the engine firmly through its entire
stoke ten times to clear the engine. Close the throttle.
2. Check and repair ignition system.
3. If the engine still does not start, refer to Engine will Not Start this chapter.

ENGINE WILL NOT START

Identifying the Problem
If the engine does not start, perform the following steps in order while remembering the Engine
Principals and Operating Requirements described in this chapter. If the engine fails to start after
performing these checks, refer to the troubleshooting procedures indicated in the steps. If the engine
starts, but idles or runs roughly, refer to Poor Engine Performance in this chapter.
1. Refer to Starting the Engine in this chapter to make sure all starting procedures are correct.
2. If the engine seems flooded, refer to Starting The Engine in this chapter. If the engine is not flooded,
continue with Step 3.
3. Remove the cap from the fuel tank and make sure the fuel tank and make sure the fuel tank has a
sufficient amount of fuel to start the engine.
4. If there is sufficient fuel in the fuel tank, remove the spark plug immediately after attempting to start
the engine. The plug’s insulator should be wet, indicating that fuel is reaching the engine. If the plug
tip is dry, fuel is not reaching the engine. Refer to Fuel System in this chapter. If there is fuel on the
spark plug and the engine will not start, the engine may not have adequate spark. Continue with
Step 5.
5. Make sure the direct ignition coil or spark plug wire is secure. Push the direct ignition coil or spark
plug cap and slightly rotate it to clean the electrical connection between the plug and the connector.
If the engine does not start. Continue with step 6

NOTE
A cracked or damaged direct ignition coil or spark
plug cap and cable can cause intermittent problems
that are difficult to diagnose. If the engine
occasionally misfires or cuts out, use a spray bottle
to wet the direct ignition coil or plug cap and plug
cable while the engine is running. Water that enters
one of theses areas causes an arc through the
insulating material, causing an engine misfire.

NOTE
Engine misfire can also be caused by water that
enters through connectors. Check the connectors
for loose wire ends. On waterproof connectors,
check for damage where the wires enter the
connector.

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 GENERAL INFORMATION

6. Perform the Spark Test in this section. If there is a strong spark, perform Step 7. If there is no spark
or if the spark is very weak, refer to Ignition System Testing in Chapter Ten.
7. If the fuel and ignition systems are working correctly, perform a leak down test (this chapter) and
cylinder compression test. If the leak down test indicates a problem, or the compression under
Engine in this chapter.

Spark Test
Perform a spark test to determine if the ignition system is producing adequate spark. This test
should be performed with a spark tester. A spark tester looks like a spark plug with an adjustable gap
between the center electrode and grounded base. Because the voltage required to jump the spark
tester gap is sufficiently larger than that of a normally gapped spark plug, the test results are more
accurate than with a spark plug. Do not assume that because a spark jumped across a spark plug gap,
the ignition 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
After removing the direct ignition coil or spark plug
cap and before removing the spark plug in Step 1,
clean the area around the spark plug with
compressed air. Dirt that falls into the cylinder
causes rapid engine wear.
1. Disconnect the direct ignition coil or spark plug cap. Check for the presence of water.
2. Visually inspect the spark plug for damage.
3. Connect a spark tester to the direct ignition coil or spark plug cap. Ground the spark tester base (or
spark plug) to a good ground. Position the spark tester or spark plug firing tip away from the open
spark plug hole. Position the spark tester so the electrodes are visible.
WARNING
Mount the spark tester or spark plug away from the
spark plug hole in the cylinder. If the engine is
flooded, do not perform this test. The spark tester
can ignite fuel ejected through the spark plug hole.
4.Shift the transmission into neutral.

WARNING
Do not hold the spark tester, spark plug or
connector or a serious electrical shock may result.
5. Turn the engine over using the starter and push the starter button. A fat blue spark must be evident
between the spark tester or spark plug terminals.
6. If there is a strong, blue spark, the ignition system is functioning properly, Check for one or more of
the following possible malfunctions:
a. Faulty fuel system component.
b. Flooded engine.

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 GENERAL INFORMATION
c. engine damage(low compression).
7. If the spark was weak (white or yellow) or if there was no spark, perform the peak voltage checks
described under Ignition System Testing.
8. Reinstall the fuel tank.

The Starter Cannot Work Repeatedly Or Can Only Work Slowly

Refer to Starting System Testing

POOR ENGINE PERFORMANCE

If the engine runs, but performance is unsatisfactory, refer to the following section that best
describes the symptoms.

The Engine Starts Slowly Or Difficultly

Check for the following:
1. Incorrect choke operation. This can be due to improper use or a stuck choke valve in the throttle.
2. Incorrect hot start valve operation. This situation can be due to improper use or incorrect hot start
valve adjustment.
3. The fuel tank connection hose is clogged.
4. The fuel hose is clogged or the oil filter is clogged.
5. The injector is clogged.
NOTE
If a warm or hot engine will start with the choke on,
or if a cold engine starts and runs until the choke is
turned off. The pilot jet is probably plugged.

8. Contaminated or stale fuel.

9. Clogged air filter.
10. Intake pipe air leak.
11. Plugged exhaust system. Check the silencer or muffler, especially if the utility terrain vehicle was
just returned from storage.
12. Faulty ignition system component.

Engine Backfires, Cuts Out or Misfires During Acceleration

A backfire occurs when fuel is burned or ignited in the exhaust system.
1. A lean air/fuel mixture can cause these engine performance problems. Check for the following
conditions:
a. Incorrect float level adjustment.
b. Plugged pilot jet or pilot system.
2. Faulty accelerator pump.
3. Loose exhaust pipe-to-cylinder head connection.
4. Intake air leak.

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 GENERAL INFORMATION
5. Incorrect ignition timing or a damaged ignition system can cause these conditions. Perform the Peak
Voltage Tests to isolate the damaged ignition system component. Check the ignition timing as
described.
NOTE
The ignition timing is controlled by the ICM and
cannot be adjusted. However, checking the ignition
timing can be used to diagnose problems.
6. Check the following engine components:
a. Broken valve springs.
b. Stuck or leaking valves.
c. Worn or damaged camshaft lobes.
d. Incorrect valve timing due to incorrect camshaft installation or a mechanical failure.

The Engine Is Not Idling Or Cannot Idle Stably

If the engine backfires when the throttle is released, check the following:
1. Lean throttle pilot system.
2. Loose exhaust pipe-to-cylinder head connection.
3. Faulty ignition system component.
4. Check the following engine components:
a. Broken valve springs.
b. Stuck or leaking valves.
c. Worn or damaged camshaft lobes.
d. Incorrect valve timing due to incorrect camshaft installation or a mechanical failure.

Poor Fuel Mileage

1. Clogged fuel system.
2. Dirty or clogged air filter.
3. Incorrect ignition timing.

Engine Will Not Idle or Idles Roughly

1. Clogged air filter element.
2. Poor fuel filter or fuel hose.
3. Faulty accelerator pump assembly.
4. Contaminated or stale fuel.
5. ECU is not working properly, according to the 33 page "5 special treatment failure".
6. Leaking head gasket.
7. Intake air leak.
8. Incorrect ignition timing
9. Low engine compression

Low Engine Power

1. Support the UTV in a stand with the rear wheel off the ground. then spins freely. If the wheel does

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 GENERAL INFORMATION
not spin freely. Check for the following conditions:
a. Dragging brakes. Check for this condition immediately after riding the UTV

NOTE
After riding the UTV. Come to a stop on a level
surface. Turn the engine off and shift the
transmission into neutral. Walk or push the UTV
forward. If the UTV is harder to push than normal.
Check for dragging brakes
b. Damaged or binding drive system
c. Damaged drive system and gear bearing
2. Test ride the UTV and accelerate quickly from first to second gear. If the engine speed in-creased
according to throttle position. Perform Step 3. If the engine speed did not increase. Check CVT
a. Warped clutch plates/discs
b. CVT spring
3. Test rides the UTV and accelerate lightly. If the engine speed increased according to throttle position.
Perform Step 4. If the engine speed did not increase. Check for one or more of the following
problems:
a. Clogged air filter
b. Restricted fuel flow
c. Pinched fuel tank breather hose (Figure 9).
d. Clogged or damaged silencer or muffler

NOTE
A clogged exhaust system will prevent some of the
burned exhaust gasses from exiting the exhaust
port at the end of the exhaust stroke. This condition
effects the incoming air/fuel mixture on the intake
stroke and reduces engine power
4. Check for retarded ignition timing. A decrease in power results when the plugs fire later than normal
5. Check for one or more of the following problems
a. Low engine compression
b. Worn spark plug
c. Fouled spark plug
d. Incorrect spark plug heat range
e. Weak ignition coil
f. Incorrect ignition timing
g. Plugged throttle passages
h. Incorrect oil level (too high or too low)
i. Contaminated oil
j. Worn or damaged valve train assembly
k. Engine overheating
6. If the engine knocks when it is accelerated or when running at high speed. Check for one or more of
the following possible malfunctions:
a. Incorrect type of fuel

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 GENERAL INFORMATION
b. Lean fuel mixture
c. Advanced ignition timing

NOTE
Other signs of advanced ignition timing are engine
overheating and hard or uneven engine starting
d. Excessive carbon buildup in combustion chamber
e. Worn pistons and/or cylinder bores

Poor Idle or Low Speed Performance

1. Check for an incorrect pilot screw adjustment
2. Check for damaged or loose intake pipe and air filter housing hose clamps. These
conditions will cause an air leak
3. Perform the spark test in this chapter. Note the following:
a. If the spark is good. Go to Step 4
b. If the spark is weak. Perform the Peak Voltage Testing
4. Check the ignition timing. If ignition timing is correct. Perform Step 5. If the timing is
incorrect. Perform the Peak Voltage Testing
5. Check the fuel system as described in this chapter

Poor High Speed Performance

1. Check ignition timing. If the ignition timing is correct. Perform Step 2. If the timing is incorrect.
Perform the Peak Voltage
2. Check the fuel system as described in this chapter
3. Check the valve clearance as described. Note the following:
a. If the valve clearance as correct. Perform Step 4
b. If the clearance is incorrect. adjust the valves clearance as described in Chapter Three
4. Incorrect valve timing and worn or damaged valve springs can cause poor high-speed
performance. If the camshaft was timed just before the UTV experiencing this type of problem.
The cam timing may be incorrect. If the cam timing was not set or changed. And all the other
inspection procedures in this section failed to locate the problem. Inspect the camshaft and valves
assembly

FUEL SYSTEM
The following section isolates common fuel system problems under specific complaints. If there is a
good spark. Poor fuel flow may be preventing the correct amount of fuel from being supplied to the
spark plug. Troubleshoot the fuel system as follows:
1. Clogged fuel tank breather hose
2. Check that there is a sufficient amount of fuel in the rank
3. Start the engine after the following examination. Remove the spark plug, see if there is fuel on the

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 GENERAL INFORMATION
end of it.
Note the following:
a. If there is no visible fuel on the end of the spark plug, go to check whether the fuel valve, oil
injector or fuel hose is clogged.
b. If the spark plug at the bottom of a fuel. And the engine has spark. Check for an excessive
intake air leak or the possibility of contaminated or stale fuel.

NOTE
If the UTV was not used for some time. And was not
properly stored. The fuel may have gone stale.
Where lighter parts of the fuel have evaporated.
Depending on the condition of the fuel. a no-start
condition can result

c. If there is too much fuel on the end of the spark plug, go to check whether there is overflow at
the air filter or the ducting damper.
Rich Mixture
The following conditions can cause a rich air/fuel mixture:
1. Air pressure sensor, oxygen sensor, solar term door position sensor fault
2. ECU program error or damage

Lean Mixture
The following conditions can cause a lean air/fuel mixture:
1. The injector is clogged
2. The pump pressure is not enough
3. ECU program chaos
4. ECU damage
5. The pressure sensor, oxygen sensor, solar term door position sensor fault

ENGINE
Engine Smoke
The color of engine smoke can help diagnose engine problems or operating conditions

Black smoke
Black smoke is an indication of a rich air/fuel mixture

Blue smoke

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 GENERAL INFORMATION
Blue smoke indicates that the engine is burning oil in the combustion chamber as it leaks past worn
valve stem seals and piston rings. Excessive oil consumption is another indicator of an engine that is
burning oil. Perform a compression test to isolate the problem.

White smoke or steam

It is normal to see white smoke or steam from the exhaust after first starting the engine in cold
weather. This is actually condensed steam formed by the engine during combustion. If the UTV is
ridden far enough, the water cannot collect in the crankcase and should not become a problem. Once
the engine heats up to normal operating temperature, the water evaporates and exits the engine
through the crankcase vent system. However, if the UTV is ridden for short trips or repeatedly started
and stopped and allowed to cool off without the engine getting warm enough, water will start to collect
in the crankcase. With each short run of the engine, more water collects. As this water mixes with the
oil in the crankcase, sludge is produced. Sludge can eventually cause engine damage as it circulates
through the lubrication system and blocks off oil passages.
Large amounts of steam can also be caused by a cracked cylinder head or cylinder block surface
that allows coolant to leak into the combustion chamber. Perform a Coolant System Pressure Test.

Low Engine Compression

Problems with the engine top end will affect engine performance. When the engine is suspect,
perform the leak down procedure in this chapter and make a compression test . Interpret the results as
described in each procedure to troubleshoot the suspect area. An engine can lose compression
through the following areas:
1. Valves:
a. The gap between the valve is not suitable.
b. Incorrect valve timing.
c. Worn or damaged valve seat surfaces.
d. Bent valves.
e. Weak or broken valve springs.
2. Cylinder head:
a.Loose spark plug or damaged spark plug hole.
b.Damaged cylinder head gasket.
c. Warped or cracked cylinder head.
3. The pressure relief system is damaged.

High Engine Compression

1. The pressure relief system malfunction.
2. Excessive carbon buildup in the combustion chamber.

Engine Overheating

(Cooling System)
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 GENERAL INFORMATION
WARNING
Do not remove the radiator cap, coolant drain plug or
disconnect any 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 and under
pressure. Attempting to remove the items when the engine is
hot can cause the coolant to spray violently from the radiator,
water pump or hose, causing severe burns and injury.
1. Low coolant level.
2. Air in cooling system.
3. Clogged radiator, hose or engine coolant passages.
4. Worn or damaged radiator cap.
5. Damaged water pump.

Engine Overheating

(Engine)
1. Improper spark plug heat range.
2. Low oil level.
3. Oil not circulating properly.
4. Valves leaking.
5. Heavy carbon deposits in the combustion chamber.
6. Dragging brake(s).
7. Slipping clutch.

The Ignition Advance Angle Is Too Large

Preignition is the premature burning of fuel and is caused by hot spots in the combustion chamber.
Glowing deposits in the combustion chamber, inadequate Cooling or an overheated spark plug can all
cause preignition. This is first noticed as a power loss but eventually causes damage to the internal
parts of the engine because of the high combustion chamber temperature.

Detonation
Detonation is the violent explosion of fuel in the combustion chamber before the proper time of
ignition. Using low octane gasoline is a common cause of detonation.
Even when using a high octane gasoline, detonation can still occur. Other causes are
over-advanced ignition timing, lean air/fuel mixture at or near full throttle, inadequate engine cooling,
or the excessive accumulation of carbon deposits in the combustion chamber.
Continued detonation can result in engine damage.

Power Loss
Refer to Poor Engine Performance in this chapter.

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 GENERAL INFORMATION
Engine Noises
Unusual noises are often the first indication of a developing problem. Investigate any new noises
as soon as possible. Something that may be a minor problem, if corrected, could prevent the
possibility of more extensive damage.
Use a mechanic’s stethoscope or a small section of hose held near your ear (not directly on your
ear) with the other end close to the source of the noise to isolate the location. Determining the exact
cause of a noise can be difficult. If this is the case, consult with a professional mechanic to determine
the cause. Do not disassemble major components until all other possibilities have been eliminated.
Consider the following when troubleshooting engine noises:
1. Knocking or pinging during acceleration can be caused by using a lower octane fuel than
recommended. May also be caused by poor fuel. Pinging can also be caused by an incorrect
spark plug heat range or carbon buildup in the combustion chamber.
2. Slapping or rattling noises at low speed or during acceleration—May be caused by excessive
piston-to-cylinder wall clearance (piston slap).

NOTE
Piston slap is easier to detect when the engine is
cold and before the piston has expanded. Once
the engine has warmed up, piston expansion
reduces piston-to-cylinder clearance.
3. Knocking or rapping while decelerating—Usually caused by excessive rod bearing clearance.
4. Persistent knocking and vibration occurring every crankshaft rotation—Usually caused by
worn rod or main bearing(s). Can also be caused by broken piston rings or a damaged piston
pin.
5. Rapid on-off squeal—Compression leak around cylinder head gasket or spark plug(s).
6. Valve train noise—Check for the following:
a. Excessive valve clearance.
b. Worn or damaged camshaft.
c. Damaged camshaft.
d. Worn or damaged valve train components.
e. The valve hose hole is damaged
f. The valve sticks on the hose
g. Broken valve spring.
h. Low oil pressure.
i. Clogged cylinder oil hole or oil passage.

ENGLNE LUBRICATION
Mis-operation of the engine lubrication system will cause the engine scrap. Check the lubrication oil
level and pressure of the engine.

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 GENERAL INFORMATION
High Oil Consumption or Excessive
Exhaust Smoke
1. Worn valve guides.
2. Worn valve guide seals.
3. Worn or damaged piston rings.
4. Incorrect piston ring installation.

Low Oil Pressure

1. Low oil level.
2. Worn or damaged oil pump.
3. Clogged oil strainer screen.
4. Clogged oil filter.
5. Internal oil leakage.
6. Oil relief valve stuck open.
7. Incorrect type of engine oil.

High Oil Pressure

1. The lubrication oil pressure valve is stuck and closed.
2. Clogged oil filter.
3. Clogged oil gallery or metering orifices.

No Oil Pressure
1. Low oil level.
2. The lubrication oil pressure valve is stuck and closed.
3. Damaged oil pump.
4. Incorrect oil pump installation.
5. Internal oil leak.

Oil Level Too Low

1. The lubrication oil does not keep at the normal level.
2. Worn piston rings.
3. Worn cylinder.
4. Worn valve guides.
5. Worn valve guide seals.
6. Piston rings incorrectly installed during engine overhaul.
7. External oil leakage.
8. Oil leaking into the cooling system.

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 GENERAL INFORMATION
Oil Contamination
1. Blown head gasket allowing coolant to leak into the engine.
2. Coolant leak.
3. Oil and filter not changed at specified intervals or when operating conditions demand more
frequent changes.

CYLINDER LEAK DOWN TEST

A cylinder leak down test can accurately pinpoint engine leakage problems from the head gasket,
water jackets in the cylinder head and cylinder, valves and valve seats, and piston rings. This test is
performed by applying compressed air to the cylinder through a special tester and then measuring the
percent of leakage. A cylinder leak down tester and an air compressor are needed to perform this test.
When performing a leak down test, the engine is first set at TDC on its compression stroke so that
all the valves are closed. When the combustion chamber is pressurized, very little air should escape.
However, the difficulty in performing a leak down test on a single cylinder engine(especially on the
engines described in this manual with low static 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 escape past an open valve seat.
In this procedure it will be necessary to lock the engine at TDC on its compression stroke and
then perform the leak down test. Follow the manufacturer’s directions along with the follow the
manufacturer’s directions along with the following information when performing a cylinder leak down
test.
1. Support the UTV on a work stand with the rear wheel off the ground.
2. Remove the air filter assembly Open and secure the throttle so it is at its wide-open position.
3. Remove the spark plug.
4. Install the threaded hose adapter from the leak down kit. Then install the leak down gauge
onto the hose.
5. Remove the ignition timing hole cap from the left crankcase cover.
6. Remove the crankshaft hole cap from the right crankcase cover.

NOTE
Because the following test is performed with the cylinder
head cover installed on the engine, the camshaft lobes
cannot be viewed to ensure that the engine is positioned at
TDC on its compression stroke. To determine when the
engine is approaching TDC on its compression stroke, or
whether it is 360°off. Observe the following two indicators
to predict engine position. First, when aligning the index
marks in Step7, listen for pressure building inside the
combustion chamber. Indicating that the piston is moving
to TDC on its compression stroke. Second, view the gauge
on the leak down tester when turning the engine. As the
piston moves toward TDC on its compression stroke,
compression building inside the combustion chamber may

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 GENERAL INFORMATION
cause the gauge needle to move slightly. If the crankshaft is
360°off, these indicators will not be present.

NOTE
The decompress or mechanism will click loudly once
during each crankshaft revolution. This is normal.
7. Use hex socket on the primary drive gear mounting bolt and turn the crankshaft clockwise and align
the TDC mark on the flywheel with the index mark on the left crankcase cover Remove the hex socket
from the primary drive gear.
8. Perform the following to lock the transmission so the engine remains at TDC on its compression
stroke when performing the leak down test:
WARNING
Do not attempt to lock the engine by trying to use a
tool to hold the Allen bolt on the end of the crankshaft.
Once the combustion chamber becomes pressurized,
any crankshaft movement can throw the tool away
from the engine under considerable force, attempting
to hole the tool can cause serious injury. Engine
damage may also occur to the crankshaft or right
crankcase cover. Lock the engine as described in this
procedure.
a. Turn the drive sprocket by hand and shift the transmission into top gear with the shift pedal.
b. Mount a holding tool or equivalent onto the drive sprocket. Use a wooden block and clamp to
hold the holding tool so it cannot move when the combustion chamber becomes pressurized.
c. Check that the TDC marks are still aligned as described in Step7,
If not, turn the crankshaft as required, then relock the holding tool in position.
9. Remove the radiator cap and the oil filler cap.
10. Perform a cylinder leak down test by applying air pressure to the combustion chamber. Follow the
manufacturer’s instructions while reading the percent of leakage on the gauge. Listen for air
leaking while noting the following:

NOTE
Because of play in the transmission gears, it is unlikely the
engine will stay at TDC on the first try If the crankshaft
turns, reposition the countershaft slightly and then relock it
in position with the holding tool. After several attempts, you
will get a feel of the transmission play and know what
direction the countershaft should be turned and locked.

NOTE
If a large amount of air escapes from the exhaust pipe or
through the throttle, the air is leaking through on open
valve, Check the index mark to make sure the engine is at
TDC on the compression stroke, If the engine is remaining

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 GENERAL INFORMATION
at TDC but there is still a large amount of air escaping from
the engine, the crankshaft is off one revolution. Turn the
engine 360°and realign the TDC mark as described in Step 7,
then relock it as described in Step8.
a. Air leaking through the exhaust pipe indicates a leaking exhaust valve.
b. Air leaking through the throttle indicates a leaking intake valve.
c. Air leaking through both the intake and exhaust valves indicates the engine is not set at
TDC on its compression stroke.
d. Air leaking through the coolant filler neck indicates a leaking cylinder head gasket or a
cracked cylinder head or cylinder liner.
e. Air leaking through the oil filler hole indicates the rings are not sealing properly in the
bore.
11. If the cylinder leak down is 10 percent or higher, further service is required.
12. Disconnect the test equipment and install all the parts previously removed.

ELECTRICAL TESTING
This section describes basic electrical testing and test equipment use.

Preliminary Checks and Precautions

Refer to the color wiring diagrams at the end of the manual for 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. Also, check any circuits that
share the same fuse (if used), ground or switch. If the other circuits work properly and the shared
wiring is good, the cause must be in the wiring used only by the suspect circuit. If all related circuits are
faulty at the same time, the probable cause is a poor ground connection or a blown fuse (if used).
As with all troubleshooting procedures, analyze typical symptoms in a systematic manner. Never
assume any thing and do not overlook the obvious like a blown fuse or an electrical connector that has
separated. Test the simplest and most obvious items first and try to make tests at easily accessible
points on the UTV.
Before starting any electrical troubleshooting, perform the following:
1. Check the fuse if the fuse is blown, replace it.
2. Inspect the battery. Make sure it is fully charged, and the battery leads are clean and securely
attached to the battery terminals.
3. Disconnect each electrical connector in the suspect circuit and make sure there are no bent
terminals in the electrical connector
4. Make sure the terminals on the end of each wire are pushed all the way into the connector. If not.
Carefully push them in with a narrow blade screwdriver
5. Check the wires where they connect to the terminals for damage
6. Make sure all terminals within the connector are clean and free of corrosion. Clean them. If
necessary. And pack the connectors with dielectric grease
7. Push the connectors with dielectric grease. The connectors are fully engaged and locked
together
8. Never pull the electrical wires when disconnecting an electrical connector-pull only on the
connector

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 GENERAL INFORMATION
Intermittent Problems
Intermittent problems are problems that do not occur all the time and can be difficult to locate. For
example. When a problem only occurs when the UTV is ridden over rough roads (vibration) or in wet
conditions (water penetration). It is intermit-ten. To locate and repair intermittent problems. Simulate
the condition when testing the compo-nets. Note the following:
1. Vibration---This is a common problem with loose or damaged electrical connectors
a. Perform a continuity test as described in the appropriate service procedure. Or under
Continuity Test in this section
b. Lightly pull or wiggle the connectors while repeating the test. Do the same when checking the
wiring harness and individual components. especially where the wires enter a housing or
connector
c. A change in meter readings indicates a poor connection. Fine and repair the problem or
replace the part. Check for wires with cracked or broken insulation

NOTE
An analog ohmmeter is useful when making
this type of test. Slight needle movements are
apparent when indicating a loose connection
2. Heat – This is another common problem with connectors or plugs that have loose or poor
connections. As these connections heat up. The connection or joint expands and separates.
Causing an open circuit. Other heat related problem occur when a component creates its own
heat as it starts to fail or go bad
a. Troubleshoot the problem to help isolate the problem or area
b. To check a connector. Perform a continuity test as described in the appropriate service
procedure. Or under Continuity test in this chapter. Then repeat the test while heating the
ground. If the lamp comes on. The problem is the connection between the lamp and
Connector with a heat gun or hair dryer. If the meter reading was normal (continuity) when the
connector was cold, then fluctuated or read infinity when heat was applied, the connection is
bad.
c. To check a component, wait until the engine is clod, then start and run the engine. Note operational
differences when the engine is cold and hot.
d. If the engine does not start, isolate and remove the component. First test it at room temperature,
and then after heating it with a hair dryer. A change in meter readings indicates a temperature
problem.
CAUTION
A heat gun or hair dryer will quickly raise the heat
of the component being tested. Do not apply heat
directly to the ICM or use heat in excess of 60℃
(140℉) on any electrical component. If available,
monitor heat with an infrared thermometer.
3. Water—when this problem occurs in wet conditions, or in areas with high humidity, start and run
the engine in a dry area. Then, with the engine running, spray water related problems repair
themselves after the component becomes hot enough to dry itself.

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 GENERAL INFORMATION
Electrical component replacement
Most UTV dealerships and parts suppliers will not accept the return of any electrical part. If you
cannot determine the exact cause of any electrical system malfunction. If you purchase a new
electrical component(s), install it, and then find that the system still does not work properly, you will
probably be unable to return the unit for a refund.
Consider any test results carefully before replacing a component that teats only slightly out of
specification, especially resistance. A number of variables can affect test results dramatically. These
include: the testing meter’s internal circuitry, ambient temperature and conditions under which the
machine has been operated. All instructions and specifications have been for accuracy: however.
Successful test results depend to a great degree upon individual accuracy.

Test Equipment
A test light can be constructed from a 12-volt light bulb with a pair of test leads carefully soldered
to the bulb. To check for battery voltage in a circuit, attach one lead to ground and the other lead to
various points along the circuit. The bulb lights when battery voltage is present.
A voltmeter is used in the same manner as the test light to find out if battery voltage is present in
any given circuit. The voltmeter, unlike the test light, also indicates how much voltage is present at
each test point. When using a voltmeter, attach the positive lead to the component or wire to be
checked and the negative lead to a good ground.

Ammeter
An ammeter measures the flow of current (amps) in a circuit when connected in series in a circuit,
the ammeter determines if current is flowing through the circuit and if that current flow is excessive
because of a short in the circuit. Current flow is often referred to as current draw. Comparing actual
current draw in the circuit or component to the manufacturer’s specified current draw provides useful
diagnostic information.

Self-powered test light

A self-powered test light can be constructed from a 12-volt light bulb, a pair of test leads and a
12-volt battery. When the test leads are touched together, the light bulb should go on.
Use a self-powered test light as follows:
1. Touch the test leads together to make sure the light bulb goes on. If not, correct the problem before
using it in a test procedure.
2. Select two points within the circuit where there should be continuity.
3. Attach one lead of the self-powered test light to each point.
4. If there is continuity, the self-powered test light bulb will come on.
5. If there is on continuity, the self-powered test light bulb will not come on, indicating an open circuit.

Ohmmeter
An ohmmeter measures the resistance (in ohms) to current flow in a circuit or component. Like the

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 GENERAL INFORMATION
self-powered test light, an ohmmeter contains its own power source and should not be connected to a
live circuit.
Ohmmeter may be analog type (needle scale) or digital type (LCD or LED readout). Both types of
ohmmeter have a switch that allows the user to select different ranges of resistance for accurate
readings. The analog ohmmeter also has a set-adjust control which is used to zero or calibrate the
meter (digital ohmmeters do not require calibration).
An ohmmeter is used by connecting its test leads to the terminals or leads of the circuit or
component to be tested. If an analog meter id used, is must be calibrated by touching the teat leads
together and turning the set-adjust knob until the meter needle reads zero. When the leads are
uncrossed, the needle reads zero. When the leads are uncrossed, the needle should move to the
other end of the scale indicating infinite resistance.
During a continuity test, a reading of infinity indicates that there is an open in the circuit or
component. A reading of zero indicates continuity, that is, there is no measurable resistance in the
meter needle falls between these two ends of the scale, this indicates the actual resistance, multiply
the meter reading by the ohmmeter scale. For example, a meter reading of 5 multiplied by the R×100
scale is 5000 ohms of resistance.

CAUTION
Never connect an ohmmeter to a circuit
which has power applied to it. Always
disconnect the battery negative lead before
using an ohmmeter.

Jumper wire
A jumper wire is a simple way to bypass a potential problem and isolate it to a particular point in a
circuit. If a faulty circuit works properly with a jumper wire installed, an open exists between the two
jumper points in the circuit.
To troubleshoot with a jumper wire, fist use the wire to determine if the problem is on the ground
side or the load side of a device. Test the ground by connecting a jumper between the lamp and a
good ground. If the lamp does not come on with the jumper installed. The lamp’s connection to ground
is good so the problem is between the lamp and the power source.
To isolate the problem. Connect the jumper between the battery and the lamp. If it comes on. The
problem is between these two points. Next. Connect the jumper between the battery and the fuse side
of the switch. If the lamp comes on. The switch is good. By successively moving the jumper from one
point to another. The problem can be isolated to a particular place in the circuit
Pay attention to the following when using a jumper wire:
1. Make sure the jumper wore gauge (thickness) is the same as that used in the circuit being
tested. Smaller gauge wire will rapidly overheat and could melt
2. Install insulated boots over alligator clips. This prevents accidental grounding. Sparks or
possible shock when working in cramped quarters
3. Jumper wires are temporary test measures only. Do not leave a jumper wire installed as a
permanent solution. This creates a severe fire hazard that could easily lead to complete loss off
the motorcycle
4. When using a jumper wire always install an inline fuse/fuse holder (available at most auto
supply stores or electronic supply stores) to the jumper wire. Never use a jumper wire across

- 51 -
 GENERAL INFORMATION
any load (a component that is connected and turned on). This would result in a direct short and
will blow the fuse(s)

Test Procedures

Voltage test
Unless otherwise specified. Make all voltage tests with the electrical connectors still connected.
Insert the test leads into the backside of the connector and make sure the test lead touches the
electrical wire or metal terminal within the connector housing. If the test lead only touches the wire
insulation. There will be a false treading
Always check both sides of the connector as one side may be loose or corroded. Thus
preventing electrical flow through the connector. This type of test can be performed with a test or a
voltmeter. A voltmeter gives the best results

NOTE
If using a test light. It does not make any
difference which test lead is attached to
ground
1. Attach the voltmeter negative test lead to a good ground (bare metal). Make sure the part used
for ground is not insulated with a rubber gasket or rubber grommet
2. Attach the voltmeter positive test lead to the point to be tested
3. Turn the ignition switch on. If using a test light. The test light will come on if voltage is present. If
using a voltmeter. Note the voltage reading. The reading should be within I volt of battery
voltage. If the voltage is less. There is a problem in the circuit

Voltage drop test

The wires. Cables. Connectors and switches in an electrical circuit are designed to carry
current with low resistance. This endures that current can flow through the circuit with a minimum
loss of voltage. Voltage drop indicates where there is resistance in a circuit. A higher than normal
amount of resistance in a circuit decreases the flow of current and cause the voltage to drop
between the source and destination in the circuit.
Because resistance causes voltage to drop. A voltmeter is used to measure voltage drop
when current is running through the circuit. If the circuit has no resistance. There is no voltage drop
so the voltmeter indicates 0 volts. The greater the resistance in a circuit. The greater the voltage
drop reading.

To perform a voltage drop:

1. Connect the positive meter test lead to the electrical source (where electricity is coming from).
2. Connect the voltmeter negative test lead to the electrical load (where the electricity is going).
3. If necessary, activate the component(s) in the circuit. For example. If checking the voltage in the
starter circuit, it would be necessary to push the starter button.
4. Read the voltage drop (difference in voltage between the source and destination) on the voltmeter.
Note the following:

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 GENERAL INFORMATION
a. The voltmeter should indicate 0 volts. If there is a drop of 0.5 volts or more. There is a problem
within the circuit. A voltage drop reading of 12 volts indicates an open in the circuit.
b. A voltage drop of 1 or more volts indicates that a circuit has excessive resistance.
c. For example, consider a starting problem where the battery is fully charged but the starter motor
turns over slowly. Voltage drop would be the difference in the voltage at the batter (source) and
the voltage at the starter (destination) as the engine is being started (current is flowing through
the batter cables). A corroded battery cable would cause a high voltage drop (high resistance)
and slow engine cranking.
d. Common sources of voltage drop are loose or contaminated connectors and poor ground
connections.

Peak voltage test

Peak voltage tests check the voltage output of the ignition coil and ignition pulse generator at
normal cranking speed. These tests make it possible to identify ignition system problems quickly and
accurately.
Peak voltage tests require a peak voltage adapter or tester. See Chapter Ten, Ignition System
Testing.

Continuity Test
A continuity test is used to determine the integrity of a circuit, wire or component. A circuit has
continuity if it forms a complete circuit, that is, if there are no opens in either the electrical wires or
components within the circuit. A circuit with an open. On the other hand, has no continuity.
This type of test can be performed with a self-powered test light or an ohmmeter. An ohmmeter
gives the best results. If using an analog ohmmeter, calibrate the meter by touching the leads together
and turning the calibration knob until the meter reads zero.
1. Disconnect the negative battery cable.
2. Attach one test lead (test light or ohmmeter) to one end of the part of the circuit to be tested.
3. Attach the other test lead to the other end of the part or the circuit to be tested.
4. The self-powered test lead comes on if there is continuity. An ohmmeter reads 0 or very low
resistance if there is continuity. A reading of infinite resistance if there is continuity. A reading of
infinite resistance indicates no continuity, the circuit is open.

Testing for a short with a self-powered test light or ohmmeter

1. Disconnect the negative battery cable.
2. Remove the blown fuse.
3. Connect one test lead of the test light or ohmmeter to the load side (battery side) of the fuse terminal
in the starter relay.
4. Connect the other test lead to a good ground (bare metal). Make sure the part used for a ground is
not insulated with a rubber gasket or rubber grommet.
5. With the self-powered test light or ohmmeter attached to the fuse terminal and ground, wiggle the
wiring harness relating to the suspect circuit at various intervals. Start next to the fuse terminals and
work away from the fuse terminal. Watch the self-powered test light or ohmmeter while progressing

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 GENERAL INFORMATION
along the harness.
6. If the test light blinks or the needle on the ohmmeter moves, there is a short-to-ground at that point
in the harness.

Testing for a short with a test light or voltmeter

1. Remove the blown fuse.
2. Connect the test light or voltmeter across the fuse terminals in the starter relay. Turn the ignition
switch ON and check for battery voltage.
3. With the test light or voltmeter attached to the fuse terminals, wiggle the wiring harness relating to
the suspect circuit at various intervals. Start next to the fuse terminal a work systematically away
from the fuse terminal. Watch the test light or voltmeter while progressing along the harness.
4. If the test light blinks or if the needle on the voltmeter moves, there is a short-to-ground at that point
in the harness.

BRAKE SYSTEM
The front and rear brake units are critical to riding performance and safety. Inspect the front and
rear brakes frequently and repair any problem immediately. When replacing or refilling the brake fluid,
use only DOT 4 brake fluid from a closed container.
Always check the brake operation before riding the motorcycle.

Soft or Spongy Brake Lever or Pedal

Operate the front brake lever or rear brake pedal and check to see if the lever travel distance
increases. If the lever travel does increase while being operated, or feels soft or spongy, there may be
air in the brake line. In this condition, the brake system is not capable of producing sufficient brake
force. When there is an increase in lever or pedal travel or when the brake feels soft or spongy, check
the following possible causes:
1. Air in system.

WARNING
If the fluid level drops too low, air can enter the
hydraulic system through the master cylinder. Air
can also enter the system from loose or damaged
hose fittings. Air in the hydraulic system causes a
soft or spongy brake lever action. This condition
is noticeable and reduces brake performance.
When it is suspected that air has entered the
hydraulic system, flush the brake system and
bleed the brakes as described in Chapter Fifteen.

2. Low brake fluid level.

WARNING
As the brake pads wear, the brake fluid level in

- 54 -
 GENERAL INFORMATION
the master cylinder reservoir drops. Whenever
adding brake fluid to the reservoir, visually check
the brake pads for wear. If it does not appear that
there is an increase in pad wear, check the brake
hoses, lines and banjo bolts for leaks.
3. Leak in the brake system.
4. Contaminated brake fluid.
5. Plugged brake fluid passages.
6. Damaged brake lever or pedal assembly.
7. Worn or damaged brake pads.
8. Warped brake disc.
9. Contaminated brake pads and disc.

WARNING
A leaking fork seal can allow oil to
contaminate the brake pads and disc.
10. Worn or damaged master cylinder cups and/or cylinder bore.
11. Worn or damaged brake caliper piston seals.
12. Contaminated master cylinder assembly.
13. Contaminated brake caliper assembly.
14. Brake caliper not sliding correctly on slide pins.
15. Sticking master cylinder piston assembly.
16. Sticking brake caliper pistons.

Brake Drag
When the brakes drag, the brake pads are not capable of moving away from the brake disc when the
brake lever or pedal is released. Any of the following causes, if they occur, would prevent correct brake
pad movement and cause brake drag.
1. Warped or damaged brake disc.
2. Brake caliper not sliding correctly on slide pins.
3. Sticking or damaged brake caliper pistons.
4. Contaminated brake pads and disc.
5. Plugged master cylinder port.
6. Contaminated brake fluid and hydraulic passages.
7. Restricted brake hose joint.
8. Loose brake disc mounting bolts.
9. Damaged or misaligned wheel.
10. Incorrect wheel alignment.
11. Incorrectly installed brake caliper.
12. Damaged front or rear wheel.

Hard Brake Lever or Pedal Operation

When applying the brakes and there is sufficient brake performance but the operation of brake

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 GENERAL INFORMATION
lever feels excessively hard, check for the following possible causes:
1. Clogged brake hydraulic system.
2. Sticking caliper piston.
3. Sticking master cylinder piston.
4. Glazed or worn brake pads.
5. Mismatched brake pads.
6. Damaged front brake lever.
7. Damaged rear brake pedal.
8. Brake caliper not sliding correctly on slide pins.
9. Worn or damaged brake caliper seals.

Brake Grabs
1. Damaged brake pad pin bolt. Look for steps or cracks along the pad pin bolt surface.
2. Contaminated brake pads and disc.
3. Incorrect wheel alignment.
4. Warped brake disc.
5. Loose brake disc mounting bolts.
6. Brake caliper not sliding correctly on slide pins.
7. Mismatched brake pads.
8. Damaged wheel bearings.

Brake Squeal or Chatter

1. Contaminated brake pads and disc.
2. Incorrectly installed brake caliper.
3. Warped brake disc.
4. Incorrect wheel alignment.
5. Mismatched brake pads.
6. Incorrectly installed brake pads.
7. Damaged or missing brake pad spring or pad retainer.

Leaking Brake Caliper

1. Damaged dust and piston seals.
2. Damaged cylinder bore.
3. Loose caliper body bolts.
4. Loose banjo bolt.
5. Damaged banjo bolt washers.
6. Damaged banjo bolt threads in caliper body.

Leaking Master Cylinder

1. Damaged piston secondary seal.
2. Damaged piston snap ring/ snap ring groove.
3. Worn or damaged master cylinder bore.

- 56 -
 GENERAL INFORMATION
4. Loose banjo bolt washers.
5. Damaged banjo bolt washers.
6. Damaged banjo bolt threads in master cylinder body.
7. Loose or damaged reservoir cap.

- 57 -
 SPECIFICATIONS

SPECIFICATIONS
HOW TO CONVERSION TABLE OF UNIT
（1）How to use conversion table
All the specified documents in this manual are taken SI and Metric as unit. With the following
conversion table, metric unit could be conversed into imperial unit.
Sample:
METRIC MULTIPLY IMPERIAL
mm 0.03937 =in
2mm × 0.03937 =0.08in
Conversion table
Conversion between metric and imperial
Know unit Multiply Product
m·kg 7.233 ft·lb
m·kg 86.794 in·lb
Torque
cm·kg 0.0723 ft·lb
cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
g 0.03527 oz
km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
Length
m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc（cm3） 0.03527 oz（IMP liq.）
Volume/capacity cc（cm3） 0.06102 cu·in
lit（liter） 0.8799 qt（IMP liq.）
lit（liter） 0.2199 gal（IMP liq.）
kg/mm 55.997 Ib/in
Others kg/cm2 14.2234 psi（lb/in2）
Centigrade 9/5（℃）+32 Fahrenheit（°F）

（2）Definition of unit
Unit Read Definition Measurement
mm Millimetre 1 mm=10-3Meter Length
cm Centimetre 1 cm =10-2Meter Length
kg Kilogram 1 kg =103Gram Weight
N Newton 1N=1 kg×meter/second² Force
N.m Newton meter 1 Nm=1Newton×1meter Torque
kgf.m Meter Kilogram 1 kgf.m =1Meter×1kgf Torque
Pa Pascal 1 Pa=1Newton/1meter2 Pressure
N/mm Newton per millimeter 1 N/mm =1Newton/ Rigid of spring
millimeter
L Litre Volume of capacity
—
cm3 Cubic centimeter
r/min Revolutions per minute — Rotational speed

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 SPECIFICATIONS

GEBERAR SPECIFICATIONS
Item Standard
Dimensions :
Overall length 3,125mm (123.0in)
Overall width 1,705mm（67.1 in）
Overall height 1,930mm（76.0in）
Seat height 850mm（33.5in）
Wheelbase 2,160mm（85.0in）
Minimum ground clearance 330 mm（13.0 in）
Minimum turning radius 5,300mm（208.7 in）
Basic weight :
With oil and full fuel tank 860kg (1,896 lb)
Engine :
Model HS2V91MY
Engine type Liquid cooled 4-stroke, Water cool
Cylinder arrangement V type twin cylinder
Displacement 976cm3
Bore×stroke 91×75mm（3.58×2.95in）
Compression ratio 11:1
Starting system Electric starter
Lubrication system Wet sump
Engine oil :
API service SE,SF,SG type or higher

Final gear oil SAE80 API GL-4 Hypoid gear oil

Differential gear oil SAE80 API GL-5 Hypoid gear oil
Engine oil
Periodic oil change 1.90 L（1.67lmp qt, 2.01 US qt）
With oil filter replacement 2.10 L（1.85 Imp qt, 2.22 US qt）
Total amount 2.40 L（2.11 Imp qt, 2.54 US qt）
Air filter Wet type element
Fuel
Type Unleaded gasoline only
Fuel tank capacity 28L（6.16 lmp gal, 7.40 US gal）

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 SPECIFICATIONS
Item Standard
Throttle
Type/quantity D54-U / 1
Spark plug
Type/manufacturer DCPR7E / 1 (NGK)
Spark plug gap 0.6-0.7 mm（0.024-0.028in）
Clutch type Dry ,centrifugal automatic
Transmission
Primary reduction system V-belt
Secondary reduction system Shaft drive
Transmission type V-belt automatic
Operation Right hand operation
Single speed automatic 2.900～0.650
Sub transmission ratio Low 34/29（1.172）
High 43/20（2.150）
Reverse gear 31/14（2.214）
Chassis
Frame type Steel tube frame
Trail 26.0mm（1.02 in）
Toe-in 8～18 mm （0.31～0.71 in）
Tire
Type Tubeless
Size Front 27×9-14
Rear 27×11-14
Pressure of front wheel 138kpa
Pressure of rear wheel 180kpa
Brake
Front brake Type Single disc brake
Operation Foot operation
Rear brake Type Dual disc brake
Operation Foot operation
Suspension
Front suspension Independent, Dual A-arm type
Rear suspension Independent, Dual A-arm type
Shock absorber
Front shock absorber Coil spring/airbag damping
Rear shock absorber Coil spring/airbag damping
Wheel travel
Front wheel travel 235mm (9.25 in)
Rear wheel travel 235mm (9.25 in)

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 SPECIFICATIONS
Item Standard
Electrical
Ignition system ECU
Generator system A.C. magneto
Battery type YUASA 6-QW-60
Battery capacity 12 V, 60.0Ah

Headlight type HS1

Bulb wattage×quantity
Headlight 12V，35W/35W × 2
Front Position Lamp 12V，0.5W（LED）
Front direction indicator 12V，0.7W（LED）
Rear direction indicator 12V，0.85W（LED）
Rear position lamp 12V，0.5W（LED）
Brake Lamp 12V，1W （LED）
Neutral LED
Reverse LCD screen
Coolant temperature LCD screen，Code display
Parking brake LED
Four-wheel drive LCD screen
Differential gear lock LCD screen

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 SPECIFICATIONS

ENGINE SPECIFICATIONS

Item Standard Limit

Cylinder head
Warp limit * ---- 0.03 mm
(0.0012 in)

Cylinder
Bore size 91.016 ~ 91.030mm ----
Measuring point * (3.544~ 3.584 in)
50 mm (1.97 in)

Camshaft
Drive method ----
Cam dimensions

Intake
“A” 25.95 ~ 26.05mm
(1.022 ~ 1.026in)
“B” 32.94 ~ 33.06mm
(1.297 ~ 1.302in)
Exhaust “A” 25.95 ~ 26.05mm
(1.022 ~ 1.026in)
“B” 32.94 ~ 33.06mm
(1.297 ~ 1.302in)
Camshaft runout limit ----

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 SPECIFICATIONS
Item Standard Limit
Cam chain
No. of links 126
Cam chain adjustment method Automatic
Rocker arm/rocker arm shaft
Rocker arm inside diameter 12.011~ 12.018 mm
(0.4729 ~ 0.4731 in)
Shaft outside diameter 11.982~ 11.989 mm ----
(0.4717 ~ 0.4720 in)
Arm-to-shaft clearance 0.022 ~ 0.036 mm ----
(0.0009 ~ 0.0014 in)
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.08~ 0.12 mm ----
(0.0031~ 0.0047in)
EX 0.12 ~ 0.15 mm ----
(0.0047 ~ 0.0059 in)
Valve dimensions

head diameter face width seat width margin thickness

“A” head diameter IN 26.9~ 27.1mm ----
(1.0591~ 1.0669 in)
EX 30.9 ~ 31.1 mm ----
(1.2165 ~ 1.2244in)
“B” face width IN 2.25 mm (0.0900 in) ----
EX 2.26 mm(0.0890 in) ----

“C” seat width IN 0.9 ~ 1.1 mm ----

(0.0354 ~ 0.0433 in)
EX 0.9 ~ 1.1 mm ----
(0.0354 ~ 0.0433 in)
“D” margin thickness IN 0.85 ~ 1.15 mm ----
(0.0335 ~ 0.0453 in)
EX 0.85 ~ 1.15 mm ----
(0.0335 ~ 0.0453 in)
Stem outside diameter IN 4.945~ 4.960mm ----
(0.1947 ~ 0.1953 in)
EX 4.945~ 4.960 mm ----
(0.1947 ~ 0.1953 in)
Guide inside diameter IN 5.000 ~ 5.012 mm ----
(0.1969~ 0.1973 in)
EX 5.000 ~ 5.012 mm ----
(0.1969~ 0.1973 in)

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 SPECIFICATIONS
Item Standard Limit
Stem-to-guide clearance IN 0.010 ~ 0.037 mm 0.08 mm
(0.0004 ~ 0.0015 in) (0.0031 in)
EX 0.025 ~ 0.052 mm 0.10 mm
(0.0010 ~ 0.0020 in) (0.0039 in)
Stem runout limit ---- 0.01 mm
(0.0004 in)

Valve seat width IN 0.9 ~ 1.1 mm ----

(0.0354 ~ 0.0433 in)
EX 0.9 ~ 1.1 mm ----
(0.0354 ~ 0.0433 in)
Valve spring
Inner spring
Free length IN 41.0mm (1.61 in) ----
EX 41.0mm(1.61in) ----
Set length (valve closed) IN 31.0mm (1.22 in) ----
EX 31.0 mm(1.22 in) ----
Compressed pressure
(installed) IN 250.0 ~ 290.0N ----
(25.51 ~ 29.59 kg, 56.25 ~ 65.25 lb) ----
EX 250.0 ~ 290.0N ----
(25.51 ~ 29.59 kg, 56.25 ~ 65.25 lb) ----
Tilt limit * IN ---- 2.5°/1.4 mm
(2.5°/0.055 in)
EX ---- 2.5°/1.6 mm
(2.5°/0.063 in)

Direction of winding
(top view) IN Clockwise ----
EX Clockwise ----

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 SPECIFICATIONS
Item Standard Limit
Piston
Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm
(0.0020 ~ 0.0028 in) (0.0059 in)
Piston size “D” 90.940 ~ 90.955mm ----
(3.5803 ~ 3.5809 in)

----
Measuring point “H” 4.0 mm (0.15 in) ----
Piston off-set 0.5mm(0.0394 in) ----
Off-set direction Intake side ----
Piston pin bore inside diameter 20.007 ~ 20.013mm ----
(0.8664 ~ 0.8667in)
Piston pin outside diameter 21.99 ~ 21.995 mm ----
(0.8657 ~ 0.8659 in)
Piston rings
Top ring

Type Barrel ----

3.5 ×1.2mm ----
(0.1378 ×0.0472in)
End gap (installed) 0.25 ~ 0.40 mm ----
(0.0098~ 0.0157 in) ----
Side clearance (installed) 0.04 ~ 0.08 mm ----
(0.0016 ~ 0.0031 in) ----
2nd ring

----
Type Taper
----
3.9×1.5mm
(0.1535~0.0591 in)
----
End gap (installed) 0.30 ~ 0.50mm
----
(0.0118 ~ 0.0197in)
----
Side clearance 0.03 ~ 0.07 mm
----
(0.0012 ~ 0.0028 in)

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 SPECIFICATIONS
Item Standard Limit
Oil ring

----

Dimensions (B×T) 4.0×2.9mm

(0.1575×0.1142in) ----

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)
Crankshaft

Crank width “A” 90.45~ 90.55mm ----

(3.561 ~ 3.565in)
Runout limit C1 ---- 0.03 mm
C2 ---- (0.0012 in)
Big end side clearance “D” 0.4 ~ 0.6 mm 0.03 mm
(0.0157 ~ 0.0236 in) (0.0012 in)
Big end radial clearance “E” 0.041 ~ 0.070 mm 1.0 mm
(0.0016 ~ 0.0028 in) (0.0394 in)

Automatic centrifugal clutch

Clutch engagement speed 1800r/min

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 SPECIFICATIONS
Item Standard Limit
Shifter
Shifter type Shift drum and guide bar ----
Air filter oil grade Engine oil ----
Oil pump
Oil filter type Chartaceous ----
Oil pump type Trochoid ---
Tip clearance 0.15 mm ----
(0.0059 in) ----
Side clearance 0.03 ~ 0.10 mm ----
(0.0012 ~ 0.0039 in) ----
Body clearance 0.09 ~ 0.17 mm ----
(0.0035 ~ 0.0067 in) ----
Bypass valve setting pressure 441.0 ~ 637.0 Kpa ----
(4.41 ~ 6.37 kg/cm2, 62.7 ~ 90.6 psi) ----
Oil pressure (hot) 65 Kpa (0.65 kg/cm2, 9.2 psi) ----
at 1,500 r/min ----
Pressure check location Cylinder head ----
Water pump
Type Single-suction centrifugal pump ----
Reduction ratio 15/15 (1.0) ----
Shaft drive
Middle gear backlash 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ----
Final gear backlash 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ----
Differential gear backlash 0.05 ~ 0.25 mm(0.002 ~ 0.010 in) ----
Cooling system
Radiator core
Width 612 mm (24.09 in) ----
Height 346 mm (13.62 in) ----
Thickness 92 mm (3.62 in) ----
Radiator cap opening pressure 140Kpa ----
(1.4kg /cm2, 20.3psi)
Radiator capacity 1.7 L (1.54 Imp qt, 1.80 US qt) ----
(including all routes)
Coolant reservoir
Capacity 0.25L (0.23 Imp qt, 0.26 US qt) ----
From low to full level 0.20 L (0.15 Imp qt, 0.21 US qt) ----

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 SPECIFICATIONS

CHASSIS SPECIFICATIONS

Item Standard Limit

Steering system
Type Rack and pinion ----
Front suspension
Shock absorber travel 140 mm (5.51 in) ----
Spring free length 350 mm (13.78 in) ----
Spring rate 39.03N/mm(3.98kg/mm) ----
Stroke 30-140 mm (1.18 ~ 5.51in) ----

Rear suspension
Shock absorber travel 155 mm (6.10 in) ----
Spring free length 365 mm (14.37 in) ----
Spring rate 45.89 N/mm (4.68 kg/mm) ----
Stroke 25 ~ 155mm (0.98~ 6.10in) ----
----
----
----
Front wheel
Type Aluminum Alloy wheel ----
Rim size 14 ×7 AT ----
Rim material A356 ----
Rim runout limit radial ---- 1.0 mm
(0.04in)
lateral ---- 1.0 mm
(0.04 in)
Rear wheel
Type Aluminum Alloy wheel ----
Rim size 14×9AT ----
Rim material A356 ----
Rim runout limit radial ---- 2.0 mm
(0.08 in)
lateral ---- 2.0 mm
(0.08 in)
Brake lever and brake pedal
Accelerator pedal free play 2 ~ 3mm (0.079 ~ 0.118 in) ----
Brake pedal free play 2 ~ 3mm (0.079 ~ 0.118 in) ----
Parking brake cable free play 2 ~ 3 mm (0.079 ~ 0.118 in) ----

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 SPECIFICATIONS
Item Standard Limit
Front disc brake
Type Single ----
Disc outside diameter × thickness 255× 5 mm (10.04 × 0.20 in) ----
Pad thickness inner 9.0 mm (0.35 in) ----
Pad thickness outer 9.0 mm (0.35 in) ----
Master cylinder inside diameter 19.0mm (0.75in) ----
Caliper cylinder inside diameter 42.8mm （1.69in） ----
Brake fluid type DOT 3 ----

Rear disc brake

Type Dual ----
Disc outside diameter × thickness 240×5 mm (9.45× 0.20in) ----
Pad thickness inner 6.0 mm (0.24 in) ----
Pad thickness outer 6.0 mm (0.24 in) ----
Master cylinder inside diameter 19.0mm (0.75in) ----
Caliper cylinder inside diameter 25.0mm （0.98in） ----
Brake fluid type DOT 3 ----

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 SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Voltage 12 V ----
Ignition system
Ignition timing (BTDC) 8°±1°before TDC ----
Advancer type ECU Digital type ----
Ignition coil
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.18 ~ 0.28 Ωat 20 °C (68 °F) ----
Secondary winding resistance 6.32 ~ 9.48 kΩat 20 °C (68 °F) ----

Spark plug cap

Resistance 5.0~5.5 kΩ ----
High voltage cap
Resistance 4.5~5.0 kΩ
Oxygen sensor
type 25325359
Charging system
Nominal output 14 V 40 A at 4,500 r/min ----
Charging coil resistance/color 0.32 ~ 0.43Ωat 20 ℃ (68 °F)/White – White – ----
White
Rectifier/regulator
Regulator type Semi conductor-Switch type ----
No load regulated voltage (DC) 14.1 ~ 14.9 V ----
Capacity 42 A ----
Withstand voltage 200 V ----
Battery
Specific gravity 1.32 ----
Circuit breaker
Type Fuse ----
Lighting system fuse 15 A×1
EFI system and instrument insurance 15 A×1 ----
Auxiliary DC jack fuse 、horn 15 A×1 ----
Four-wheel drive fuse 10 A×1 ----
EFI system and instrument often 5A×1 ----
energized insurance ----
Signaling system fuse 10 A×1 ----
Backup fuse) 5 A×1
10 A×1
15 A×1

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 SPECIFICATIONS
Item Standard Limit
Radiator fan
Running rpm 2,950 r/min

Electric starter system

Type Constant mesh type ----
Starter motor ----
Output 0.8 kW ----
Armature coil resistance 0.025 ~ 0.035 Ω ----
Brush overall length 12.5 mm (0.49 in) ----
Starter relay
Amperage rating 180 A ----
Coil winding resistance -----

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 SPECIFICATIONS

LUBRICATION PIONTS AND LUBRICANT TYPES

Engine
Lubrication points Lubricant
Oil seal lips Apply lithium-soap-based grease
Bearings Apply engine oil
O-rings Apply lithium-soap-based grease
Piston, piston ring Apply engine oil
Piston pin Apply engine oil
Buffer boss and balancer drive gear Apply engine oil
Crankshaft seal and spacer Apply engine oil
Valve stem Apply molybdenum disulfide oil
Valve stem end Apply molybdenum disulfide oil
Rocker arm shaft Apply engine oil
Rocker arm Apply molybdenum disulfide grease
Camshaft lobe and journal Apply molybdenum disulfide grease
Oil pump assembly Apply engine oil
Oil filter cartridge O-ring Apply lithium-soap- based grease
Starter idle gear shaft Apply molybdenum disulfide grease
Starter wheel gear Apply engine oil
Clutch housing assembly shaft end Apply lithium-soap- based grease
Clutch carrier assembly Apply engine oil
One-way clutch bearing Apply molybdenum disulfide grease
Middle driven shaft splines Apply molybdenum disulfide oil
Drive axle, driven sprocket, high wheel gear, and low wheel
Apply molybdenum disulfide oil
gear
Middle drive gear and clutch dog shift fork groove Apply molybdenum disulfide oil
Driven chain/sprocket Apply engine oil
Shift drum Apply engine oil
Shift fork guide bar Apply engine oil
Shift drum stopper ball Apply engine oil
Shift lever 2 assembly Apply lithium-soap- based grease
Shift lever 1 Apply engine oil
Shift lever 1 and shift lever 2 assembly mating surface Apply engine oil

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 SPECIFICATIONS

CHASSIS
Lubrication points Lubricant
Lip of oil seal (full) Light lithium-base grease
o-ring(full) Light lithium-base grease
Steering shaft (upper end ,lower end) Light lithium-base grease
Ball connection of steering pushing rod Light lithium-base grease
Front wheel fork(ball-shaped joint) Light lithium-base grease
Front wheel bearing Grease used for bearing
Front & rear brake Light lithium-base grease
Dust-proof ring of brake Light lithium-base grease
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
Adjusting nut and pin of rear brake cable Light lithium-base grease
Rear brake pedal pivot and brake pedal axle hole Light lithium-base grease
Throttle rotating frame shaft and end section of throttle cable Light lithium-base grease
Reverse gear lever pivot Light lithium-base grease
Connection bolt of rear wheel fork and frame,rear wheel fork Light lithium-base grease
bearing
Rubber sleeve and rear wheel fork Seal gum
Rear shock absorber bushing Light lithium-base grease

- 73-
 SPECIFICATIONS

HYDROGRAPHIC CHART

Hydrographic chart
：Pressure

- 74-
 SPECIFICATIONS

LUBRICATION OIL WAY

LUBRICATION OIL WAY

：Pressure
：splashing oil

- 75-
 SPECIFICATIONS

Engine gearbox lubrication oil path circuit

Gearbox lubrication oil path circuit

：Pressure
：splashing oil

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 MAINTENANCE AND ADJUSTMENT OF THE UTV
MAINTENCE AND ADJUSTMENT OF THE UTV
CAUTION:
Be sure you have sufficient knowledge, experience, the proper replacement parts and tools
before you attempt any vehicle maintenance task.
If you don’t have the knowledge and equipment which are necessary to perform the
maintenance task, consult your local dealer.

MAINTENANCE SCHEDULE
MAINTENANCE INTERVAL (WHICHEVER
ITEM COMES FIRST) REMARKS
Hours Frequency Miles (KM)
Pre-Ride Inspection Check
Steering - Pre-Ride - Inspect for loose hardware or abnormal wear
Front-suspension - Pre-Ride - Inspect for loose hardware or abnormal wear
Rear-suspension - Pre-Ride - Inspect for loose hardware or abnormal wear
Tires - Pre-Ride - Proper tire pressure
Brake fluid level - Pre-Ride - Inspect and add if needed
Brake pedal travel - Pre-Ride - See Owner's Manual
Brake systems - Pre-Ride - Make adjustments as needed.
Lug Nuts - Pre-Ride - Ensure lug nuts are torque to spec
Frame fasteners - Pre-Ride - All fasteners are secured
Engine Oil Level - Pre-Ride - Inspect and add if needed
Coolant - Pre-Ride - Inspect and add if needed

Head / Tail / Brake Lights - Pre-Ride - Check operation

Break-In Maintenance Check

Replace break-in oil & filter with proper oil
Engine Oil/Filter change 10 - First 50 (75)
type
Initial fluid level inspection; add lubricant if
Transmission 20 - First 100 (150)
needed
Inspect periodically; adjust when parts are
Toe adjustment 20 - First 100 (150)
replaced
Clutches (Drive and
20 - First 100 (150) Inspect; clean; replace worn parts
Driven)
Routine Maintenance Check (performed at each interval below, whichever comes first)
Air filter 5H - - Inspect; replace as needed
Brake pad wear 20 H Monthly 250 (402) Inspect periodically
Throttle Body Intake 20 H 1M 250 (402) Inspect duct for proper sealing/air leaks
Battery 20H Monthly 250 (402) Check terminals; clean; test
Fuel System 25 H Monthly 250 (402) Check lines & fittings for leaks
General lubrication 25H 3M 250 (402) Lubricate all fittings, pivots, cables, etc.
Shift Linkage 25H 3M 250 (402) Inspect, lubricate, adjust
Engine Oil & Filter 50 H 6M 500 (800) Replace
Steering 50 H 6M 500 (800) Lubricate
Front / Rear Gearcase
50H 6M 500 (800) Change Fluid
Fluid
Front / Rear Stabilizer
50H 6M 500 (800) Lubricate and inspect bushings
Bars
Throttle Pedal/Cable 50 H 6M 500 (800) Inspect for free movement & lubricate

Drive Belt 50 H 6M 500 (800) Inspect; replace as needed

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 MAINTENANCE AND ADJUSTMENT OF THE UTV

MAINTENANCE INTERVAL (WHICHEVER

ITEM COMES FIRST) REMARKS
Hours Frequency Miles (KM)
Antifreeze Coolant 50 H 6M 500 (800) Pressure Test / Add Fluid

Tranmission Fluid 50 H 6M 500 (800) Replace

Engine mounts 100 H 12 M 1000 (1600) Inspect; replace as needed

Cooling Hoses 100 H 12 M 1000 (1600) Inspect for cracks and leaks

Drive Shafts 100H 12M 1000 (1600) Remove and grease

Spark plug 100 H 12 M 1000 (1600) inspect; replace as needed

Clutches (Drive and
100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
Driven)
Wiring 100 H 12 M 1000 (1600) Inspect for wear & routing

Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed

Shocks 100 H 12 M 1000 (1600) Check for oil leaks

Cam Chain Tensioner 100H 12 M 1000 (1600) Check; replace as needed

Brake Fluid 100 H 12M 1000 (1600) Change every two years

Suspension Components 100H 12M 1000 (1600) Inspect; replace if necessary

Spark arrestor 100H 12 M - Clean out

Valve clearance 100 H 12M 1000 (1600) Inspect; adjust

Extreme Maintenance Check (cut the Routine Maintenance Schedule in half)

*Service Note: Under extreme use, change gear case fluid every 25 hours. "Extreme Use" is defined as constant 4WD
operation on hilly or mountainous terrain, or if 4WD is the primary mode of operation.

LUBRICATION RECOMMENDATIONS
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart above , or
more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be
lubricated at the general lubrication interval.
ITEM LUBE METHOD
See Viscosity Chart (10-3)
Engine Oil Add to proper level on dipstick.
API-SJ & JASO/MA
Brake Fluid DOT 3 or 4 Brake Fluid Maintain level between fill lines.
Fill to bottom of fill plug or
Rear Differential SAE 80w90
0.455L or 14 oz.)
Fill to bottom of fill plug or
Front Differential Dextron 3 ATF
(volume of oil)
Drive Shaft U-Joint Grease Locate fittings and grease.

ENGINE OIL
Always check and change the oil at the intervals outlined in the Service Interval Chart above. Always
use the recommended engine oil. Always change the oil filter whenever changing oil.
Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident and injury.
Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart. Failure
to perform routine maintenance could result in voiding of remaining warranty.

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MAINTENANCE AND ADJUSTMENT OF THE UTV
ENGINE
Adjusting the valve clearance

NOTE:
·The valve clearance must be adjusted when the
engine is cool to the touch.
·Adjust the valve clearance when the piston is at
the Top Dead Center TDC) on the compression
stroke.
·Remove:
·driver seat
·passenger seat
·console

1. Remove following parts：

① spark plug
② cylinder cover
③ Crankshaft position sensor
④ Inspection hole cover
⑤ bolt M6 x 10
⑥ cylinder #1
⑦ cylinder #2

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MAINTENANCE AND ADJUSTMENT OF THE UTV
2. Remove：
① remove the bolts
② Crankshaft position sensor
③ Inspection hole cover
④ cylinder cover
3. Check:
·valve clearance
·Beyond the standard Adjust.

Valve clearance (cold)

Intake
0.08 ~ 0.12 mm
(0.0031 ~ 0.0047 in)
Exhaust
0.12 ~ 0.16 mm
(0.0047 ~ 0.0063 in)

4. calibration
adjusting tools ○
A

Spin the crank, when the rotoflex’s scale shows 1,

it is cylinder 1’s timing; spin the crank counter
clockwise280°, the rotoflex’s scale shows 2, it is
cylinder 2’s timing, the valve clearance of cylinder
2 can be adjusted

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MAINTENANCE AND ADJUSTMENT OF THE UTV
5. Adjust the valve clearance of cylinder 1, and
cylinder 2 the same way
valve clearance
① Pin lock nut
② Valve thickness gauge（gap Regulation）
③ Regulator
④ Adjust tools
· Loosen the locknut ①.
· Insert a thickness gauge ③ between the adjuster
end and the valve end.
·Turn the adjuster ③ clockwise or counterclockwise
with the tappet adjusting tool ④until the proper
clearance is obtained.
· in order to avoid adjuster rotating along, fix the lock
nut after finishing

Fixed nut
14 Nm(1.4 m·kgf, 10 ft·lbs)

· Measuring clear
· Measure the clearance of valve with gap gauge.
· If the gap beyond the standard value, repeat the
above steps until the correct gap.
6. Install all removed parts
According to remove the reverse order for
installation
① left front cover, crankcase
② ignition sensor
③ Bolt M6×10
④ air intake valve cover
⑤ Lower the cargo bed.
⑥ console
⑦ passenger seat
⑧ driver seat
Refer to “SEATS” in chapter 5.

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MAINTENANCE AND ADJUSTMENT OF THE UTV
CHECKING THE SPARK PLUG
1. lift up cargo box and dismount the seat
2. Remove:
pull out the spark plug cap ①
3. Check:
·spark plug type
Incorrect Replace.

Standard spark plug

DCPR7E/NGK

4. Check:
·electrode ①
To check if it is burned blunt or much carbon is
there, then check the pole clearance by thickness
gauge. It is qualified if the pole clearance is between
0.8 to 0.9mm. Otherwise it should be adjusted.
Wear/damage Replace.
·insulator ②
Abnormal color Replace.
Normal color is a medium-to-light tan color.
5. Clean the spark plug with a spark plug cleaner or
wire brush.
6. Install:
·spark plug
17.5 Nm(1.75 m·kgf, 12.7 ft·lbs)

·Then hook up the spark plug cap.

NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
7. Install:
·Lower the cargo bed
·console
·passenger seat
·driver seat

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MAINTENANCE AND ADJUSTMENT OF THE UTV
CHECKING THE IGNITION TIMING

NOTE:
before checking the ignition timing, adjust the
engine’s racing speed and throttle cable.

1. Remove:
·driver seat
·passenger seat
·console
Refer to “SEATS” in chapter 5.
2. Lift the cargo bed up.
3. Attach:
· Engine tachometer ⑤
(to the spark plug lead)
4. Remove:
Refer to remove manual starting mechanism ②、③、
① name
5. Check:
· Engine tachometer
a. worm up the engine at specified speed

Engine speed
1,400 ~ 1,500 r/min

b. Remove Ignition signal sensor ②

c. Visually check the stationary pointer ③ to verify it
is within the required firing range④indicated on the
flywheel.
Incorrect firing range Check the pulser coil
assembly.
d. Install the timing plug.
6. Install:
·Engine manual starting mechanism
7 Nm (0.7 m ·kg, 5.1 ft ·lb)
7. Install:
·manual starting mechanism cover
10 Nm (1.0 m ·kg, 7.2 ft ·lb)
8. Detach:
· timing light
9. Lower the cargo bed.
10. Install:
·console
·passenger seat

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MAINTENANCE AND ADJUSTMENT OF THE UTV
·driver seat
Refer to “SEATS” in chapter 5.

MEASURING THE COMPRESSION PRESSURE

NOTE:
Insufficient compression pressure will result in
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 meter ①
and joint utensil ② on the hole of the spark plug
4. check
valve clearance
Out of specification Adjust. Refer to “ADJUSTING
THE VALVE CLEARANCE”
standard value
standard compression pressure data
1200Kpa (12kg/c)-1000r/min
5. read the highest data on the compression
pressure meter
·Above the maximum pressure:
Check the cylinder head, valve surfaces, and
piston crown for carbon deposits.
·Below the minimum pressure:
Check the accumulation carbon in the firebox of
the cylinder head and accumulation carbon on the
piston head.
·Refer to the table below.

Compression pressure(with oil introduced into

cylinder)
Reading Diagnosis
Higher than Worn or damaged pistons
without oil
Same as without Defective ring(s), valves,
oil cylinder head gasket or
piston is possible.

Compression pressure
(at sea level)
Standard: 1,324Kpa
(13.24 kg/cm2, 188.31Psi)
Minimum: 1,150Kpa

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MAINTENANCE AND ADJUSTMENT OF THE UTV

(11.5 kg/cm2, 163.57Psi)

Maximum: 1,480Kpa
(14.8 kg/cm2, 210.50Psi)
·Crank over the engine with the electric starter (be
sure the battery is fully charged) with the throttle
wide-open until the compression reading on the
gauge stabilizes.

NOTE:
When cranking the engine, ground the spark plug
lead to prevent sparking.
4. Install:
·spark plug
18 Nm-20Nm (1.8 m ·kg, 13 ft ·lb)
5. Lower the cargo bed.

CHECKING THE ENGINE OIL LEVEL

1. Place the vehicle on a level surface
2. Remove:
·driver seat
·passenger seat
·console
Refer to “SEATS” in chapter 5.
3. Check:
·engine oil level
Oil level should be between the maximum
②and minimum ③marks.
Oil level low Add oil to the proper level.
NOTE:
Do not screw the dipstick ① in when checking
the oil level.

Recommended oil
Follow the left chart.

NOTE:
Recommended oil classification:
API-SJ & JASO/MA

NOTE:
Do not allow foreign material to enter the
crankcase.

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MAINTENANCE AND ADJUSTMENT OF THE UTV
4. Stop the engine and check the oil level again
NOTE:
Wait a few minutes until the oil settles before
checking the oil level.

NOTE:
Never remove the dipsti]ck just after high speed
operation because the heated oil could spurt out.
Wait until the oil cools down before removing the
dipstick.

6. Install:
·console
·passenger seat
·driver seat
Refer to “SEATS” in chapter 5.

CHANGING THE ENGINE OIL

Place the vehicle on a level surface.
1. Start the engine and let it warm up for several
minutes.
2. Stop the engine and place an oil pan under the
engine.
3. Remove:
·driver seat
·passenger seat
·console
4. Remove:
dismount the following parts step by stem
① oil gauge
⑤ oil-draining blind nut, crankcase
⑥ oil-draining bolt, gear box
⑦ bolt M6 x 20 ,oil filter
⑧ oil filter cover
⑨ sealing ring
⑩ paper core oil filter
5. If you need to change the oil filter core, please
follow the steps below exactly (Generally change
the oil and core after run in-time.)
·Take out the oil gauge, and then dismount ②and
③, drain the oil.
· Dismount bolt ④ with a pipe wrench #8,remove
⑤ and ⑥,then take out ⑦.

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MAINTENANCE AND ADJUSTMENT OF THE UTV
· Replacement of the filter element, assembly by
disassembly sequence reverse operation.
.
6. Install：
·engine oil drain bolt ②
·Final gear oil drain bolt ③

7. conditions
·Change for new oil filter before impouring oil to
crankcase, and make sure it is in good working
condition before assembling.
·make sure that the oil reach regular level when the
vehicle is placed on flat ground.
Oil level of gearbox
Periodic oil change
The oil capacity after the engine is
disassembled and reassembled.
2L
The oil should be put into the engine for after
all the oil is drawn out
2L
8. Install:
·engine oil filler plug
9. Worm up the engine for a few minutes, and then
stop the engine.
10. Check:
·engine (for engine oil leaks)
·refer to Chapter 4 check the level of engine oil
11. Check:
·engine oil pressure
12. Install:
·console
·passenger seat
·driver seat
Refer to “SEATS” in chapter 5.

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MAINTENCE AND ADJUSTMENT OF THE UTV

CHASSIS
CLEANING THE AIR FILTER
NOTE:
There is a check hose ① at the bottom of the
air filter case. If dust and/or water collect in
this hose, clean the air filter element and air
filter case.

1. Remove:·
· Front face plate
·air filter case cover ②
·air filter element assembly③
·air filter element④
·Element retaining plat⑤

NOTE:
Never operate the engine with the air filter
element removed. This will allow unfiltered air to
enter, causing rapid wear and possible engine
damage. Additionally, operation without the
filter element will affect carburetor tuning with
subsequent poor performance and possible
engine overheating.

2. Check:
·air filter element④
·Damaged Replace.
3. Clean:
·air filter element
a. Wash the element gently, but thoroughly in
solvent.

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MAINTENCE AND ADJUSTMENT OF THE UTV

WARNING:
Use a cleaning solvent which is designed to
clean parts only. Never use gasoline or low
flash point solvents as they may cause a
fire or explosion.

b. squeeze the excess solvent out of the element

and let it dry.
NOTE:
Do not twist or wring out the element. This could
damage the foam material.

c. Squeeze out the excess oil.

NOTE:
The element should be wet but not dripping.

4. Install:
·air filter element
·air filter case cover
NOTE:
To prevent air leaks make sure that the sealing
surface of the element matches the sealing
surface of the case.

·console
·passenger seat
·driver seat
CHECKING THE COOLANT LEVEL
1. Place the vehicle on a level surface.
2. Remove front faceplate
3. Check:
·start the engine, warm it up for several minutes,
and then turn it off.
·coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.

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 MAINTENCE AND ADJUSTMENT OF THE UTV

·coolant level
The coolant level should be between the
minimum level mark ○
a and maximum level

mark ○
b .Below the minimum level mark

Add the recommended coolant to the proper level.

CHANGING THE COOLANT

1.Remove:
Front faceplate
·coolant reservoir cap ① ；
·Disconnect coolant reservoir hose ②；
· Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is used
instead of coolant, check and if necessary,
correct the antifreeze concentration of the
coolant；
·Use only distilled water. However, soft water
may be used if distilled water is not available.
2. Drain:
·coolant
(from the coolant reservoir)
3. Connect:
·coolant reservoir hose

4. Remove:
·coolant drain bolt (water pump) ①(along with the
copper washer)

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 MAINTENCE AND ADJUSTMENT OF THE UTV

5. Remove:
·radiator cap ①
WARNING:
A hot radiator is under pressure. Therefore, do
not remove the radiator cap when the engine is
hot. Scalding hot fluid and steam may be blown
out, which could cause serious injury. When the
engine has cooled, open the radiator cap as
follows: Place a thick rag or a towel over the
radiator cap and slowly turn the radiator cap
counterclockwise toward the detent to allow
any residual pressure to escape.
When the hissing sound has stopped, turn
the radiator cap counterclockwise while
pressing down on it and then remove it.

6. Drain:
·coolant
7. Disconnect:
·coolant outlet hose ①
·water pump inlet hose ②
8. Drain:
·coolant

9. Check:
·copper washer ①
·coolant drain bolt ②
Damage Replace.
10. Install:
·coolant drain bolt (water pump) T R.

10 Nm (1.0 m ·kg, 7.2 ft ·lb)

11. Connect:
·water pump inlet hose
·coolant outlet hose

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 MAINTENCE AND ADJUSTMENT OF THE UTV

12. Remove:
·air bleed bolt ①
13. Fill cooling
(with the specified amount of the recommended
coolant)

Recommended antifreeze
High-quality ethylene glycol antifreeze
containing corrosion inhibitors for
aluminum engines
Mixing ratio
1 : 1 (antifreeze : water)
Quantity total amount
1.32 L
Coolant reservoir capacity
0.627 L

NOTE:
The specified amount of coolant is a standard
amount. Fill the cooling system with coolant
until coolant comes out of the hole for the air
bleed bolt.
Coolant is potentially harmful and should be
handled with special care.

WARNING:
·If coolant splashes in your eyes, thoroughly
wash them with water and consult a doctor；
·If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water；
·If coolant is swallowed, induce vomiting and
get immediate medical attention；
·If coolant comes into contact with painted
surfaces, immediately wash them with water；
·Do not mix different types of antifreeze.

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 MAINTENCE AND ADJUSTMENT OF THE UTV

NOTE:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if
necessary, correct the antifreeze concentration
of the coolant. Use only distilled water.
However, soft water may be used if distilled
water is not available.

14. Install:
·air bleed bolt

9 Nm (0.9 m ·kg, 6.5 ft ·lb)

·radiator cap；
·Fill coolant reservoir；
·Install coolant reservoir cap:
·Start the engine, warm it up for several minutes,
and then turn it off.
·Check:
coolant level

Refer to “THE COOLANT” in chapter 4.

NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.

·Close the hood.

·Install driver seat
Refer to “SEATS,” in chapter 5.

CHECKING THE COOLANT TEMPERATURE

WARNING LIGHT
Coolant temperature indicator light ①

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 MAINTENCE AND ADJUSTMENT OF THE UTV

Coolant temperature warning light checking method

Turn the main switch “ON”.

Coolant temperature warning light Coolant temperature warning light

does not come on. come on.

Turn the main switch to “START”

with the transmission in neutral
position.

Coolant temperature warning light Coolant temperature warning

comes on momentarily . light does not come on.

Coolant temperature and electrical

Check the electrical circuit
circuit are OK .Go ahead with riding.

CHECKING THE V-BELT

1. Remove:
·driver seat
·drive belt cover
·Check:
a. V-belt ①
Cracks/wear/scaling/chipping Replace.
Oil/ grease Check primary sheave and
secondary sheave。
b. V-belt width ②
Out of specification Replace.

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 MAINTENCE AND ADJUSTMENT OF THE UTV

V-belt width: 31.2 mm

<Limit:> 26 mm

·Replace V-belt:
Install the bolts ① into the secondary fixed
sheave hold.

NOTE:
Tightening the bolts ①will push the secondary
sliding sheave away, causing the gap between
the secondary fixed and sliding sheaves to
widen.

·Remove the V-belt ①from the primary sheave

and secondary sheave.
·Install the V-belt.

NOTE:
Install the V-belt so that its arrow faces the
direction shown in the illustration.

· Remove the bolts.

2. Install:
· drive belt cover
· console
· passenger seat
· driver seat
CLEANING THE SPARK ARRESTER
1. Clean:
Tap the tailpipe lightly with a soft-face hammer or
suitable tool, then use a wire brush to remove any
carbon deposits from the spark arrester portion of
the tailpipe and the inner contact surfaces of the
muffler.
2. Spark arrester

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MAINTENCE AND ADJUSTMENT OF THE UTV

WARNING:
· Select a well-ventilated area free of
combustible materials.
·Always let the exhaust system cool before
performing this operation.
· Do not start the engine when removing the
tailpipe from the muffler.

3. Remove:
·Remove the bolts①.
·Remove the tailpipe ② by pulling it out of the
muffler.
4. Install：
·Insert the tailpipe ② into the muffler and align the
bolt holes.
·Insert the bolt 1 and tighten it.
·Start the engine and rev it up approximately
twenty times while momentarily creating exhaust
system back pressure by blocking the end of the
muffler with a shop towel.
·Stop the engine and allow the exhaust pipe to
cool.

ADJUSTING THE BRAKE PEDAL

1. Check:
·brake pedal free play a Out of specification
adjust.

NOTE:
The end of the brake rod ① should lightly
contact the brake master cylinder ②

Brake pedal free play

0 mm (0.0 in)

3. Adjust：
·brake pedal free play
a. Loosen the locknut ①

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MAINTENCE AND ADJUSTMENT OF THE UTV

b. Turn brake rod ② in or out until the correct free

play is obtained.

Turning in Free play is increased.

Turning out Free play is decreased.
c. Tighten the locknut to specification.

Locknut
17 Nm (1.7 m ·kg, 12 ft ·lb)

NOTE:
Make sure that there is no brake drag on the
front or rear wheels.

CHECKING THE BRAKE FLUID LEVEL

1. Place the vehicle on a level surface.

NOTE:
When checking the brake fluid level, make sure
that the top of the brake fluid reservoir top is
horizontal.

2. Lift the hood up.

3. Check:
·brake fluid level Fluid level is under “MIN” ①
Level line Fill up.

NOTE:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.

WARNING:
· Use only the designed quality brake fluid:
otherwise, the rubber seals may deteriorate,
causing leakage and poor brake performance.
·Refill with the same type of brake fluid: mixing
fluids may result in a harmful chemical
reaction and lead to poor performance.
·Be careful that water does not enter the master

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 MAINTENCE AND ADJUSTMENT OF THE UTV
. cylinder when refilling. Water will significantly
lower the boiling point of the fluid and may
result in a vapor lock.

4. Close the hood.

CHECKING THE FRONT BRAKE PADS

1. Remove:
·front wheels
2. Check:
·brake pads Wear indicator groove ○
a almost

disappeared
Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 5.

Brake pad wear limit ○

a
1.5 mm (0.06 in)
3. Operate the brake pedal.
4. Install:
·front wheels

CHECKING THE REAR BRAKE PADS

1. Check:
·brake pads
Wear indicator groove ○
a almost disappeared

Replace the brake pads as a set.

Refer to “FRONT AND REAR BRAKES” in
chapter 5.

Brake pad wear limit ○

a
1.5 mm (0.06 in)

3. Operate the brake pedal.

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MAINTENCE AND ADJUSTMENT OF THE UTV

CHECKING THE BRAKE HOSES AND BRAKE

PIPES
1. Remove:
·driver seat
Refer to “SEATS” in chapter 5.
2. Lift the hood up.
3. Check:
·front brake hoses ①
·rear brake hoses ②

Cracks/wear/damage Replace.
Fluid leakage Replace all damaged parts.
Refer to “FRONT AND REAR BRAKES” in
chapter 5.
NOTE:
Hold the vehicle in an upright position and apply
the brake pedal.

4. Install driver seat

BLEEDING THE HYDRAULIC BRAKE SYSTEM

WARNING:
Bleed the brake system if:
·The system has been disassembled.
· A brake hose or brake pipe have been
loosened or removed.
·The brake fluid has been very low.
The brake operation has been faulty. A loss of
braking performance may occur if the brake
system is not properly bled.

1. Bleed:
·brake system
a. Add the proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to spill any
fluid or allow the reservoir to overflow.
c. Remove the cover of the brake oil pump ① add
the moderate brake liquid.

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 MAINTENCE AND ADJUSTMENT OF THE UTV
.
d. Place the other end of the hose into a container.
e. Slowly apply the brake pedal several times.
f. Push down on the pedal and hold it.
g. Loosen the bleed screw and allow the pedal to
travel towards its limit.
h. Tighten the bleed screw when the pedal limit has
been reached, then release the pedal.
i. Repeat steps (e) to (h) until all the air bubbles
have disappeared from the fluid.
j. Tighten the bleed screw.

Front brake caliper bleed screw

6 Nm (0.6 m ·kg, 4.3 ft ·lb)
Rear brake caliper bleed screw
5 Nm (0.5 m ·kg, 3.6 ft ·lb)

NOTE:
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the system have disappeared.

k. Add brake fluid to the proper level.

WARNING:
Check the operation of the brake after bleeding
the brake system.

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MAINTENCE AND ADJUSTMENT OF THE UTV

ADJUSTING THE SELECT LEVER SHIFT ROD

(BENCH)
① Neutral
② High
③ Low
④ Reverse
⑤ Parking
⑥ Select lever shift rod
WARNING:
Before shifting, you must stop the vehicle and
take your foot off the accelerator pedal.
Otherwise, the transmission may be damaged.

1. Adjust:
·Select lever shift rod
A. Make sure the select lever is in NEUTRAL.
B. Lock nut ①.
WARNING:
The select lever shift rod locknut (select lever
side) has left-handed threads. To loosen the
locknut, turn it clockwise.

C. Lock nut ①.

ADJUSTING THE BRAKE LIGHT SWITCH

NOTE:
· The brake light switch is operated by
movement of the brake pedal.
·The brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.

1 . Check
·brake light operation timing
Incorrect Adjust.
2. Adjust:
·brake light operation timing

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 MAINTENCE AND ADJUSTMENT OF THE UTV

ADJUSTING THE SELECT LEVER SHIFT ROD

(BUCKET)
① Neutral
② High
③ Low
④ Reverse
⑤ Parking
⑥ Select lever shift rod
WARNING:
Before shifting, you must stop the vehicle and
take your foot off the accelerator pedal.
Otherwise, the transmission may be damaged.

1. Adjust:
·Select lever shift rod
A. Make sure the select lever is in NEUTRAL.
B. Lock nut ①.
WARNING:
The select lever shift rod locknut (select lever
side) has left-handed threads. To loosen the
locknut, turn it clockwise.

C. Lock nut ①.

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MAINTENCE AND ADJUSTMENT OF THE UTV

CHECKING THE FINAL GEAR OIL LEVEL

1. Place the vehicle on a level surface.
2. Remove:
·oil filler plug ②
3. Check:
·oil level
Oil level should be up to the brim of the hole.
Oil level low Add oil to the proper level.

Recommended oil
SAE 80 API GL-4Hypoid gear oil

WARNING:
Take care not allow foreign material to enter the
final gear case.

4. Install:
·oil 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 used oil.
3. Remove:
·oil filler plug ②
·Fill:
final gear case

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 MAINTENCE AND ADJUSTMENT OF THE UTV

Periodic oil change : 0.25 L (0.22 Imp qt)

Total amount :
0.4 L (0.35 lmp qt, 0.42 US qt)

WARNING:
Take care not to allow foreign material to enter
the final gear case.

·Install:
oil filler plug

23 Nm (2.3 m ·kg, 17 ft ·lb)

CHECKING THE DIFFERENTIAL GEAR OIL

1. Place the vehicle on a level surface.
2. Remove:
·oil filler plug ①
3. Check:
·oil level
Oil level should be up to the brim of hole.
Oil level low Add oil to proper level.
WARNING:
Take care not allow foreign material to enter the
differential gear case.

4. Install:
·oil filler plug

23 Nm (2.3 m ·kg, 17 ft ·lb)

CHANGING THE DIFFERENTIAL GEAR OIL

1. Place the vehicle on a level surface.
2. Place a receptacle under the differential gear
case.
3. Remove:
·oil filler plug ①
4. Drain:
·differential gear oil
. .

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 MAINTENCE AND ADJUSTMENT OF THE UTV

5. Install:
·drain plug

10 Nm (1.0 m ·kg, 7.2 ft ·lb)

NOTE:
Check the gasket (drain plug). If it is damaged,
replace it with new one.

6. Fill:
·differential gear case

Periodic oil change

0.32 L (0.28 Imp qt, 0.34 US qt)
Total amount
0.1 L (0.085 lmp qt, 0.105 US qt)

NOTE:
If gear oil is filled to the brim of the oil filler hole,
oil may start leaking from the differential gear
case breather hose. Therefore, check the
quantity of the oil, not its level.

WARNING:
Take care not to allow foreign material to enter
the differential gear case.

7. Install:
• oil filler plug

23 Nm (2.3 m ·kg, 17 ft ·lb)

CHECKING THE CONSTANT VELOCITY JOINT

DUST BOOTS
1. Check:
• dust boots ①
Damage Replace.
Refer to “FRONT CONSTANT VELOCITY
JOINTS,” in chapter 5.
□
F Front

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 MAINTENCE AND ADJUSTMENT OF THE UTV

□
R Rear

CHECKING THE STEERING SYSTEM

1. place the vehicle on the flat ground .
● Check:
Clamp seat of steering vertical column and sliding
bearing on the lower end of steering vertical column,
upper ＆ lower and front ＆ rear moving steering
bar .If the clearance is too large, replace the
sliding bearing.
Refer to section “Steering system” of chapter 5.

● Check:
Ball joints and/or wheel bearings Move the wheels
laterally back and forth. Excessive free
play Replace the front arms (upper and lower)
and/or wheel bearings.

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MAINTENCE AND ADJUSTMENT OF THE UTV

ADJUSTING THE TOE-IN

1. Place the vehicle on a level surface.
2. Measure:
• toe-in
Out of specification Adjust.

Toe-in
8~ 18 mm (0.00 ~ 0.39 in)
(with tires touching the ground)

NOTE:
Before measuring the toe-in, make sure that the
tire pressure is correct.

a. Mark both front tire tread centers.

b. Lift the front end of UTV to keep the front wheel
from force .
c. Faster the steering forward . Meager the wide the
between two marks.
d. Rotate the front tires 180° until the marks are
exactly opposite one another.
e. Measure distance □
B between the marks.

f. Calculate the toe-in using the formula given

below.

Toe-in=□
B -□
A

g. If the toe-in is incorrect, adjust it。

3. Adjust toe-in

WARNING:
Make sure that left / right tension rods have
turned the same turns . Otherwise the UTV will
still go UTV left and right even though . Operate
the UTV to go forward straightly with steering
bar , easily causing to getting out of control and
accident . After adjusting the toe-in correctly
drive the UTV to move forward a span of
distance by fastering the steering bar so as
tomake , sure if the Steering bar is pormal , if
not , adjust the tension rod left or right within
the specification .

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MAINTENCE AND ADJUSTMENT OF THE UTV

ADJUSTING THE FRONT AND REAR SHOCK

ABSORBERS
WARNING:
These shock absorber assemblies contain
highly pressurized nitrogen gas, read and
understand the following information before
handling the shock absorber assemblies.
· Do not tamper with or attempt to open the
cylinder assemblies.
·Do not subject the shock absorber assemblies
to an open flame or other high heat source. This
may cause the unit to explode due to excessive
gas pressure.
·Do not deform or damage the cylinders in any
way. Cylinder damage will result in poor
damping performance.
· Do not dispose of a damaged or worn out
shock absorber assembly yourself. Take the
shock absorber assembly to a HSUN dealer for
any service.

The spring preload, rebound damping and

compression damping forces of the front and rear
shock absorber assemblies can be adjusted to suit
the operating conditions.
NOTE:
Never turn an adjusting mechanism beyond the
minimum and maximum settings.

Spring preload
1. Loosen the locknut.
2. Turn the spring preload adjusting nut in direction
ⓐ to increase the spring preload and thereby
harden the suspension, and in direction ⓑ to
decrease the spring preload and thereby soften
the suspension.
Locknut ①
Spring preload adjusting nut ②
Special wrench ③

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MAINTENCE AND ADJUSTMENT OF THE UTV
· A special wrench can be obtained at a HSUN
dealer to make this adjustment.
·The spring preload setting is determined by
measuring ①, shown in the illustration. The shorter
① is, the lower the spring preload; the longer
distance A is, the higher the spring preload. With
each complete turn of the adjusting nut.

Spring travel setting(Front)

Maximum(hard): 140mm
Spring travel setting(Rear)
Maximum(hard): 155mm
3. Tighten the locknut.

NOTE:
Always tighten the locknut against the
adjusting nut, and then tighten it to the
specified torque.

Rebound damping force

Turn the rebound damping force adjusting screw ①
in direction S to increase the rebound damping force
and thereby harden the damping, and in direction F
to decrease the rebound damping force and thereby
soften the damping.

Compression damping force

Turn the compression damping force adjusting
screw ① (use 3.0 all en wrench) in direction ⓐ to
increase the compression damping force and
thereby harden the damping, and in direction ⓑ to
decrease the compression damping force and
thereby soften the damping.

WARNING:
·Suspension components become hot during
operation. Never touch the compression
damping force adjusting screw, the rebound
damping force adjusting screw or the oil
reservoir with your bare hand or skin until
suspension components have cooled.
·Always adjust the shock absorber
assemblies on the left and right side to the same

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MAINTENCE AND ADJUSTMENT OF THE UTV

setting. Uneven adjustment can cause poor

handling and loss of stability, which could lead
to an accident.

CHECKING THE TIRES

WARNING:
• TIRE CHARACTERISTICS
Tyre characteristics influence the handling
of vehicle’s. If other tire combinations are
used, they can adversely affect your vehicle’s
handling characteristics and are therefore not
recommended.
Size Type
Front 6PR 27× 9-14
Rear 6PR 27× 11-14

• TIRE PRESSURE
a. Recommended tire cold pressure
Front 138Kpa (20psi)
Rear 180KPa (26psi)
when seating the tire beads. Higher pressure
may cause the tire to burst.
Inflate the tires slowly and carefully.
Fast inflation could cause the tire to burst.
• MAXIMUM LOADING LIMIT
a. Vehicle loading limit (total weight of cargo,
operator, passenger and accessories, and
tongue weight): 407kg
b. Cargo bed: 159kg
c. Trailer hitch:
Pulling load (total weight of trailer and cargo):
800 kg
Tongue weight (vertical weight on trailer hitch
point): 58 kg
Be extra careful of the vehicle balance and
stability when towing a trailer.

1. Measure:
• Tire pressure (cold tire pressure) out of
specification Adjust.

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MAINTENCE AND ADJUSTMENT OF THE UTV

NOTE:
• The tire pressure gauge ① is included as
standard equipment.
• If dust or the like is stuck to this gauge, it will
not provide the correct readings. Therefore,
take two measurements of the tire’s pressure
and use the second reading.

WARNING:
Uneven or improper tire pressure may adversely
affect the handling of this vehicle and may
cause loss of control.
• Maintain proper tire pressures.
• Set tire pressures when the tires are cold.
• Tire pressures must be equal in both front
tires and equal in both rear tires.

2. Check:
• tire surfaces
Wear/damage○
a Replace.
Tire wear limit ○
a

Front and rear: 3.0 mm (0.12 in)

WARNING:
It is dangerous to ride with a worn-out tire.
When tire wear is out of specification, replace
the tire immediately.

CHECKING THE WHEELS

1. Check:
• Wheels ① Damage/bends Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.

WARNING:
• Never attempt even small repairs to the wheel.
• Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.

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 MAINTENCE AND ADJUSTMENT OF THE UTV
. CHECKING AND LUBRICATING THE CABLES

WARNING:
A damaged cable sheath may cause corrosion
and interfere with the cable movement. An
unsafe condition may result so replace a
damaged cable as soon as possible.

1. Check:
• cable sheath Damage Replace.
• cable operation Unsmooth operation Lubricate
or replace.
NOTE:
Hold the cable end up and apply several drops
of lubricant to the cable.

2. Apply:
• lithium-soap-based grease (onto end of the cable)

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MAINTENCE AND ADJUSTMENT OF THE UTV

ELECTRICAL
CHECKING AND CHARGING THE BATTERY
WARNING:
Batteries generate explosive hydrogen gas and
contain electrolyte which is made of poisonous
and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling or
working near batteries;
• Charge batteries in a well-ventilate2d area;
• Keep batteries away from fire, sparks or open
flames (e.g., welding equipment, lighted
cigarettes);
• Do not smoke when charging or handling
batteries;
• keep batteries and electrolyte out of reach of
children;
• Avoid bodily contact with electrolyte as it can
cause severe burns or permanent eye injury;
first aid in case of bodily contact:
External
• Skin — Wash with water;
• Eyes — Flush with water for 15 minutes and
get immediate medical attention;
Internal
Drink large quantities of water or milk followed
with milk of magnesia, beaten egg or vegetable
oil. Get immediate medical attention.

WARNING:
• This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery
performance will deteriorate;
• Charging time, charging amperage and
charging voltage for an MF battery are
different from those of conventional
batteries.
The MF battery should be charged as
explained in the charging method
illustrations. If the battery is overcharged, the

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MAINTENCE AND ADJUSTMENT OF THE UTV

electrolyte level will drop considerably;

• Therefore, take special care when charging
the battery.

NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by
measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.

1. Remove:
• Lift the hood up;
• battery case cover;
• disconnect;
battery leads
NOTE:
First, disconnect the negative battery lead ①,
and then the positive battery lead ②.

• Remove;
battery
• Check;
battery charge
a. Connect a pocket tester to the battery terminals.

Positive tester probe

positive battery terminal
Negative tester probe
negative battery terminal

NOTE:
• The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive terminal is
disconnected).
• No charging is necessary when the
open-circuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown in the

charts and the following example.
Example
c. Open-circuit voltage = 12.0 V

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 MAINTENCE AND ADJUSTMENT OF THE UTV
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
2. Charge:
• Battery (refer to the appropriate charging method
illustration) .

WARNING:
Do not quick charge a battery.

NOTE:
• Never remove the MF battery sealing caps.
• Do not use a high-rate battery charger since
it forces a high-amperage current into the
battery quickly and can cause battery
overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful not
to overcharge the battery.
• When charging a battery, be sure to remove
it from the vehicle. (If charging has to be done
with the battery mounted on the vehicle,
disconnect the negative battery lead from the
battery terminal).
• To reduce the chance of sparks, do not plug
in the battery charger until the battery charger
leads are connected to the battery.
• Before removing the battery charger lead clips
from the battery terminals, be sure to turn off
the battery charger.
• Make sure the battery charger lead clips are in
full contact with the battery terminal and
thatthey are not shorted. A corroded battery
charger lead clip may generate heat in the
contact area and a weak clip spring may cause
sparks.
• If the battery becomes hot to the touch at any
time during the charging process, disconnect
the battery charger and let the battery cool
before reconnecting it. Hot batteries can
explode!
• As shown in the following illustration, the
open-circuit voltage of an MF battery
stabilizes about 30 minutes after charging
has been completed. Therefore, wait 30
minutes after charging is completed before
measuring the open-circuit voltage.

Charging method using a variable-current

(voltage) charger
.

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 MAINTENCE AND ADJUSTMENT OF THE UTV

NOTE:
• Leave the battery unused for more than 30
minutes before measuring its open-circuit
voltage.
• Set the charging voltage to 14.0 ~14.2 V. (If
the charging voltage is lower, charging will
be insufficient, if it is higher, the battery will
be over-charged.)

. Measure the open-circuit voltage

prior to charging.

Connect a charger and ammeter to

the battery and start charging.

YES Is the amperage higher than the NO

standard charging amperage
written on the battery?

Adjust the charging voltage to

14.0 ~ 14.2 V

Monitor the amperage for 3 ~ 5

Adjust the voltage to obtain the YES
minutes. Is the standard charging
standard charging amperage amperage exceeded?

NO

If the amperage does not

Set the timer to the charging time
exceed the standard charging
determined by the open circuit voltage.
amperage after 5 minutes,
replace the battery.

If the required charging time exceeds 5 hours, it is advisable to check the charging
amperage after 5 hours. If there is any change in the amperage, readjust the voltage to
obtain the standard charging amperage.

Leave the battery unused for more than 30 minutes before measuring its open-circuit
voltage.
12.8 V Charging is complete.
12.0 ~ 12.7 V Recharging is required.
Under 12.0 V → Replace the battery.

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 MAINTENCE AND ADJUSTMENT OF THE UTV

Charging method using a constant voltage charger

NOTE:
Leave the battery unused for more than 30
minutes before measuring its open-circuit
voltage.

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MAINTENCE AND ADJUSTMENT OF THE UTV

NOTE:
Constant amperage chargers are not suitable
for charging MF batteries.

3. Install:
• battery
• Connect:
battery leads
NOTE:
First, connect the positive battery lead ①, and
then the negative battery lead ②.

• Check:
battery terminals Dirt Clean with a wire brush.
Loose connection Connect properly.
• Lubricate:
battery terminals
• Install:
battery case cover
• Close the hood.

CHECKING THE FUSES

NOTE:
Always turn off the main switch when
checking or replacing a fuse. Otherwise, a
short circuit may occur.

1. Remove:
• lift the hood up.
• battery case cover
2. Check:
• fuses
a. Connect the pocket tester to the fuse and check it
for continuity
NOTE:
Set the tester to the “Ω × 1” position.

• blown fuse

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 MAINTENCE AND ADJUSTMENT OF THE UTV

. b. If the tester indicates“∞”, replace the fuse.

3. Replace:
a. Turn off the ignition.
b. Install a new fuse of the proper amperage.
c. Turn on switches to verify operation of the
related electrical devices.
d. If the fuse immediately blows again, check the
electrical circuit.
Current
Description rating Quantity

Lighting
15 A 1
system fuse
Ignition 10 A 1

Terminal
10 A 1
(Auxiliary DC jack)

4WD(Four wheel
5A 1
drive)
Signaling
10 A 1
system fuse
Backup fuse 10 A 1
Reserve 15 A 1
Reserve 10 A 1
Reserve 5A 1

WARNING:
Ever use a fuse with a rating other than that
specified. Never use other materials in place of a
fuse. An improper fuse may cause extensive
damage to the electrical system, a malfunction
of the lighting and ignition systems and could
possibly cause a fire.

4. Install:
• battery case cover
5. Close the hood.

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MAINTENCE AND ADJUSTMENT OF THE UTV

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
• headlight beam (vertically)
• turn the adjuster ① in or out

Turning in Headlight beam raised.

Turning out Headlight beam lowered.

CHANGING THE HEADLIGHT BULB

1. Remove:
• Lift the hood up.
• headlight bulb holder cover ①
• headlight bulb holder (with bulb) ②
• bulb

NOTE:
Remove the defective bulb by unhooking the
headlight bulb holder tabs ③

WARNING:
Keep flammable products and your hands away
from the bulb while it is on, since it will be hot.
Do not touch the bulb until it cools down.

2. Install:
• bulb new
Secure the new bulb with the headlight bulb
holder.
NOTE:
Avoid touching the glass part of the bulb. Keep
it free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on the bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.

• headlight bulb holder (with bulb)

• headlight bulb holder cover
• Close the hood.

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 MAINTENCE AND ADJUSTMENT OF THE UTV

CHANGING THE TAIL/BRAKE LIGHT BULB

1. Remove:
• Rear panel
•Tail/brake light bulb holder ①
• Secure the new bulb with the rear position lamp
direction indicator lamp and stop lamp

NOTE:
Turn the bulb holder counterclockwise and
remove the defective bulb.

WARNING:
Keep flammable products and your hands away
from the bulb while it is on, since it will be hot.
Do not touch the bulb until it cools down.

2. Install:
• bulb new
Secure the new bulb with the tail/brake light bulb
holder.

NOTE:
Avoid touching the glass part of the bulb. Keep
it free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on the bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.

• Tail/brake light bulb holder ①

• bed panel

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 ENGINE
ENGINE

ENGINE NOTE
1．Make sure the components, oil, adhesive, sealant are from the company or recommended.
2．Original removal oil seal，gasket, O-ring, piston ring can not be re-assemblied again, make sure all
these parts are new.
3．Pay attention to keep dismantled parts orderly, make sure their original positions for reassembling.
4．Prevent dismantled parts damaged, clean before measure and assembly, remove the oil with
compressed air. Paint the rotating and sliding parts with specified oil, paint or inject designated
location with recommended grease.
5．Bolts and nuts tightening order: pre-fixed bolts, and then tighten them from the large diameter to
small diameter, from inside to outside by diagonal points 2 or 3 times to the specified torque.
Opposite order is for removing bolts and nuts.
6．Make sure sealing bolt (with the sealant) must be replaced
7．Make sure to use new bearing when remove assembly set up by pressure.
8．Determined axial and radial clearance of inner and outer bearing ring by touch, new bear should be
replaced if the clearance is too large or non-rotating flexible.
9．Bearing assembly directions: bearing logo should be visible assemblies; confirm bearing outer ring
rotate and move reliably and flexibly when assemble bearing by pressure.
10．Oil seal assembly: pay attention to seal side is in the side of oil, logo side outwards, seal side be
painted with grease, and make sure seal side without scratch and oil seal be vertical.
11．Before assembly, sealing material attached to all engine covers and crank case combination
surface should be cleaned.
12．Before assembly engine, be familiar with engine lubrication circuit, clean and blow oil circuit.

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 ENGINE
ENGINE REMOVAL

No. Part Name Qty Remarks

Removing throttle and intake Remove the parts in the order listed.
manifold.
1 Gasket 1PK-N862C-4 intake pipe 2
2 Intake pipe 2
3 Flange bolt M8×40 4
4 Clamp Φ40～Φ60 4
5 Intake pipe joint 1
6 Three-way intake pipe 1
7 Inlet temperature/pressure sensor 28086011 1
8 TMAP pressure plate 1
9 Cross recess pan head screw M4×8 1
10 Fuel injector(25384016) 2
11 Fuel injector fixing base 2
12 Inner hexangular screw M6×20 4

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 ENGINE

No. Part Name Qty Remarks

13 Oil Pipe Φ8×Φ14×80 2
14 Three-way pipe (copper) 1
15 Oil Pipe clip Φ14.8 4
16 Damper(D54A) 1
For installation, reverse the removal
procedure.

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 ENGINE
CYLINDER HEAD AND CYLINDER HEAD COVER

No. Part Name Qty Remarks

Removing the cylinder head and Remove the parts in the order listed.
cylinder head
1 Thermostat cover 2
2 Thermostat 1
3 Cylinder water outlet connector 1
4 Washer 1
5 O-ring 2
6 Cylinder head cover 2
7 Cylinder cover pad 2
8 Spark plug 2
9 Stud Bolt M8×45 (stainless steel ) 4
10 Temperature sensor 1
11 Cylinder head 2
12 Timing chain tensioner cap bolt 2

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 ENGINE

No. Part Name Qty Remarks

13 Timing chain tensioner/gasket 2
14 Dowel pin 4
15 Timing chain guide (exhaust side) 2
For installation, reverse the removal
procedure.

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ENGINE
1、CHECK
1). Checking the valve clearance
• Valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.

2). Checking the cylinder head cover

• cylinder head cover
Cracks/damage Replace the cylinder head
cover and cylinder head as a set.

3). Checking the tappet covers

• Cylinder head cover ①
Cracks/damage Replace.
• Cylinder cover pad ②
NOTE:
When installing, new replacement washer
and apply wheel bearing grease LS.

4). Removing the screwdriver and slowly release

the timing chain tensioner rod.
NOTE:
Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner housing
smoothly. If there is rough movement,
replace the timing chain tensioner.

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ENGINE

5). Checking the cylinder head

(1). Eliminate:
• carbon deposits (from the combustion
chamber)
Use a rounded scraper.

NOTE:
Do not use a sharp instrument to avoid
damaging or scratching:
• spark plug threads
• valve seats

(2). Check:
• cylinder head
Scratches/damage Replace the cylinder
head cover and cylinder head as a set.
• cylinder head water jacket
Mineral deposits/rust Eliminate.

2、INSTALL
1). Installing the cylinder head
• cylinder head gasket
• cylinder head
• bolts (M9: 1 ~ 6, 38Nm)
• bolts (M6: 7, 10Nm)
NOTE:
• Tighten the bolts in the proper sequence.
• Follow the numerical order shown in the
illustration. Tighten the bolts in two stages.

• timing chain guide (exhaust side)

• timing chain tensioner
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
b. While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver ①
until it stops.
c. With the screwdriver still inserted into the
timing chain tensioner, install the timing chain
tensioner and gasket onto the cylinder block.

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ENGINE
Then, tighten the timing chain tensioner bolts
to the specified torque.
WARNING:
Always use a new gasket.

NOTE:
The “UP” mark on the timing chain tensioner
should face up.

Timing chain tensioner bolt (10 Nm)

d. Remove the screwdriver, make sure that the

timing chain tensioner rod releases, and
tighten the cap bolt to the specified torque.

Timing chain tensioner cap bolt (7 Nm)

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 ENGINE
ROCKER ARMS AND CAMSHAFT

No. Part Name Qty Remarks

Removing the rocker arms and Remove the parts in the order listed.
amshaft
camshaft
Cylinder head cover
1 Rocker arm shaft 4
2 Wave washer 8
3 Rocker arm (exhaust) 2
4 Rocker arm (intake) 2
5 Valve adjuster 8
6 Locknut 8
7 Camshaft sprocket 2
8 Camshaft station plate 2
9 Camshaft 1
10 Cylinder head 1

For installation, reverse the removal

procedure.

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ENGINE
1、CHECK
1). Checking the rocker arms
• rocker arm lobes
• valve adjusters
Blue discoloration/pitting/scratches Replace.
• rocker arms
• rocker arm shafts
Damage/wear Replace.

a. Check whether the rocker arm is worn out, or

damaged and whether the oil hole is blocked.
b. If there is a rocker arm to be replaced, check
the camshaft prominent position of unfairness.
c. Measure the inside diameter of the rocker arm
holes ①.
Out of specification Replace.

Rocker arm inside diameter repairing limit

value
Φ12.05mm
d. Check the surface of the rocker arm shafts.
Worn/pitting/scratches Replace.
e. Measure the external diameter of rocker arm
shaft with micrometer.
Out of specification Replace.

Rocker arm shaft outside diameter

repairing limit value
Φ11.96mm

f. Calculate the clearance by subtracting the

rocker arm shaft outside diameter from the
rocker arm inside diameter.
Out of specification Replace the defective
part(s).

Rocker arm to shaft clearance repairing

limit value
0.08mm

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ENGINE
2). Checking the camshaft
• cam lobes
Pitting/scratches/blue discoloration Replace
• camshaft journal
Wear/damage Replace
• Measure the external diameter of camshaft
journal with micrometer.
Out of specification Replace.
• small holes on camshaft sprocket
• rotor “I” mark
Out of alignment

3). Checking the camshaft sprocket

• camshaft sprocket
Wear/damage Replace the camshaft
sprocket and timing chain as a set.
(a)1/4 of a tooth
(b)Correct
① Timing chain
② Sprocket

4). Checking the decompression system

• decompression system
Check while the camshaft sprocket is installed
on the camshaft.

2、INSTALL
1). Installing the rocker arms
• rocker arms
• rocker arm shafts
NOTE:
• After installation, make sure that the thread
hole of the rocker arm shaft is positioned
correctly.

2). Installing the camshaft

• camshaft
• camshaft sprocket

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 ENGINE
VALVES AND VALVE SPRINGS

No. Part Name Qty Remarks

moving the valves and valve springs Remove the parts in the order listed.
Cylinder head cover
1 Valve lock clip 16
2 Valve spring retainer 8
3 Intake valve spring 4
4 Exhaust valve spring 4
5 Intake valve 4
6 Exhaust valve 4
7 Valve stem seal 8
8 Valve spring seat 8
For installation, reverse the removal
procedure.

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ENGINE
1、CHECK
• valve sealing
Leakage at the valve seat Check the valve
face, valve seat and valve seat width.
a. Pour a clean solvent ① into the intake and
exhaust ports.
b. Check that the valve seals properly. There
should be no leakage at the valve seat ②.
• valve face
Pitting/wear Grind the face.
• valve stem end
Mushroom shape or diameter larger than the
body of the stem Replace.
• valve seats
Pitting/wear Reface the valve seat.

2、MEASURE:
1).Measure:
• The valves surface width

Repairing limit value

2.0mm
• stem-to-guide clearance

Stem-to-guide clearance = valve guide

inside diameter – valve stem diameter
NOTE:
If the mating surface is coarse, corrode or
cannot contact with valve seat normally,
replace it.

Stem-to-guide clearance
repairing limit value
Intake:0.08mm Exhaust:0.10mm
• margin thickness (a)
Out of specification Replace.

Margin thickness
Intake:2 mm
Exhaust:2.2 mm

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ENGINE
• valve stem runout
Out of specification Replace.

Runout limit 0.01 mm

NOTE:
• When installing a new valve always replace
the guide.
• If the valve is removed or replaced always
replace the oil seal.

• The valve seat surface width

Out of specification Reface the valve seat.

Repairing limit value

2.0mm
a. Install the valve into the cylinder head.
b. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
c. Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
• Valve spring free length
• Valve spring squareness
Out of specification Replace.

Valve spring free length

Intake:41mm Exhaust:41mm
Valve spring squareness
Intake:1.60mm Exhaust:1.60mm

• compressed spring force(a)

Out of specification Replace.
(b) Installed length

Compressed spring force

Intake: 470 N at 24.5 mm
Exhaust: 270 N at 31.0 mm

2). Remove:
• valve guide

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 ENGINE

NOTE:
To ease guide removal, installation and to
maintain correct fit, heat the cylinder head to
100 °C (212 °F) in an oven.

a. Install the new valve guide using a valve guide

remover ① and valve guide installer ②.
b. After installing the valve guide, bore the
valve guide using a valve guide reamer ③
to obtain proper stem-to-guide clearance.
NOTE:
After replacing the valve guide reface the
valve seat.

c. If the valve seat is to wide or narrow or

cracked, grind it to ensure impermeability.
3). Lap:
• valve face
• valve seat
NOTE:
After reface the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.

a. If the pipe will be replaced, grind the valve

seat again.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the guide.

b. Install the valve into the cylinder head.

c. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the compound.
NOTE:
‘ For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.

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ENGINE
d. Apply a fine lapping compound to the valve
face and repeat the above steps.
NOTE:
After every lapping operation be sure to
clean off all of the compound from the valve
face and valve seat.

e. Install the valve into the cylinder head.

g. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
h. Measure the valve seat width again. If the
valve seat width is out of specification, reface
and relapse the valve seat.

3、INSTALL:
1). Apply:
• molybdenum disulfide oil
(onto the valve stem and valve stem seal)
2). Install:
• valve spring seats
• valve stem seals
• valves
• valve springs
• valve spring retainers
NOTE:
Install the valve springs with the larger pitch
(a) facing upwards.

(b) Smaller pitch

• valve cotters

NOTE:
Install the valve cotters while compressing
the valve spring with the valve spring
compressor ① and valve spring compressor
attachment ②.

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 ENGINE
CYLINDER AND PISTON

No. Part Name Qty Remarks

Removing the cylinder and piston Remove the parts in the order listed.
Water pump outlet hose
1 Pin Φ14×16 4
2 Gasket cylinder body 1
3 Cylinder body assy 2
4 Gasket cylinder head 1
5 Piston ring set 2
6 Piston 2
7 Piston circlip 4
8 Piston pin 2
For installation, reverse the removal
procedure.

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ENGINE
1、CHECK
1).Checking the cylinder and piston
• cylinder and piston walls Vertical
scratches Rebore or replace the cylinder
and the piston.
2).Checking the piston rings
• piston ring
(Insert in cylinder piston ring will be ① ,and
measure the end gap.)
NOTE:
Check whether the piston and the piston
groove is cracked and abraded.

3).Checking the piston pin

• piston pin
Blue discoloration/grooves Replace, then
check the lubrication system.
2、MEASURE
• At the top, the middle and the bottom of the
piston stroke.
NOTE:
Measure the bore diameter at directions of
right-angle intersection.

Repairing limit value

Out of roundness:0.10mm
Taper:0.10mm
• The external diameter 10mm above the bottom
of the piston skirt.
NOTE:
Repair limit on the clearance between the
piston and cylinder.

Repairing limit value

0.10mm

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ENGINE
• ring end gap
Out of specification Replace.

Repairing limit value

Top ring/2nd ring:0.5mm
• ring side clearance
Use a thickness gauge.
Out of specification Replace the piston and
rings as a set.
NOTE:
Clean carbon from the piston ring grooves
and rings before measuring the side
clearance.

Side clearance
Standard Limit
Top ring 0.04~0.08mm 0.13mm
2nd ring 0.03~0.07mm 0.13mm
• piston pin-to-piston clearance.
a. Measure the piston pin outside diameter.

b. Measure the piston pin bore inside diameter.

Repairing limit value

0.08mm
c. Calculate the piston pin-to-piston clearance
with the following formula.
Piston pin-to-piston clearance = Piston pin
bore inside diameter – Piston pin outside
diameter
d. If out of specification, replace the piston.

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ENGINE
3、INSTALL:
1). Installing the piston
• piston rings (onto the piston)
NOTE:
• Be sure to install the piston rings so that
the manufacturer’s marks or numbers are
located on the upper side of the rings.
• Lubricate the piston and piston rings
liberally with engine oil.

• piston ①
• piston pin ②
• piston pin clips ③ (new replacement)
NOTE:
• Apply engine oil onto the piston pin, piston
rings and piston.
• Be sure that the arrow mark a on the piston
points to the exhaust side of the engine.
• Before installing the piston pin clip, cover
the crankcase with a clean rag to prevent
the piston pin clip from falling into the
crankcase.

2). Installing the cylinder

• cylinder
• O-ring
NOTE:
Install the cylinder with one hand while
compressing the piston rings with the other
hand.

CAUTION:N:
• Be careful not to damage the timing chain
guide during installation.
• Pass the timing chain through the timing
chain cavity.

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 ENGINE
ENGINE LEFT CRANKCASE COVER AND A.C. MAGNETO

No. Part Name Qty Remarks

Removing the engine left crankcase Remove the parts in the order listed.
cover and A.C. magneto
Engine oil
Water pump assembly
1 Left crankcase cover 1
2 Inspection port cover /O-ring 1/1
3 Crankcase location sensor/ O-ring 1/1
4 Plug oil level gauge/O-ring 1/1
5 A.C. magneto clip 1
6 Stator assembly 1
7 Left crankcase cover gasket 1
8 Dowel pin 2
9 A.C. magneto rotor 1
10 Starter clutch 1
11 Starter wheel gear 1

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 ENGINE

No. Part Name Qty Remarks

12 Starter idle gear 1
13 Starter idle gear shaft 1
For installation, reverse the removal
procedure.

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ENGINE
1、CHECK
1). Checking the A.C. magneto
• stator coil
• pickup coil
Damage Replace.

2). Checking the starter clutch

• starter clutch ①
Cracks/damage Replace.
• starter clutch bolts ②
Loose Replace with new ones, and clinch
the end of the bolts.
NOTE:
• The arrow mark on the starter clutch must
face inward, away from the A.C. magneto
rotor.
• When installing, apply the locking agent.

a. Install the starter wheel gear onto the starter

clutch, and hold the starter clutch.

b. Turn the starter wheel gear counterclockwise

① to check that the starter clutch and wheel
gear engage.
If the starter clutch and wheel gear do not
engage, replace the starter clutch.
c. Turn the starter wheel gear clockwise ② to
check the starter wheel gear for smooth
operation.
If operation is not smooth, replace the starter
clutch.

• starter idle gear teeth ①

• starter wheel gear teeth ②
Burrs/clips/roughness/wear Replace.
• starter wheel gear
(contacting surface)
Damage/pitting/wear Replace.

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ENGINE
2、INSTALL
• woodruff key
• dowel pins
• A.C. magneto rotor
NOTE:
• Before installing the rotor, clean the
outside
of the crankshaft and the inside of the rotor.
• After installing the rotor, check that the
rotor rotates smoothly. If not, reinstall the
key and rotor.

• dowel pins
• gasket (New replacement)

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 ENGINE
STARTER MOTOR AND WAER PUMP

No. Part Name Qty Remarks

Removing the starter motor and water Remove the parts in the order listed.
pump
1 Hexagonal socket head plugnpt1/8 1
2 Oil plug M10×1.25×12 crankcase 1
3 Oil filter 1
4 O-ring 61.5×2.4 1
5 Oil filter cover 1
6 Flange bolt M6×20 3
7 Pressure sensor 1
8 Pressure limiting plunger 1
9 Spring Φ8×Φ1×32.5 1
10 Aluminum Washer Φ12.5×Φ20×2 1
11 Hollow bolt M12×1.25×15 1
12 Gasket left crankcase cover 1

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 ENGINE

No. Part Name Qty Remarks

13 Pin Φ8×12 2
14 Duplicate gear shaft Φ10×50 2
15 Duplicate gear 1
16 Middle gear 1
17 Water pump assy 1
18 Straight pin Φ4×16 1
19 Water pump double gear 1
20 Bearing HK1010 1
21 Flange bolt M6×65 1
22 Aluminum Washer Φ6×Φ12×1.5 1
23 Flange bolt M6×35 2
24 Starting motor assy 1
25 Flange bolt M8×25 1
26 Flange bolt M6×40 1
For assembly, reverse the disassembly
procedure.

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ENGINE
1、CHECK
1) Checking the starter idle gear
• starter idle gear
Cracks/wear/damage Replace

2) Checking the timing chain and guides

• timing chain
Cracks/stiff Replace the timing chain and
Camshaft sprocket as a set.
• Timing chain guides
Wear/damage Replace.

3) Checking the relief valve spring

• Pressure Limiting Plunger①
•Spring ②
•Aluminum Washer③
•Hollow Bolt④
Damage/wear Replace the defective part(s).

4) Checking the oil filter cartridge

• Oil filter cartridge
Damage Replace.
Contaminants Clean with engine oil.

5) Checking the starter motor

• starter motor
Damage/wear Replace the defective part(s).
2、INSTALL
• Starter motor
• Oil filter cartridge
• Starter idle gear shaft
• Starter idle gear
NOTE:
Apply the molybdenum disulfide grease to
the thread of axle and nut.

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 ENGINE
PRIMARY AND SECONDARY SHEAVES

No. Part Name Qty Remarks

Removing the primary and secondary Remove the parts in the order listed.
sheaves
Engine assembly
1 Clutch cover assy 1
2 Flange Bolt M6×28 9
3 Gasket clutch cover 1
4 Double-sided toothed belt91-SA-29-5 945 31.2 26 14.6 1
5 Bolt M12×140 1
6 Bolt M10×110 1
7 Washer Φ16×Φ37×4.5 1
8 Washer Φ16×Φ39×0.5 1
9 Washer Φ10.3×Φ40×3 1
10 CVT primary clutch 1

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 ENGINE

No. Part Name Qty Remarks

11 CVT secondary clutch 1
12 Clutch cover seat assy 1
13 Flange bolt M6×22 9
14 O-ring 56.75×3.53 1
15 O-ring 50×4 1
16 Self-lock nut M6 2
17 Spring Washer Φ6 9
18 Gum cover 1
19 Clutch cover plug 1
20 Flange bolt M6×25 1
For assembly, reverse the disassembly
procedure.

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ENGINE
1、Check
1). Checking the primary sheave
• primary pulley slider
• primary sliding sheave splines
Wear/cracks/damage Replace.
• spacer
• primary pulley cam
Cracks/damage Replace.

• primary sliding sheave

• primary fixed sheave
Cracks/damage Replace.

2、Measure
• secondary sheave spring free length (a)
Out of specification Replace the secondary
sheave spring.

3、INSTALL
1). Assembling the primary sheave
(1)Clean:
• primary sliding sheave ①
• primary fixed sheave ②
• primary sliding sheave cam face
NOTE:
Remove any excess grease.

(2)Install:
• weights ①
NOTE:
• Apply grease (90g) to the whole outer
surface of the weights and install.
• Apply grease to the inner surface of the
collar.
• Apply grease to the inner surface of the
primary sliding sheave.

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ENGINE
2). Assembling the secondary sheave
(1)Apply:
• assembly lube
(to the secondary sliding sheave ① inner
surface and oil seals)。
• assembly lube
(to the bearings, oil seals and inner surface of
the secondary fixed sheave ②)

3). Installing the primary and secondary

sheaves
(1) Install:
• secondary sheave assembly
• V-belt
• primary sheave assembly

NOTE:
• Tightening the bolts will push the
secondary sliding sheave away, causing
the
gap between the secondary fixed and
sliding sheaves to widen.
• Install the V-belt so that its right faces the
direction show in the illustration.

(2)Tighten:
• primary sheave nut (70Nm)
• secondary sheave nut (50Nm)
NOTE:
• Use the sheave holder to hold the primary
sheave.
• First, tighten the primary sheave nut , then
tighten the secondary sheave nut .

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 ENGINE
CRANKCASE COVER AND OIL PUMP

No. Part Name Qty Remarks

Removing the crankcase cover and oil
Remove the parts in the order listed.
pump
Crankcase separation
1 Crankshaft cover 1
2 Gasket 1
3 Dowel pin 2
4 Crankcase exhaust pipe 1
5 Crankcase block 1
6 Oil seal 1
7 Oil pump gasket 1
8 Oil pump 1
9 Outer rotor 1
10 Innter rotor 1

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 ENGINE

No. Part Name Qty Remarks

11 Shaft/pin 1/2
12 Oil pump housing 1
13 Oil pump gear 1
14 Water pump Ⅱ gear/circlip 1/1
15 Shaft/pin 1/1
16 Water pump Ⅰ gear/washer 1/1
17 Oil pump middle gear 1
18 Shaft 1
19 Bearing 1
20 Fuel and air separator assy 1
21 V-ring 1
22 Shaft 1
23 Valve piece plate 1

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 ENGINE

No. Part Name Qty Remarks

24 Valve piece 1
25 Chain plate 1
26 Timing chain guide(secondly cylinder) 1
27 Timing chain 1
28 Right crankcase 1
For assembly, reverse the disassembly
procedure.

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ENGINE
1、CHECK
1). Checking the oil pump
• rotor housing
• rotor cover
Cracks/wear/damage Replace.
• oil pump operation
Unsmooth Repeat steps #1 and #2 or
replace the defective parts.

2) Checking the timing chain and guides

• timing chain
Cracks/stiff Replace the timing chain and
camshaft sprocket as a set.
• timing chain guides
Wear/damage Replace.

2、MEASURE
1). Measure the oil pump
• tip clearance(a)
(between the inner rotor ① and the out rotor ②)
• side clearance(b)
(between the outer rotor ② and the pump
housing ③)
• body clearance (c)
(between the outer rotor ② and the pump
housing ③)
Out of specification Replace the oil pump.

Tip clearance Limit: 0.23 mm

Side clearance Limit: 0.25 mm
Body clearance Limit: 0.20 mm

3、INSTALL
1). Assembling the oil pump
• inner rotor
• outer rotor
• oil pump shaft
(with the recommended lubricant)

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 ENGINE
CRANKCASE AND MIDDLE DRIVEN SHAFT

No. Part Name Qty Remarks

Remove the crankcase and middle Remove the parts in the order listed.
drive shaft
Crankcase separation
1 solid pin Φ6×12 1
2 right crankcase assy 1
3 bolt M10×1.25×25 1
4 Washer Φ10×Φ32×5 2
5 o-ring 25×2.4 1
6 shaft sleeve 1
7 shaft sleeve bush 1
8 oil seal 25×47×7 1
9 flange bolt M6×20 3
10 front drive bearing seat 2
11 bearing seat paper gasket 2

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 ENGINE

No. Part Name Qty Remarks

12 Bearing 6005 1
13 Output shaft y-2 1
14 Bearing 6906 1
15 O-ring 51×2.4 1
16 Oil seal 30×47×7 1
17 Flange bolt M6×20 3
18 4-WD shift sleeve 1
19 Transmission shaft spring 1
20 Bearing 6206 1
21 Y output shaft 1 1
22 Adjusting Washer Φ30×Φ40×(0.4～1.2) 1
23 Bush Φ30×Φ42×22.5 1
24 Bearing 6305 1
25 O-ring 90×3 1

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 ENGINE

No. Part Name Qty Remarks

26 Rear drive bearing seat 1
27 Flange bolt M8×25 4
28 O-ring 25×2.4 1
29 Y Shaft bush Φ25×Φ32×14.5 1
30 Bush Φ25×Φ32×18 1
31 U-joint A Φ22 1
32 Washer Φ10×Φ32×5 2
33 Bolt M10×1.25×25 1
34 Cross U-joint 22 1
35 ClipΦ22 4
36 U-joint A Φ22 1
37 U-joint B Φ22 1
38 Right crankcase 1
For installation, reverse the removal
procedure.

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 ENGINE
1、CHECK
1). Checking the middle drive
• O-ring
Damage Replace.
• bearings
Clean and lubricate, then rotate the inner race
with a finger.
Pitting/damage Replace.
• universal joint movement
Roughness Replace universal joint.

2). Checking the crankcase

(1) Thoroughly wash the case halves in a mild
solvent.
(2) Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly
(3) heck:
• crankcase
Cracks/damage Replace.
‘
• oil delivery passages
Clogged Blow out with compressed air.

2、MEASURE
1). Measure the crankshaft
• crank width (A)
Out of specification Replace the crankshaft.

Crank width
90.52 ~ 90.58 mm
• side clearance (D)
Out of specification Replace the crankshaft
Big end side clearance
Limit: 1.0 mm (0.0384 in)
• runout (b)(C)
Out of specification Replace the crankshaft.

Runout limit
(b): 0.03 mm （0.0012 in）
(C): 0.03 mm （0.0012 in）

The crankshaft ① and the crank pin ② oil

passages must be properly interconnected with

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ENGINE
a tolerance of less than 1 mm (0.04 in).

CAUTION:
The buffer boss and woodruff key should be
replaced when removed from the crankshaft.

2). Assembling the crankcase

(1) Apply:
• sealant (Quick Gasket)
(to the mating surfaces of both case halves)
(2) Install:
• dowel pins
(3) Fit the left crankcase onto the right case. Tap
lightly on the case with a soft hammer

CAUTION:
Before installing and torque the crankcase
holding bolts, be sure to check whether the
transmission is functioning properly by
manually rotating the shift drum in both
directions.

(4)Tighten:
• crankcase bolts
(follow the proper tightening sequence)
NOTE:
• Tighten the bolts in stages, using a crises
cross pattern.

3、INSTALL
1). Installing the crankshaft
• crankshaft
NOTE:
Hold the connecting rod at the Top Dead
Center (TDC) with one hand while turning the
nut of the installing tool with the other.
Operate the installing tool until the
crankshaft bottoms against the bearing.

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ENGINE

2). Installing the middle driven shaft

• universal joint.
a. Install the opposite yoke into the universal
joint.
b. Apply wheel bearing grease to the bearings.
c. Install the bearing ① onto the yoke.

CAUTION:
Check each bearing. The needles can easily
fall out of their races. Slide the yoke back
and forth on the bearings; the yoke will not
go all the way onto a bearing if a needle is
out of place.

a. Press each bearing into the universal joint

using a suitable socket.
NOTE:
The bearing must be inserted far enough into
the universal joint so that the circlip can be
installed.

b. Install the circlip ② into the groove of each

bearing.

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ENGINE
1、CHECK
1). Checking the output shaft Y-1
• Drive shaft coupling
• Output shaft Y-1
Pitting/galling/wear Replace.
• O-ring
Damage Replace.
• bearings
Pitting/damage Replace.

2、MEASURE
• Output shaft Y-1 swing
a. Temporary install the gearcase .
b. Wrap a rag ① around a screwdriver ②, and
then insert it into the installation hole ③ of the
right crankcase speed sensor to hold the
middle driven gear.
c. Attach the gear lash measurement tool ④
and dial gauge ⑤.
a)6.7 mm (0.26 in)
d. Measure the gear lash while rotating the
output shaft Y-1 back and forth.

NOTE:
Measure the gear lash at 4 positions. Rotate
the middle driven gear 90°each time.

3、INSTALL
• bearing retainer ①
a. Place a rag ② in the vise.
b. Secure the bearing housing edge in the vise.
c. Attach the bearing retainer wrench ③.
d. Tighten the bearing retainer.
CAUTION:
The middle driven shaft bearing retainer has
left-handed threads. To tighten the retainer,
turn it counterclockwise.

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ENGINE
• shims ①
• universal joint yoke
• washer
• nut ①
NOTE:
Use the universal joint holder ② to hold the
yoke.

• universal joint.
a. Install the opposite yoke into the universal
joint.
b. Apply wheel bearing grease to the bearings.
c. Install the bearing ① onto the yoke.

CAUTION:
Check each bearing. The needles can easily
fall out of their races. Slide the yoke back
and forth on the bearings; the yoke will not
go all the way onto a bearing if a needle is
out of place.

a. Press each bearing into the universal joint

using a suitable socket.
NOTE:
The bearing must be inserted far enough into
the universal joint so that the circlip can be
installed.

e. Install the circlip ② into the groove of each

bearing.

• drive shaft coupling

• washer
• nut ①
NOTE:
Use the coupling gear/middle shaft tool ②
to hold the drive shaft coupling.

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 ENGINE
GEARCASE SHIFT LEVER AND OIL PUMP

No. Part Name Qty Remarks

Removing the shift lever and gearcase Remove the parts in the order listed.
Gear case separation
1 Inner hexangular screw M8×45 1
2 Inner hexangular screw M8×40 3
3 Spring Washer Φ8 4
4 Flange bolt M6×45 1
5 Flange bolt M6×35 4
6 Bracket clutch cover seat 1
7 Flange bolt M6×16 2
8 Gearshift indicator 1
9 O-ring 29.6×2.4 1
10 Flange bolt M10×1.25×16 1
11 Aluminum washer Φ10.2×Φ16×1.2 1
12 Bolt M14×1.5×21 1
13 Copper washer Φ14×φ 21×1 1

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 ENGINE

No. Part Name Qty Remarks

14 Spring Φ24×1 1
15 Steel ball SΦ9.5 1
16 Gearshift drum assy 1
17 CirclipΦ12 2
18 Fork shaft seat 2
19 Fork shaft Φ12×111.2 1
20 H spring 1
21 H shift fork 1
22 R l shift fork 1
23 R l spring 1
24 Fork shaft seat 2
25 Circlip Φ12 2
26 Oil seal 15×25×5 1
27 Flange bolt M6×25 3

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 ENGINE

No. Part Name Qty Remarks

28 Side cover shift arm 1
29 active gear shift assembly 1
30 Drive segment gear shift 1
31 Flange bolt M6×20 1
32 Pin Φ8×12 1
33 Fan driven gear combination
34 Pin Φ10×16 2
35 Oil pump assy (Gear Box) 1
36 Nut M10×1.25 1
37 Stud bolt M10×1.25×50 1
38 Pin Φ10×16 1
39 Gearbox gasket 1
40 Pin Φ10×16 1
41 Engine oil plug 1

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 ENGINE

No. Part Name Qty Remarks

42 O-ring 18×3.5 1
43 Gear box 1
44 Exhaust pipe nozzle 1

For assembly, reverse the disassembly

procedure.

- 168 -
 ENGINE
GEARCASE TRANSMISSION

No. Part Name Qty Remarks

Removing the gear case transmission Remove the parts in the order listed.
Gear case separation
1 Gear case cover 1
2 Bearing 6305 1
3 Bearing plate 1
4 Cross recessed countersunk head screw 3
5 M6×12shaft
Main 1
6 Pin Φ2×18 1
7 Needle bearing 25×29×12.6 2
8 H drive gear 1
9 Washer Φ27×Φ32×2 3
10 L drive gear 1

- 169 -
 ENGINE

No. Part Name Qty Remarks

11 Bearing 6204 DU 1
12 Bearing 6403 1
13 Washer Φ17×Φ34×2.2 1
14 R driven gear 1
15 Washer Φ25.4×Φ33×1 1
16 H driven gear 1
17 L driven gear 1
18 Needle bearing 25×29×9.6 2
19 Counter shaft 1
20 Needle bearing 15×28×2 1
21 Washer Φ15.3×Φ32×1.5 1
22 Needle bearing 19×27×16 1
23 R idle gear 1

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 ENGINE

No. Part Name Qty Remarks

24 R idle gear shaft 1
25 Reverse gear-shaft Φ12×56 1
26 Bracket clutch cover seat 1
27 Flange bolt M6×35 4
28 Flange bolt M6×45 1
29 Bush Φ25×Φ32×18 1
30 O-ring 25×2.4 1
31 Oil seal 32×47×7 1
32 Inner hexangular screw M8×40 3
33 Spring washerΦ8 4
34 Inner hexangular screw M8×45 1
For assembly, reverse the disassembly
procedure.

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ENGINE
1、CHECK
1). Checking the shift forks
• shift fork follower ①
• shift fork pawl ②
Scoring/bends/wear/damage Replace.
• guide bar
Roll the guide bar on a flat surface.
Bends Replace.

WARNING：
Do not attempt to straighten a bent guide
bar.

• shift fork movement

(on the guide bar)
Unsmooth operation Replace the shift fork
and the guide bar.

• springs
Cracks/damage Replace.

2). Checking the shift drum

• shift drum grooves
Scratches/wear/damage Replace.

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ENGINE

3). Checking the bearings

(1) Check:
• bearings
Clean and lubricate, then rotate the inner race
with a finger.
Roughness Replace

4). Checking the oil pump

• rotor housing
• rotor cover
Cracks/wear/damage Replace.
• oil pump operation
Unsmooth Repeat steps #1 and #2 or
replace the defective parts.

2、Measure:
1). Measure the oil pump
• tip clearance(a)
(between the inner rotor ① and the out rotor
②)
• side clearance(b)
(between the outer rotor ② and the pump
housing ③)
• body clearance (c)
(between the outer rotor ② and the pump
housing ③)
Out of specification Replace the oil pump.
Tip clearance Limit: 0.23 mm
Side clearance Limit: 0.25 mm
Body clearance Limit: 0.20 mm

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ENGINE
3、INSTALL
1). Assembling the shift fork
• guide bar ①
• shift fork 2 ②
• long spring ③
• shift fork 1 ④
• short spring ⑤

2). Installing the shift levers

• shift lever 2 assembly ① (14Nm)
• shift lever 1 ②
NOTE:
When installing the shift lever 1, align the
punch mark (a) on the shift lever 1 with the
punch marks (b) on the shift lever 2.

3). Assembling the oil pump

• inner rotor
• outer rotor
• oil pump shaft
(with the recommended lubricant)

- 174 -
 CHASSIS

MALFUNCTION INSPECTION
Appearance malfunction inspection
No. Phenomenon Measure
1. Replace new plastic cover.
2. Check whether installation supporter deformed, repairing
1 Plastic cover damaged
or re-painting is needed before replacing new plastic cover.
3. Re-paste decals and re-rivet warning labels.
1. Replace new bumper.
2. Check whether installation supporter deformed or
2 Bumper damaged
damaged, repairing or re-painting is needed before
replacing new bumper.
1. Replace new frame toe-board.
2. Check whether gearbox and differential of front and rear
Frame toe-board damaged
3 axle damaged or leakage.
3. Check plastic cover whether deformed or damaged,
repairing deformed or damaged plastic cover.
4 Warning labels Replace damaged and vague warning labels

Brake system malfunction inspection

No. Phenomenon Measure
1. Check whether brake disc plates deformed.
1 Locked braking system 2. Check whether hydraulic cylinder of brake clamp locked
or brake clamp assembly parts deformed.
1. Check whether disc plates abrasion exceeded limits.
2. Check whether brake shoe of clamp abrasion exceeded
2 Brake performance degressive
limits or polluted by friction material such as oil.
3、Check whether the oil cup of brake fluid lack oil.
Grinding noises emerged from 1. Check whether brake plate deformed.
front brake or brake plate 2. Check whether hydraulic cylinder of brake clamp locked
3
become red during drive due or brake clamp assembly parts deformed.
to superheat.
1. Check whether brake plate deformed.
Grinding noises emerged from 2. Check whether hydraulic cylinder of brake clamp locked
4 rear brake or brake plate or brake clamp assembly parts deformed.
become red during drive 3. Check whether rear brake clamp parking institution
running flexible or return accurately.
1. Check whether front brake power deviation from left and
right is within specified scope.
Off tracking by braking at 2. Check whether front brake power degressive caused to
5
high-speed rear wheel locked before front wheel in brake process.
3. Check whether left and right absorber spring force
deviation is exceeded specified value.

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 CHASSIS
4. Check whether front wheel and front wheel axle nut
loosen or damaged.
Off tracking by braking at 5. Check whether front wheel hub inner spline and front
5
high-speed wheel axle outer spline worn or loosen.
6. Check whether rubber cushion connected to front
suspension rocker and frame damaged.

Other system malfunction inspection

No. Phenomenon Measure
1. Check whether steering wheel clip loosen or damaged.
2. Check whether steering column clip and clip seat loosen
Steering wheel loosen, shift
1 or damaged.
up and down
3. Check whether steering column bottom end inner
bearing damaged.
1. Check whether tie-rod and steering column locknut
Front wheel steering loosen or damaged, or steering knuckle and steering
2
clearance excessive column locknut loosen or damaged.
2. Check whether tie-rod two ball joint damaged.
1. Check whether steering knuckle bearing damaged.
2. Check whether king pin ball joint damaged.
3. Check whether front wheel and axle locknut loosen or
damaged.
3 Front wheel sway during drive
4. Check whether front wheel hub inner spline and front
wheel axle outer spline worn or loosen.
5. Check whether rubber cushion connected to front
suspension rocker and frame damaged.
1. Check whether rear axle bearing damaged.
2. Check whether sliding bearing connected to rear axle
bearing housing and rocker loosen or damaged.
3. Check whether rear wheel and axle locknut loosen or
Rear wheel sway during drive
4 damaged.
4. Check whether rear wheel hub inner spline and rear
wheel axle outer spline worn or loosen.
5. Check whether rubber cushion connected to rear
suspension rocker and frame damaged.
1. Check whether wheel rim deformed.
5 Wheel hop during drive 2. Check whether front and rear axles bent.
3. Check whether tyre aging and deformed.
1. Check whether over loading.
Absorber become soft and 2. Check whether absorber spring become soft.
6
comfortability depressed 3. Check whether absorber lost of damping force
incompression and prolongation.

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 CHASSIS
No. Phenomenon Measure
1. Check whether front and rear axles splines damaged.
2. Check whether gears of front gearbox and differential over
Front and rear axles arise worn.
7
abnormal sound during drive 3. Check whether rear gearbox gears over worn.
4. Check whether axle universal joint rubber boot damaged
or universal joint damaged.
1. Check whether four wheel drive switch normal.
Fail to shift into four-wheel-drive 2. Check whether power divider damaged.
8
or lock differential. 3.Check whether differential mechanical conversion agency
locked or damaged.
1. Check whether the switch of rear axle differentiation lock
Rear axle differentiation lock on the dashboard is damaged .
9
failure 2. Check whether the differential mechanical conversion
mechanism within the rear axle reducer is damaged.

- 177-
 CHASSIS

PANEL AND CARGO BED

Front Panel

No. Part Name Qty Remarks

Removing the front panel
1 Headlight cover 1
2 Socket hexagon plain head screws M6×16 2
3 Screw thread clip M6×2 10
4 Right fender, front cover 1
5 Socket hexagon plain head screws M6×16 16
8 Rubber bush 2
9 Left fender, front cover 1
10 Front board (model A) 1
11 Socket hexagon plain head screws M6×16 7
12 Cross plate head tapping screw ST3.9×13 2

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 CHASSIS

No. Part Name Qty Remarks

13 Plate of front board 1
14 Knob 2
15 Dashboard 1
16 Screw thread clip M6×2 4
17 Cover, glove box 1
18 Screw ST4.8×13 4
19 Plastic jaw 2
20 Glove compartment locker 1
21 Meter connecting plate 1

- 179-
CHASSIS

DIASSEMBLING THE HOOD

Remove:
① Turn switch
② Hood cover

To open the hood, turn the switch as the direction

in below picture to release the latch and lift the
hood off. To close, tilt cover back to closed position
and fasten the latches.
CAUTION:
 Never open operator’s seat while the
engine is running.

- 180-
 CHASSIS

Side Cover

No. Part Name Qty Remarks

Removing the side cover
1 Protective plate R 1
2 Protective plate L 1
3 Seater inner plate (R) 1
4 Seater inner plate (L) 1
5 Decoration plate (R) 1
6 Side decoration plate (L) 1
7 Socket hexagon plain head screws M6×16 16
8 Screw thread clip M6×2 16
9 Cross large plate head screw M6×16 4

- 181-
 CHASSIS

Middle Cover (Bench seat)

No. Part Name Qty Remarks

Removing the side cover
1 Seat lower protection plate 1
2 Cross large plate head screw M6×16 4
3 Battery mounting plate 2
4 Knob 2
5 Adjuster cap 1
6 Holder 1
7 Cross small plate head tapping screw ST3.9×13 2
8 Inlet pipe, clutch 1
9 Cross large plate head screw M6×20 4
10 Rear right board, seat 1

- 182-
 CHASSIS

No. Part Name Qty Remarks

11 Rear left board, seat 1
12 Cross large plate head screw M6×16 14
13 Right protective plate, rear body 1
14 Left protective plate, rear body 1
15 Socket hexagon plain head screws M6×16 6
16 Speaker cover 1
17 Hexagon flange nut M6 4
18 Rubber bush 2
19 Cusion Φ15×Φ22×1.5 2

- 183-
 CHASSIS

Middle Cover (Bucket seat)

No. Part Name Qty Remarks

Removing the side cover
1 Middle board, seat 1
2 Seat lower protection plate I(Right) 1
3 Seat lower protection plate I( Left) 1
4 Seat lower protection plate II(Right) 1
5 Seat lower protection plate II(Left) 1
6 Inspection spot 1
7 Battery mounting plate 1
8 Gearshift decoration cover 1
9 Rubber bush 2
10 Knob 2

- 184-
 CHASSIS

No. Part Name Qty Remarks

11 Socket hexagon plain head screws M6×16 20
12 Screw thread clip M6×2 8
13 Speaker cover 1
14 Cross large plate head screw M6×16 22
15 Hexagon flange nut M6 4
16 Rear right board, seat 1
17 Rear left board, seat 1
18 Right protective plate,rearbody 1
19 Left protective plate,rearbody 1
20 Cushion Φ15×Φ22×1.5 2

- 185-
 CHASSIS
Cargo Bed 1

No. Part Name Qty Remarks

Removing the cargo bed 1
1 Cargo bed plate assy 1
2 Cargo bed rotating shaft assy 2
3 Nylon collar bushing Φ12×Φ18×Φ34×22 4
4 Cargo bed mounting plate 2
5 Grip rubber bush Ⅱ 2
6 Hydraulic supporting shaft 1
7 Cargo bed supporting plate 1
8 Screw ST6×16 2
9 U-shaped rubber sleeve 4
10 Invert bracket fixing board, carrier 4

- 186-
 CHASSIS

No. Part Name Qty Remarks

11 Hexagon flange bolt M6×12 10
12 Hydraulic supporting assy 1
13 Pin Φ10.1×44.5 2
14 Hexagon flange bolt M6×20 2
15 Pin Φ10×41.5 2
16 Cotter pin 2×30 4
17 Cargo bed door mounting Assy 1
18 Hexagon flange bolt M6×16 13
19 Tube 1
20 Cargo bed mounting bracket 2
21 Hexagon Flange lock nut M6 2
22 Nylon collar bushing Φ12×Φ18×Φ34×22 2

- 187-
 CHASSIS

No. Part Name Qty Remarks

23 Rear door lock assy 2
24 Cross large plate head screw M6×20 4
25 Rotary shaft , carrier door switch 2
26 Rotated slotted liner tube 2
27 Screw M6×12 2
28 Self tapping screw,cross pan headed St4.8×13 4
29 Cargo door plate cable 2
30 Clip , metal water pipe 1
31 Gasket Φ10×Φ20×2 4
32 Hexagon flange bolt M8×12 2
33 Hexagon flange nut M6 8

- 188-
 CHASSIS
Cargo Bed 2

No. Part Name Qty Remarks

Removing the cargo bed 2
1 cargo bed 1
2 front panel,cargo bed 1
3 Screw thread clip M6×2 22
4 Cross large plate head screw M6×16 4
5 Left side board assy, carrier 1
6 Cargo bed damping rubber 2
7 Socket hexagon plain head screws M6×20 8
8 Cotter pin 2×30 2
9 Screw ST4.2×13 28
10 Right side board assy, carrier 1
11 Cross large plate head screw M6×16 20

- 189-
 CHASSIS

No. Part Name Qty Remarks

12 Washer Φ6×Φ18×1.6 2
13 Left cargo bed decoration panel 1
14 Right cargo bed decoration panel 1
15 Drawstring pothook 4
16 Cross large plate head screw M6×16 8
17 Liner panel cargo bed 1
18 Washer Φ6×Φ18×1.6 8
19 Supporting plate cargo bed 1
20 Decorative board, cargo bed door 1
21 Rear door switch assy. 1
22 Nut 8

- 190-
 CHASSIS
Head Shed Frame (Bench seat)

No. Part Name Qty Remarks

Removing the head shed frame
1 Horizontal tube assy. Ⅰ , shed 1
2 Front segment of roof rod (Right) 1
3 Front segment of roof rod (Left) 1
4 Screw M10×1.25×25 4
5 Nut M10×1.25 4
6 Waved seal Ⅰ 2
7 Horizontal tube assy. Ⅱ, shed 1
8 Hexagon flange bolt M10×1.25×16 12
9 Head rest 2

- 191-
 CHASSIS

No. Part Name Qty Remarks

10 Screw M10×1.25×25 4
11 Nut M10×1.25 4
12 Cross large plate head screw M6×16 8
13 Cross large plate head screw M6×20 10
14 Nut M6 2
15 Horizontal tube assy. Ⅲ, shed 1
16 Curved washer 4
17 Hexagon socket head bolt M8×22-Φ10×16 2
18 Hexagon socket head bolt M8×25 2
19 Backrest mounting pipe assy. 1
20 Head rear mounting support 1

- 192-
 CHASSIS

No. Part Name Qty Remarks

21 Socket hexagon screw M4×12 8
22 Left mirror assy. 1
23 Right mirror assy. 1
24 Waved seal Ⅱ 2

- 193-
 CHASSIS
Head Shed Frame (Bucket seat)

No. Part Name Qty Remarks

Removing the head shed frame
1 Horizontal tube assy. Ⅰ , shed 1
2 Front segment of roof rod (Right) 1
3 Front segment of roof rod (Left) 1
4 Screw M10×1.25×25 4
5 Nut M10×1.25 4
6 Waved seal Ⅰ 2
7 Horizontal tube assy. Ⅱ, shed 1
8 Hexagon flange bolt M10×1.25×16 12

- 194-
 CHASSIS

No. Part Name Qty Remarks

9 Waved seal Ⅱ 2
10 Screw M10×1.25×25 4
11 Nut M10×1.25 4
12 Left mirror assy. 1
13 Right mirror assy. 1
14 Socket hexagon screw M4×12 8
15 Horizontal tube assy. Ⅲ, shed 1
16 Curved washer 4
17 Hexagon socket head bolt M8×22-Φ10×16 2
18 Hexagon socket head bolt M8×25 2
19 Horizontal tube assy. Ⅳ, shed 1

- 195-
 CHASSIS

DIRECTION SYSTEM
Steering Wheel part

No. Part Name Qty Remarks

Removing the steering wheel
1 Steering wheel comp 1
2 Steering wheel cap 1
3 Socket hexagon plain head screws M6×16 6
4 Lower cover 1
5 Horn 1
6 Steering pole cover 1
7 Clamp 1
8 Bearing 6003-2Z 2
9 Steering pole assy 1
10 Steering pipe 1

- 196-
 CHASSIS

No. Part Name Qty Remarks

11 Ignition switch 1
12 Hexagon flange bolt M6×16 4
13 Gas spring assy 1
14 Pin shaft Ⅰ 1
15 Cotter pin Φ5×1 2
16 Steering pipe bracket 1
17 Hexagon flange bolt M10×1.25×16 3
18 Bolts M6×10-Φ10×20.5 2
19 Hexagon flange Nut M10×1.25 2
20 Steering drive axle 1
21 Hexagon flange bolt M8×30 1
22 Pin shaft Ⅱ 1

- 197-
 CHASSIS

No. Part Name Qty Remarks

23 Steering wheel cover (right) 1
24 Steering wheel cover (left) 1
25 Socket hexagon screw M6×12 2
26 Cross small plate head tapping screw ST3.9×13 3

- 198-
 CHASSIS

Steering mechanism part

No. Part Name Qty Remarks

Removing the steering mechanism
1 Steering mechanism comp 1
2 Bolt M8×1.25×20 2
3 Bolt M8×1.25×80 2
4 Rubber boot 2
5 Clamp 2
6 Steel clamp Φ15 2
7 Hexagonal nut M12 2
8 Ball Joint 2
9 Hexagon nut M12×1.25 2
10 Cotter pin 2×32 2
11 Hexagon flange nut M8 4

- 199-
CHASSIS
THE STRUCTURE OF STEERING WHEEL PART
DIASSEMBLING THE PARTS OF THE
STEERING WHEEL
Remove:
• screw M6×16 ①
• Decoration cover for steering wheel ②
• Horn assembly ③
a. Takes down the screw ①
b. Takes down the decoration cover for steering
wheel ② and horn assembly ③
c. Use the special tools pull out the steering
wheel ④.

CHECKING THE PARTS OF THE STEERING

WHEEL
Check:
• steering wheel ①
• rocky ledge ②
• reverse turning clearance ③
crack/ break Replace.
loose/play Adjust.
the steering wheel to rotate whether nimble, do
not have stagnation. Adjust the torque of the
steering wheel whether obviously
increase Adjust.
NOTE:
The steering force cutting which exerts to
transfers in steering wheel outflow boundary is
smaller than 245N.

The reverse running clearance whether does

surpass the limited stipulation Adjust
NOTE:
The reverse running clearance is less than
30mm.

The grip part which is covered by the foam whether

has damaged, if it is, must replace a new steering
wheel.

- 200-
CHASSIS
Inspect fastens nut of the steering wheel whether
does have flaw and fissure , if it is, must replace.
Check the internal spline between the steering
wheel and steering column whether have
damaged, if the attrition is serious, must replace
the steering wheel.
NOTE:
The tolerance clearance between the internal
spline on the steering wheel and outer spline
on the steering column is smaller than 0.1mm.

WARNING：
If find some problems in the check, it should be
service immediately to ensure the normal
work of the steering system.

DIASSEMBLING THE STEERING COLUMN

PARTS
Remove:
• Front cover
• connection covers part
• steering wheel cover
• display board
• steering wheel
a. Takes down the parts of the front panel and the
connection covers part and the display board
and the steering wheel center covers
b. Take down the steering wheel
• bolt
• steering shaft
c. Loose the bolt which is on the steering drive
axle, the top of spline, draws out the cross
gimbal.
d. Loose the fastening two pieces M8×13.5 bolt
on the steering shaft, take down the steering shaft
from the frame.

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CHASSIS

CHECKING AND SERVICE THE STEERING

COLUMN PARTS
1. Check:
• steering column tube ①
• bearing ②
• central axis of the steering shaft ③
• spline ④
• loosening ⑤
The central axis of the steering shaft whether
flexible and moves. If does, dismantle and check
the axis, bearing and retaining ring whether ware
or damaged, according to the inspection situation
to instead the parts.
2. Check:
The two ends of the spline on the central axis
whether is wear out, if so, instead the central
axis.
3. Check:
The spline in the two ends of the central axis
whether have wear, if dose, instead the central
axis.
4. Check:
The steering shaft tube and welding line of the
branch whether have crack and corrosion, if it
does, instead the steering shaft tube.

DIASSEMBLING THE STEERING DRIVE AXLE

1. Loose the clamp one piece flange bolt in the
cross gimbal, internal spline on the top of the
steering drive axle, pull out the top of the
steering drive axle.
2. Loose the clamp one piece flange bolt in the
cross gimbal, spline on the bottom of the
steering drive axle, pull out the lower of the
steering drive axle.

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CHASSIS

STEERING MACHINE PARTS

THE STRUCTURE OF THE STEERING

1. Check:
• pressure pad ①
• Rubber dust cover ②
Wear/damage Replace.
Damage/degradation Replace
NOTE:
When replace the dust boots of the ball ,
must enter 1/2 volume in lithium grease in
to the dust boots.

2. Check:
• Ball joint steering mechanism ①
• turning ②
• rocky ledge ③
Free play Replace the tie-rod end.
Turns roughly Replace the tie-rod end.

3. Check:
• tie-rods
Bends/damage Replace.
4. Check:
·steering joint
Crack/distortion Replace.

- 203-
 CHASSIS
BRAKE SYSTEM
PREPARATION FOR CHECKING BEFORE THE
MAINTENANCE OF THE BRAKE SYSTEM.
Brake system is crucial to the life safety of the
operator and therefore must be periodically
inspected and maintained.
This vehicle uses the single return route
hydraulic pressure disc brake system. Please
follow the tips of inspection as below.
①. To check the amount of liquid in the oil cup. If
it is min than the minimum mark, refill the box
with the same type of fluid as was recommended
by the manufacturer, to ensure to fluid level is
higher than the minimum mark.
②.The brake should be kept between
3mm-5mm, Otherwise, please adjust the screw
to meet required travel distance.
1. Inspect the brake pedal does maintain the
certain counter-tension
When checks disk brake plate, the saved liquid
in the oil cup will pour automatically into the
pressure pipe and the liquid level along with it to
reduce, the periodic inspection the disk brake
plate liquid volume will be an important project.

Must use DOT3 Brake Fluid

2.
·rear disk brake plate ①
·thickness ②
Periodical inspection of the wear condition of rear
disk brake plate is also necessary. Disk brake
plate must be replaced depending on its wear
condition.
3. Disk brake plate uses hydraulic pressure of the
brake fluid. Therefore, fuel pipe must be
periodically inspected and replaced.
Inspection method: If the oil tubing has the aging,
crack or distortion, must replace the oil tubing.

- 204-
 CHASSIS

DISK BRAKE COMPONENTS

No. Part Name Qty Remarks

Removing brake components
1 Front brake pad 2
2 Front right brake oil pipe 1
3 Front left brake oil pipe 1
4 Front brake caliper assy.(R) 1
5 Front brake caliper assy.(L) 1
6 Front outer brake pad 2
7 Rear brake pipe (Left) 1
8 Hexagon flange bolt M10×1.25×30 4
9 Cooper seal 13

- 205-
 CHASSIS

No. Part Name Qty Remarks

10 Strainer bolt 4
11 Cable clip 7
12 Hexagon flange bolt M6×16 7
13 Rear brake pump 1
14 Rear brake pipe (Right) 1
15 Hexagon flange bolt M10×1.25×30 2
16 Inner brake pad assy. 1
17 Strainer bolt 1
18 Cotter pin 1
19 Rear disk brake main tube 1
20 Front outer brake pad (Left) 1
21 Front outer brake pad (Right) 1

- 206-
 CHASSIS

No. Part Name Qty Remarks

22 Strainer bolt 1
23 Hexagon flange bolt M6×30 1
24 Rear brake caliper assy. (Right) 1
25 Rear brake caliper assy. (Left) 1
26 Front inner brake pad 2
27 Front outer brake pad 1
28 Bolt M10×1.25×22 4
29 Braking plate 1
30 Hexagon step cylinders M6×14-Φ7×15 6
31 Hexagon flange self-lock nuts M6 6
32 Middle brake assy. 1

- 207-
 CHASSIS

No. Part Name Qty Remarks

33 Hexagon flange nut M10×1.25×25 2
34 Rear brake plate 2
35 Connecting fork 1
36 Connecting fork pin 1
37 Rear brake pipe (Left) 1

- 208-
CHASSIS
CHECKING THE FRONT BRAKE DISC
1. Check:
• brake disc
Galling/damage Replace.
2. Measure:
• brake disc deflection
Out of specification Check the wheel runout.
If wheel runout is within the limits, replace the
brake disc.

Brake disc maximum deflection

0.10 mm (0.004 in)

• brake disc thickness ①

• wheel hub ②
• wheel tyre ③
Out of specification Replace.

Brake disc minimum thickness

3.0 mm (0.12 in)

NOTE:
Apply the locking agent to the 30Nm bolt with
screw down.

- 209-
CHASSIS

REPLACING THE FRONT BRAKE PADS

NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.

1.Check:
• brake pad ①
Damage/wear Replace
2.Measure:
• brake pad thickness ⓐ
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
1.5 mm (0.06 in)

3. Install:
• brake pads
• brake pad spring
NOTE:
Always install new brake pads and brake pad
spring as a set.

a. Connect a suitable hose ① tightly to the brake

caliper bleed nozzle ②. Put the other end of this
hose into an open container.
b. Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into the
brake caliper.
c. Tighten the brake caliper bleed screw.
Brake caliper bleed screw
6 Nm (0.6 m ·kg, 4.3 ft ·lb)

d. Install the retaining bolts and brake caliper.

Brake pad holding bolt
18Nm (1.8 m ·kg, 13 ft ·lb)

- 210-
CHASSIS
INSTALLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
front brake calipers.
1. Install:
• brake caliper assembly
• bolt flange

48Nm (4.8m ·kg,35 ft ·lb)

• brake hose ①
• copper washers ②
• union bolt ③
NOTE:
When installing the brake hose on the brake
caliper, make sure that the brake pipe touches
the projection a on the brake caliper.

WARNING:
Proper brake hose routing is essential to insure
safe vehicle operation.

2. Fill:
• brake reservoir

Must use DOT3 Brake Fluid

NOTE:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.

3. Air bleed:
• brake system

4. Check:
• brake fluid level
Brake fluid level is below the “MIN” level line
Add the recommended brake fluid to the
proper level.

- 211-
CHASSIS
REPLACING THE REAR BRAKE PADS
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.

1.Check:
• brake pad ①
Damage/wear Replace
2.Measure:
• brake pad thickness ⓐ
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
1.5 mm (0.06 in)

3. Install:
• brake pads
• brake pad spring
NOTE:
Always install new brake pads and brake pad
spring as a set.

a. Connect a suitable hose ① tightly to the brake

caliper bleed nozzle ②. Put the other end of this
hose into an open container.
b. Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into the
brake caliper.
c. Tighten the brake caliper bleed screw.
Brake caliper bleed screw
6 Nm (0.6 m ·kg, 4.3 ft ·lb)

d. Install the retaining bolts and brake caliper.

Brake pad holding bolt
18Nm (1.8 m ·kg, 13 ft ·lb)

- 212-
CHASSIS
4. Check:
• brake fluid level
• minimum level mark ①

Must use DOT3 Brake Fluid

5. Check:
• brake pedal operation
Soft or spongy feeling Bleed the brake
system.

DISASSEMBLING THE REAR BRAKE

CALIPERS

WARNING:
• Brake caliper is one of the most important
security components. Disassembly and
maintenance must have a rich experience in
technology and complete tool.
•Wrong disassembly and reassembly may
cause serious injury and even death.
Replace damaged brake caliper.
•If only replace the brake caliper of one side,
please check carefully whether the braking
force of right and left are balance and equal.

1. Remove:
• brake caliper pistons
• dust seals ①
• caliper piston seals ②
a. Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.
WARNING:
• Never try to pry out a caliper piston.
• Cover the caliper piston with a rag. Be careful
not to get injured when the piston is expelled
from the caliper cylinder.

- 213-
CHASSIS
b. Remove the dust seals and caliper piston
seals.

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. Check:
• brake caliper pistons ①
Scratches/rust/wear Replace the brake
caliper assembly.
• brake caliper cylinders ②
Wear/scratches Replace the brake caliper
assembly.
• brake caliper body ③
Cracks/damage Replace.
• brake fluid delivery passage (brake caliper
body)
Blockage Blow out with compressed air.

WARNING:
Replace the caliper piston seals and dust
seals whenever the brake caliper is
disassembled.

- 214-
CHASSIS
ASSEMBLING THE REAR BRAKE CALIPERS

WARNING:
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

Must use DOT3 Brake Fluid

• Replace the caliper piston seals and dust seal

whenever a brake caliper is disassembled.

1. Install:
• caliper piston seals ①
• dust seals ②

2. Install:
• brake caliper pistons ①

INSTALLING THE REAR BRAKE CALIPERS

The following procedure applies to both of the
front brake calipers.
1. Install:
• brake caliper assembly
• bolt flange

48Nm (4.8m ·kg,35 ft ·lb)

• brake hose ①
• copper washers ②
• union bolt ③

- 215-
CHASSIS
NOTE:
When installing the brake hose on the brake
caliper, make sure that the brake pipe touches
the projection a on the brake caliper.

WARNING:
Proper brake hose routing is essential to insure
safe vehicle operation.

2. Fill:
• brake reservoir

Must use DOT3 Brake Fluid

NOTE:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.

3. Air bleed:
• brake system

4. Check:
• brake fluid level
Brake fluid level is below the “MIN” level line
Add the recommended brake fluid to the
proper level.

- 216-
CHASSIS

CHECKING THE PARKING BRAKE DISC

1. Check:
• parking disc ①
Galling/damage Replace.
2. Measure:
• parking disc deflection
Out of specification Replace.

Parking disc maximum deflection

0.10 mm (0.004 in)

• parking disc thickness ②

Out of specification Replace.

Parking disc minimum thickness

4.5 mm (0.18 in)

- 217-
CHASSIS

REPLACING THE PARKING BRAKE PADS

1. Check:
• brake pad
• brake pad plate
Damage/wear Replace
2. Measure:
• brake pad thickness
Out of specification Replace the brake
pads as a set.

Brake pad wear limit

1.0 mm (0.04 in)

3. Install:
• brake pads
• pad spring

NOTE:
Always install new brake pads, new brake pad
shims, new insulators, and a new brake pad
spring as a set.

4. Check:
• brake fluid level
• minimum level mark ①
Should the fluid level falls under the minimum
mark, please refill the box with the same type of
fluid as was recommended by the manufacturer to
ensure the fluid level is higher than the minimum
mark.

Must use DOT3 Brake Fluid

- 218-
CHASSIS

DISASSEMBLING THE PARKING BRAKE

CALIPER

WARNING:
• Brake caliper is one of the most important
security components. Disassembly and
maintenance must have a rich experience in
technology and complete tool.
•Wrong disassembly and reassembly may
cause serious injury and even death.
Replace damaged brake caliper.
•If only replace the brake caliper of one side,
please check carefully whether the braking
force of right and left are balance and equal.

1. Remove:
• brake caliper piston ①
• dust seal ②
• caliper piston seal ③
a. Turn the brake caliper piston counterclockwise
to remove it.
b. Remove the dust seal and caliper piston seal.

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.

.Check:
• brake caliper pistons ①
Scratches/rust/wear Replace the brake
caliper assembly.
• brake caliper cylinders ②
Wear/scratches Replace the brake caliper
assembly.
Cracks/damage Replace.

- 219-
CHASSIS

• brake caliper body ③

• brake fluid delivery passage (brake caliper
body)
Blockage Blow out with compressed air.

WARNING:
Replace the caliper piston seals and dust
seals whenever the brake caliper is
disassembled.

ASSEMBLING THE REAR BRAKE CALIPER

WARNING:
• All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.

Must use DOT3 Brake Fluid

• Replace the caliper piston seal and dust

seal whenever a brake caliper is disassembled.

1. Install:
• caliper piston seal ①
• dust seal ②

2. Install:
• brake caliper piston ①
Turn the brake caliper piston clockwise until
section ⓐ of the brake caliper piston is level with
the surface of the brake caliper body.
NOTE:
Align an end ⓑ of the groove in the brake
caliper piston with the punch mark ⓒon the
brake caliper body.

- 220-
CHASSIS

3. Install:
• gasket ①
• parking brake case ②
• parking brake case bolts ③

22Nm (2.2 m ·kg,16 ft ·lb)

• O-ring ④

4. Install:
• parking brake arm shaft ①
• parking brake arm ②
• set bolt ③
• parking brake arm nut ④
NOTE:
Apply lithium-soap-based grease to the parking
brake arm shaft and set bolt.

a. Screw in the parking brake arm shaft

counterclockwise completely so that the punch
mark ⓐ on the parking brake arm shaft is
between the alignment marks ⓑ.
NOTE:
The hole for the parking brake arm shaft has
multiple threads. If the punch mark ⓐ on the
parking brake arm shaft is not between the
alignment marks ⓑ when the parking brake
arm shaft is screwed in completely, remove the
parking brake arm shaft and screw it in from a
different starting position.

b. Turn the parking brake arm shaft approx-

imately 60°clockwise.
c. Install the parking brake arm to the parking
brake arm shaft so that the punch mark ⓒ on the
parking brake arm is aligned with the punch
mark ⓐon the parking brake arm shaft.
d. Turn the parking brake arm until it contacts the
pin ⓓ.
e. Finger tighten the set bolt.
f. Tighten the parking brake arm nut.

- 221-
CHASSIS
5. Install:
• brake pad (piston side) ①
(with insulator and pad shim)
NOTE:
Align the projection a on the piston side of the
brake pad with the groove in the brake caliper
piston.

6. Install:
• brake pad holding bolts

17Nm (1.7 m ·kg,12 ft ·lb)

INSTALLING THE REAR BRAKE CALIPER

1. Install:
• brake caliper assembly
• brake caliper mounting bolts

40Nm (4.0m ·kg,29 ft ·lb)

• brake hose ①
• copper washers
• union bolt ②

48Nm (4.8m ·kg,35 ft ·lb)

NOTE:
Tighten the union bolt while holding the brake
hose as shown.

WARNING:
Proper brake hose routing is essential to
insure safe vehicle operation.

2. Fill:
• brake reservoir

Must use DOT3 Brake Fluid

NOTE:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.

- 222-
CHASSIS

3. Air bleed:
• brake system
4. Check:
• brake fluid level
Brake fluid level is below the “MIN” level
line Add the recommended brake fluid to the
proper level.
5. Adjust:
• parking brake cable free play

CHECKING THE MASTER CYLINDER

1. Check:
• brake master cylinder
Wear/scratches Replace the brake master
cylinder assembly.
• brake master cylinder body
Cracks/damage Replace.
• brake fluid delivery passage
(brake master cylinder body)
Blockage Blow out with compressed air.

• brake master cylinder kit

Scratches/wear/damage Replace as a set.
3. Check:
• brake fluid reservoir
• brake fluid reservoir diaphragm
Cracks/damage Replace.

ASSEMBLING THE BRAKE MASTER

CYLINDER
WARNING：
• All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.

Must use DOT3 Brake Fluid

• Whenever a master cylinder is disassembled
replace the piston seals and dust seals.

- 223-
CHASSIS
INSTALLING THE BRAKE MASTER CYLINDER
1. Install:
• brake master cylinder

16Nm (1.6 m ·kg,11 ft ·lb)

2. Install:
• brake pipe

19Nm (1.9 m ·kg,13 ft ·lb)

• washer plate
• brake hose
• union bolt

27Nm (2.7 m ·kg,19 ft ·lb)

3. Fill:
• brake fluid reservoir

Must use DOT3 Brake Fluid

NOTE:
Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled brake
fluid immediately.

4. Air bleed:
• brake system
5. Check:
• brake fluid level
Brake fluid level is under the “MIN” level line

- 224-
 CHASSIS
FOOTREST PART

No. Part Name Qty Remarks

Removing the footrest part
1 Inner fender 1
2 Accelerator pedal welding assy. 1
3 Mounting seat assy. accelerator pedal 1
4 Socket hexagon plain head screws M6×20 4
5 Cotter pin 2×30 1
6 Throttle cable 1
7 Parking pedal welding assy. 1
8 Foot pedal cover 1
9 Foot pedal cover 1
10 Spring Φ3×Φ30×72° 1
11 Bush Φ10.2×Φ15×35.5 1
12 Parking brake cable 1

- 225-
 CHASSIS

No. Part Name Qty Remarks

13 Hexagon flange bolt M8×16 4
14 Hexagon socket head bolt M6×20 4
15 Parking system 1
16 Hexagon flange bolt M8×16 2
17 Dustproof plate, parking pedal 1
18 Parking cable assy. 1
19 Parking pedal 1
20 Screw thread clip M6×2 18
21 Hexagon flange nut M6 2
22 Hexagon flange bolt M6×16 2
23 Reverse cable 1
24 Hexagon bolt M10×1.25×55 1
25 Spring Φ2.5×Φ23×90° 1

- 226-
 CHASSIS

No. Part Name Qty Remarks

26 Rubber binder plate parking 1
27 Hexagon flange nut M10×1.25 1
28 Speaker cover 1
29 Inlet cap clutch 1
30 Cross large plate head screw M6×16 4
31 Hexagon flange nut M6 4

- 227-
CHASSIS
CHECKING THE BRAKE PEDAL
① Brake pedal
② Free type travel
③ Pedal stroke

Inspect the brake pedals for free clearance and

smooth operation.
Adjust if incorrect measurement is found.

- 228-
 CHASSIS
WHEEL AND TYRE PARTS
FRONT WHEELS

No. Part Name Qty Remarks

Removing the front wheel

1 Front wheel 2
2 Front tire 2
3 Cycle valve 2
4 Nut M12×1.25 8
5 Wheel decoration cover Ⅳ 2
WARNING：
6 Nut M22×1.5 2 Securely support the vehicle so
7 Front hub 2 There is no danger of it falling over.
8 Connecting bolt 4

- 229-
 CHASSIS
REAR WHEELS

No. Part Name Qty Remarks

Removing the rear wheel
1 Front wheel 2
2 Front tire 2
3 Cycle valve 2
4 Front hub 2
5 Connecting bolt 4
WARNING:
6 Nut M12×1.25 8 Securely support the vehicle so
7 Wheel decoration cover Ⅳ 2 There is no danger of it falling over.

8 Nut M22×1.5 2
9 Cotter pin 3.2×50 2

- 230-
CHASSIS
CHECKING THE WHEEL TYRE
1. Check:
• wheel tyre
2. Measure:
• wheel runout
Over the specified limit Replace the
wheel or check the wheel bearing play ①.

3. Check:
• wheel balance
Out of balance
Adjust.

Wheel runout limit

Radial ②: 2.0 mm (0.08 in)
Lateral ③: 2.0 mm (0.08 in)

WARNING:
The profile depth falls below 3mm, Please
replace the tyre immediately.

• tire wear limit ○

a

CHECKING THE WHEEL HUB

1. Check:
• wheel hub ①
Cracks/damage Replace.
• splines (wheel hub) ②
Wear/damage Replace.
·nuts (wheel hub)
loosen or distorted Replace or tighten

- 231-
CHASSIS
INSTALLING THE WHEEL HUB
1. Install:
• axle nut

260 Nm (26.0 m ·kg, 190 ft ·lb)

INSTALLING THE WHEEL TYRE

1. Install:
• wheel
NOTE:
The arrow mark ① on the tyre must point in
the direction of rotation □
A of the wheel.

2. Tighten:
• wheel nuts ①

The angle of the conical bores is 60°

WARNING:
Tapered wheel nuts ① are used for both the
front and rear wheels. Install each nut

- 232-
CHASSIS
SPECIFICATION OF WHEEL AND TYRE

Tyre
Wheel hub Tyre
Pressure
Dimension Dimension
（Kpa /PSI）
Front
14×7 27×9-14 138/20
Wheel
Rear
14×9 27×11-14 180/26
Wheel

• Since wheels and tyres are crucial to the vehicle

operation, inspection for tyre pressure and profile
depth is necessary.
• To ensure maximum security and longer life
expectancy of the wheel, please periodically inspect
the tyre pressure and profile depth. Insufficient tyre
pressure can result in not only intensified wearing of
the tyre but also instability during the course of
operating the vehicle (such as hard turning).
Excessive tyre pressure can also reduce the friction
force between the tyre and ground, causing spinning
or lose of control. Therefore, please ensure the tyre
pressure strictly complies with figures shown in the
chart above.
• Before operating the vehicle each time, please
check if profile depth of the tyre is over worn, which
might result in spinning, instability, lose of control
and other potential security risk of the vehicle.

- 233-
 CHASSIS

TRANSMISSION SYSTEM
C.V Axle, Front Axle

No. Part Name Qty Remarks

1 Circlip 1
2 Double off-set joint assembly 2
3 Circlip 2
4 Circlip 2
5 Hoop A, dust P shed Φ80 4
6 Outer rubber dust-P cover (C-1610) 2
7 Hoop B, dust P shed Φ32 4
8 Joint shaft 1
9 Inner rubber dust-P cover (C-1605) 2
10 Front left C.V axle 1
11 Front right C.V axle 1

- 234-
 CHASSIS
Front Bridge

No. Part Name Qty Remarks

Removing the front bridge
1 Front differential assy. 1
2 Front differential case 1
3 Front differential cover 1
4 Rear transmission shaft, front differential 1
5 Master-accessory gear 1
6 Spring Washer d0=19 1
7 Speed sensor 1
8 O-seal Φ2.3×Φ18.4 1
9 Seal Φ24×Φ38×8, output shaft 1
10 Seal Φ24×Φ38×8, output shaft 1

- 235-
 CHASSIS

No. Part Name Qty Remarks

11 Adjust gasket Φ50×Φ61.5 2
12 Bolt M8×20 3
13 Dustproof rubber bush 2
14 Clamp Φ20-32 1
15 Screw M8×10 1
16 Bolt M8×25 6
17 Spring washer d0=62 1
18 Straight pin Φ5×80 1
19 Transfer case assembly 1
20 Sliding sleeve 1
21 Rack 1

- 236-
 CHASSIS

No. Part Name Qty Remarks

22 Shaft fork 1
23 O-Ring Φ2×Φ81,transfer case 1
24 O-seal Φ2.4×Φ140 1
25 Bearing 6007R 1
26 Bearing 6912 1
27 Bearing 16007 1
28 Bearing HK152112 1
29 Bearing M14×1.5×10 2
30 O-ring Φ1.5×Φ9, oil filling plug 1
31 Divide device connection 1
32 Adjust gasket Φ71×Φ83 1
33 Dustproof rubber bush 1

- 237-
 CHASSIS

No. Part Name Qty Remarks

34 Copper washer Φ14×2 1
35 Ventilation tube L=700mm 1
36 Oil pipe clip Φ8 1
37 Front shaft, front differential 1
38 Spring 1
39 Middle shaft, front differential 1
40 Hexagon flange bolt M8×25 4
41 Spring guard plate Φ22.5 2
42 Universal joint Ⅰ 3
43 Fork Ⅱ 6
44 Spring washer-8 3

- 238-
 CHASSIS

No. Part Name Qty Remarks

45 Cross shaft 3
46 Bearing mounting base 2
47 Clip Φ22 12
48 Hexagon flange bolt M8×16 3
49 Cushion Φ8×Φ24×2 3

- 239-
 CHASSIS
Front Bridge
DISASSEMBLING THE FRONT BRIDGE
1. Take down the left and right front wheel parts.
2. Sequently remove the front disk brake clip,
cotter pin, open-groove nut, cushion and front
wheel hub.
3. Disassembly the left and right arm rocker and
cross steering knuckle.
4. Disassembly the differential device
5. Take down the front bridge from the frame
6. Emit the oil in the differential device
7. Pull out the left and right transmission shaft from
the differential device.

DISASSEMBLING THE UNIVERSAL JOINT

Remove:
• universal joint
a. Remove the circlips ①.
b. Place the universal joint in a press.
c. With a suitable diameter pipe ② beneath the
yoke ③, press the bearing ④ into the pipe as
shown.
d. Repeat the steps for the opposite bearing.
e. remove the yoke.

NOTE:
It may be necessary to lightly tap the yoke with
a punch.

- 240-
CHASSIS
CHECKING THE C.V AXLE, FRONT AXLE

1.Check:
• Rubber dust-P cover
Cracks/damage Replace

2.Check:
• double off-set assembly
• ball joint spline
• shaft spline
Wear/damage Replace.
• balls and ball races
• inner surface of double off-set
Pitting/wear/damage Replace.

·Check whether the inner and outer ball cage of the

left and right transmission shaft movement is
Smooth, ceaseless. If it is stagnation and obvious
becoming less loosen, replace it.
·Disassemble the left and right transmission
shaft ,cleaning and assemble it again.

NOTE:
1. The dustproof rubber wrap on the ball cage
is not allow to contact with the gas and diesel
oil.
2. The dustproof rubber wrap does not allow to
be scratched, a slight scratches can damage
the dustproof rubber wrap very quickly.
3. When reassembles the left and right
transmission shaft, in the ball cage must
sufficiently enter 2/3 volume with the Lithium
lubricating.

- 241-
CHASSIS
ASSEMBLING THE UNIVERSAL JOINT
Install:
• universal joint
a. Install the opposite yoke into the universal
joint.
b. Apply wheel bearing grease to the bearings.
c. Install the bearing ① onto the yoke.
d. Press each bearing into the universal joint
using a suitable socket.

CAUTION:
Check each bearing. The needles can easily
fall out of their races. Slide the yoke
back and forth on the bearings; the yoke
will not go all the way onto a bearing if a
needle is out of plate.

NOTE:
The bearing must be inserted far enough into
the universal joint so that the circlip can be
installed.

e. Install the circlips ② into the groove of each

bearing.

- 242-
 CHASSIS
C.V Axle, Rear Axle

No. Part Name Qty Remarks

Removing the rear axle
1 Circlip 2
2 Double off-set joint assembly 2
3 Hoop A, dust P shed Φ80 4
4 Inner rubber dust-P cover (C-1520) 2
5 Hoop B, dust P shed Φ32 4
6 Double off-set joint assembly 2
7 Inner rubber dust-P cover (C-1605) 2
8 Half axle assembly 2
9 Rear left C.V axle 1
10 Rear right C.V axle 1
11 Circlip 2
12 Double off-set joint assembly 2

- 243-
 CHASSIS
Rear Bridge Reducer

No. Part Name Qty Remarks

Removing the rear bridge
1 Rear differential housing Ⅱ 1
2 Rear differential housing Ⅰ 1
3 Oil seal Φ52×Φ35×7 2
4 Bearing 32008E 1
5 Rear differential 1
6 Connecting bush 1
7 O- ring 1
8 Rear differential component 1
9 Spring Φ2.3×Φ25×20 1
10 Middle transmission axle 1

- 244-
 CHASSIS

No. Part Name Qty Remarks

11 Bearing 32010E 1
12 Bearing seat 1
13 Metal bushing 1
14 Drain O-ring 1
15 Drain bolt 1
16 Welding combination of shift fork 1
17 U type spring 1
18 Fix bracket 1
19 Returning spring 2
20 Sleeve of shift fork 1
21 Fork pin 1
22 Spring 2
23 Oil filling plug 1

- 245-
 CHASSIS

No. Part Name Qty Remarks

24 Oil filling o-ring 1
25 Rubber bush 1
26 Hexagon flange nut M10×1.25 2
27 Oil filling o-ring 1
28 Hexagon flange nut M12×1.25×25 1
29 Steel clamp 1
30 Rear differential pipe 1
31 Magnetic valve 1
32 Rear adjust gasket Ⅰ 3
33 Washer Φ12×Φ30×4 1
34 Adjust bushing Ⅰ 1
35 Gasket of adjust bushing 1

- 246-
 CHASSIS

No. Part Name Qty Remarks

36 Adjust bushing Ⅱ 1
37 Bearing 32206E 2
38 O-ring 1
39 Mount bracket rear disk brake plate 1
40 Rear differential drive gear 1

- 247-
 CHASSIS
Rear Bridge
(The service method of the rear bridge parts is
as the same as the front bridge parts, please
refer to the before-mentioned to operate.)
NOTE:
Apply lithium-soap-based grease to the bearing
assembly and o-ring and bearing and driven
gear and oil seal and drive shaft coupling and
final drive pinion gear bearing housing.

- 248-
 CHASSIS

Shift Operating System (Bench seat)

No. Part Name Qty Remarks

Removing the shift operating system
1 Gear shifter assembly 1
2 Hexagon flange bolt M8×20 1
3 Bush 11×Φ16×Φ23×11 4
4 Gear shift mounting plate 1
5 Hexagon flange bolt M6×16 3
6 Hexagon flange nut M8 4
7 Hexagon flange bolt M8×16 4
8 Gear shift cover 1
9 Cushion Φ8×Φ24×2 1
10 Hexagon flange nut M6 3
11 Gearshift cover 1
12 Hexagon flange self-lock nuts M6 2

- 249-
 CHASSIS

No. Part Name Qty Remarks

13 Gear shift rod 1
14 Shifting arm assy. 1
15 Shift arm mounting plate 2
16 Spring Φ2.5×Φ23×90° 1
17 Cotter pin 12×1 2
18 Gearshift cable assy. 1
19 Hexagon Flange Self-lock Nut M6 2
20 Washer Φ6×Φ18×1.6 2
21 Gear shift rod 1
22 Hexagon flange bolt M6×16 1
23 Gearshift cable fix plate 1
24 Hexagon flange bolt M6×30 1
25 Hexagon flange self-lock nut M8 4
26 Hexagon flange bolt M8×55 4

- 250-
 CHASSIS

Shift Operating System (Bucket seat)

No. Part Name Qty Remarks

Removing the shift operating system
1 Gear shifter assembly 1
2 Gear shift knob 1
3 Hexagon flange bolt M6×30 1
4 Gear shift boot 1
5 Clamp 1
6 Gear shift assy. 1
7 Hexagon flange bolt M8×16 3
8 Gear shift rod 1
9 Hexagon flange self-lock nut M6 4
10 Shifting arm assy. Ⅰ 1

- 251-
 CHASSIS

No. Part Name Qty Remarks

11 Hexagon flange bolt M8×16 1
12 Cushion Φ8.4×Φ16×1.6 1
13 Gear shift rod 1
14 Shifting arm assy. 1

- 252-
 CHASSIS
Reverse mechanism parts (Bench seat)
ADJUSTING REVERSE MECHANISM PARTS
① Neutral
② High
③ Low
④ Reverse
⑤Select lever shift rod

NOTE:
Before shifting, you must stop the vehicle
and take your foot off the accelerator pedal.
Otherwise, the transmission may be
damaged.

1. Adjust:
• Select lever shift rod
a. Make sure the select lever is in NEUTRAL.
b. Loosen both in nuts ①.
c. Adjust the shift rod length for smooth and
correct shifting ②.
d. Tighten the nuts ①.

Nut
23 Nm (2.3 m ·kg, 17 ft ·lb)

- 253-
 CHASSIS
Reverse mechanism parts (Bucket seat)
ADJUSTING REVERSE MECHANISM PARTS
① Neutral
② High
③ Low
④ Reverse
⑤Select lever shift rod

NOTE:
Before shifting, you must stop the vehicle
and take your foot off the accelerator pedal.
Otherwise, the transmission may be
damaged.

1. Adjust:
• Select lever shift rod
a. Make sure the select lever is in NEUTRAL.
b. Loosen both in nuts ①.
c. Adjust the shift rod length for smooth and
correct shifting②.
d. Tighten the nuts ①.

Nut
23 Nm (2.3 m ·kg, 17 ft ·lb)

- 254-
 CHASSIS
Reverse mechanism parts
CHECKING AND SERVICE OF REVERSE
MECHANISM
1. Check the mobility of gear shift handle. If it is
not working properly, remove the gear shift
Mechanism to check if the fork , ball and spring is
stuck.,in which case replace the defective
component and try again.The last way is to turn to
the professional repairman.
2. If there is lack in the gear shift mechanism ,
adjust the nut of the fork to correct position and
strengthen gear shift mechanism .
3. Remove the gear shift mechanism and check
whether the linking rod is cracked; If so, it should
be changed.
4. Check whether the bouncing spring of gear shift
mechanism is intense enough.
5. Check whether the gear is engaged correctly
and whether there are tripstop or lack. If these
situation exists, call for the maintanance staff to
test and repair it.
6. If the gear can not be engaged, we can test it
from the following aspects:
·whether the clutch can completely declutch;
·whether the gearshift is greased
reliable(whether the oil pipe of gear shift
mechanism is blocked);
· whether gear shift mechanism jams;If these
situation happens, maintanance staff would come
to test and repair it.

- 255-
 CHASSIS

SUSPENSION
Front suspension

No. Part Name Qty Remarks

Removing the front swing arm
1 Left front lower swing arm 1
2 Right front lower swing arm 1
3 Hexagon flange bolt M10×1.25×70 4
5 Bush Φ10×Φ23×50 4
6 Bush Φ22×Φ28×Φ35×20 8
7 Hexagon flange nut M10×1.25 4
8 U-joint B 2
9 Hexagon nut M12×1.25 4
10 Cotter pin 2×30 4
11 Hexagon flange bolt M10×1.25×45 2

- 256-
 CHASSIS

No. Part Name Qty Remarks

12 Front upper suspension assy. 2
13 Hexagon flange bolt M10×1.25×30 4
14 Hexagon flange bolt M10×1.25×230 2
15 Bush Φ14×Φ19×Φ35×30 4
16 Bush 2
17 Hexagon flange nut M10×1.25 2
18 Joint a，suspension 2
19 Spring washer d0=30 4
20 Front air-bag shock kit 2
21 Hexagon bolt M10×1.25×55 2

- 257-
 CHASSIS

No. Part Name Qty Remarks

22 Hexagon flange nut M10×1.25 4
23 Hexagon bolt M10×1.25×55 2
24 Front left suspension plate 1
25 Front right suspension plate 1
26 Hexagon flange bolt M6×16 4
27 Spring washer -12 2

- 258-
 CHASSIS
Front Suspension and arm
DISASSEMBLING, SERVICE AND ASSEMBLY
THE SUPPORTING ROCKER PARTS
1. Disassembling and Service
In the suspension, there is easy to appear the
problem with bushing, cotter pin and shock
absorber.
·If the left and right rocker rocks fiercely, check the
few aspect, whether the bushing of the rocker is
crushed, the middle rubber separate is aging and
chapped.
·check whether the cotter pin is credible, if it is not
instead the same spec cotter pin.
·The problem with the shock absorber and
maintain method, whether it can returns to the
position under the pressure and the torsional
spring is rupture. If it is rupture or nearly to rupture,
instead the shock absorber. whether it leak oil, if so
instead the same spec shock absorber. According
to the different request, if there is a oil cup on the
rocker, must check it whether complete and
refuels.
2. Install:
Mount fore L/R damper,up-and-down rocker arm
assembly onto the frame with Flange Bolt M10
nuts, Flange Bolt and M10 Nut, self-locking to
ensure a torque of 40～45Nm.
CAUTION:
·These components should be greased with
butter before assembly.
·The surface of components can not be
cracked.

- 259-
 CHASSIS
Front Suspension and arm
·Check whether these components are greased
with butter and then tighten the up-and-down
rocker arm assembly and L/R fore dampers and
the components. Fix the L/R tension rods into hole
by way of the trough of open-groove nut with
cotter pin, and make these tension rods bisection
on feet.

CHECKING THE STEERING KNUCKLES

1. Check:
• steering knuckles
Damage/pitting Replace

CHECKING THE FRONT ARMS

1. Check:
• front arms
Bends/damage Replace.
2. Check:
• Middle bushing
Wear/damage Replace.
3. Check:
• ball joints
Damage/pitting Replace the ball joint.
Free play Replace the ball joint.
Turns roughly Replace the ball joint.

CHECKING THE FRONT SHOCK ABSORBER

1. Check:
• shock absorber rod
Bends/damage Replace the shock
absorber assembly.
• shock absorber assembly
Oil leaks Replace the shock absorber
assembly.
• spring
Fatigue Replace the shock absorber
assembly.
Move the spring up and down.

- 260-
 CHASSIS
Front Suspension and arm
INSTALLING THE FRONT ARMS AND FRONT
SHOCK ABSORBER
1. Install:
• front arms
• front shock absorber

a. Install the front upper arm ①and front lower arm

②.

NOTE:
• Lubricate the bolts ③ with lithium-soap-based
grease.
• Be sure to position the bolts ③ so that the
bolt head faces inward.
• Temporarily tighten the nuts ④.

b. Install the front shock absorber ⑤.

Nut ⑥
45 Nm (4.5 m ·kg, 32 ft ·lb)

c. Install the front knuckle.

Nut ⑧
45 Nm (4.5 m ·kg, 32 ft ·lb)

d. Tighten the nuts ④.

Nut ④
45 Nm (4.5 m ·kg,32 ft ·lb)

- 261-
 CHASSIS
Rear Suspension

No. Part Name Qty Remarks

Removing the rear suspension
1 Rear right lower swing arm (Right) 1
2 Rear left lower swing arm (Left) 1
3 Hexagon flange bolt M10×1.25×70 4
4 Bush 16
5 Bush Φ10×Φ23×50 8
6 Hexagon flange nut M10×1.25 8
7 Rear air-bag shock kit 2
8 Hexagon flange bolt M6×16 4
9 Hexagon flange bolt M12×1.25×60 2

- 262-
 CHASSIS

No. Part Name Qty Remarks

10 Hexagon flange nut M12×1.25 2
11 Hexagon flange bolt M10×1.25×60 2
12 Hexagon flange nut M12×1.25 2
13 Rear right upper swing arm (Right) 1
14 Rear left upper swing arm (Left) 1
15 Hexagon flange bolt M10×1.25×70 4
16 Rear left suspension plate 1
17 Rear right suspension plate 1
18 Hexagon flange bolt M10×1.25×115 4
19 Dust P. Cover 8
20 Axle sleeve liner 4
21 Bush Φ10.5×Φ18×10.7 8

- 263-
 CHASSIS
Rear Suspension and arm
CHECKING AND SERVICE OF REAR
SUSPENSION
1. It is similar to the front suspension ,Check if
there exists any distortion or crack on the install
axis of the shock absorber in which case it must be
replaced.
2. Inspect the rocker bushing and the middle
rubber separate is integrant.( According to the front
Suspension)
3. The cotter pin on the head of the install axis
which in the rear shock absorber whether is
credible.
NOTE:
After disassemble the rear shock absorber,
check if there exists any distortion or crack on
the frame connection hole and the rear shock
absorber, if so, inform the special serviceman
to inspect and service first or install the rear
shock absorber on the frame after
instead.(Attention, the bolts must be the
special self-lock nut, the fastening torque must
be 45-55Nm)

- 264-
 CHASSIS
Rear Suspension and arm
CHECKING THE STEERING KNUCKLES
1. Check:
• steering knuckles
Damage/pitting Replace

CHECKING THE REAR ARMS

1. Check:
• rear arms
Bends/damage Replace.
2. Check:
• Middle bushing
Wear/damage Replace.

CHECKING THE REAR SHOCK ABSORBER

1. Check:
• shock absorber rod
Bends/damage Replace the shock
absorber assembly.
• shock absorber assembly

assembly.
• spring
Move the spring up and down.
Fatigue Replace the shock absorber
assembly.

- 265-
CHASSIS

INSTALLING THE REAR ARMS AND

REAR SHOCK ABSORBER
1. Install:
• rear arms
• rear shock absorber

a. Install the rear upper arm ① and rear lower

arm ②.

NOTE:
• Lubricate the bolts ③with lithium-soap-based
grease.
• Be sure to position the bolts ③so that the bolt
head faces outward.
• Temporarily tighten the nuts ④.

b. Install the rear shock absorber ⑤.

Nut ⑥
45 Nm (4.5 m ·kg, 32 ft ·lb)

c. Install the ball joints.

Nut ⑦
30 Nm (3.0 m ·kg, 22 ft ·lb)

d. Install the new cotter pins.

e. Tighten the nuts.

Nut ④
45 Nm (4.5 m ·kg, 32 ft ·lb)

- 266-
 CHASSIS
COOLING SYSTEM
Water And Oil Radiator

No. Part Name Qty Remarks

Removing the radiator
1 Water tank 1
2 Radiator cover 1
3 Oil cooler 1
4 Radiator assy. 1
6 Radiator fan assy. 1
7 H-shaped rubber washer 10
8 Hexagon flange nut M6 4
9 Metal pipe IV 1

- 267-
 CHASSIS

No. Part Name Qty Remarks

10 Water pipe 1
11 Clip Φ9 2
12 Water inlet assy. 1
13 ClipΦ9 1
14 Rubber pipe Φ7×Φ11×750 1
15 Auxiliary radiator assy. 1
16 Hexagon flange bolt M6×16 2
17 Metal pipe Ⅲ 1
18 Rubber tube Φ5×Φ9×550 1
19 Clamp Φ20-32 10
20 Front water pipe(R) 1
21 Front left water pipe 1

- 268-
 CHASSIS

No. Part Name Qty Remarks

22 Metal water pipe 2
23 Clip , metal water pipe 6
24 Hexagon flange bolt M6×16 6
25 Rear left water pipe 1
26 Rear right water pipe 1
27 Rubber pipe I Φ10×Φ17×280 2
28 Rubber pipe Φ10×Φ17×650 2
29 Hexagon flange bolt M6×16 7
30 Screw Hoop Φ12-20 12
31 Metal pipe Ⅰ 1
32 Metal pipe Ⅱ 1
33 M-shaped fixed pipe clamps 7

- 269-
CHASSIS

CHECKING THE RADIATOR

1. Check:
• radiator fins
Obstruction Clean.
Apply compressed air to the rear of the radiator
Damage Repair or replace.
NOTE:
Straighten any flattened fins with a thin,
flat-head screwdriver.

2. Check:
• all rubber hose
Cracks/damage Replace.
3. Check:
• Bolt clip
the tightness of Bolt clip. If loosen, please have
the hoop tightened immediately.
4. Check:
• radiator fan
Damage Replace.
Malfunction Check and repair.

5. Measure:
• radiator cap opening pressure
Below the specified pressure Replace
the radiator cap.

Radiator cap opening pressure

107.9 ~ 137.3 KPa
(1.079 ~ 1.373 kg/cm2, 15.35 ~ 19.53 psi)

a. Install the radiator cap tester ① and adapter

② onto the radiator cap ③.
b. Apply the specified pressure for ten sec-onds
and make sure that there is no drop inpressure.

- 270-
CHASSIS

INSTALLING THE RADIATOR

1. Fill:
• cooling system
Start engine when pour full the refrigerating fluid,
loose the exhaust nut on the pipe, the water level
will get lower at this time, Supply the refrigerating
fluid until the water level stop to change, then
screw the exhaust nut, cover the water tank lid.
The water tank inspection is finished. .
2. Check:
• cooling system
Leaks Repair or replace any faulty part.

- 271-
CHASSIS

CHECKING THE OIL COOLER

1. Check:
• oil cooler
Obstruction Clean.
Apply compressed air to the rear of the oil
cooler.
Damage Repair or replace the oil cooler.
NOTE:
Straighten any flattened fins with a thin,
flathead screwdriver.

2. Check:
• oil pipes
Cracks/damage

- 272-
 CHASSIS
SEAT (Bench seat)

No. Part Name Qty Remarks

Removing the seat
1 Bench seat 1
2 Hexagon flange bolt M10×1.25×20 2
3 Backrest assy. 1
4 Baffle plate 1
5 Safety belt assy. 2
6 Socket hexagon plain head screws M6×16 2
7 Hexagon flange step bolt M10×1.25×20-Φ14×5 4
8 Hexagon flange bolt M10×1.25×20 2
9 Hexagon flange nut M10×1.25 6
10 Cross large plate head screw M6×16 6
11 Safety belt placing plate 2
12 Safety belt buckle 2
13 Rubber insulation（Left） 1
14 Rubber insulation（Right） 1

- 273-
 CHASSIS
SEAT (Bucket seat)

No. Part Name Qty Remarks

Removing the seat
1 Seat mounting board 2
2 Lock plate seat 2
3 Lock plate assy. 2
4 Slide rail comp.(Left) 2
5 Safety belt assy. 2
6 Socket hexagon plain head screws M6×20 4
7 Hexagon flange step bolt M10×1.25×20 4
8 Hexagon flange bolt M10×1.25×20 4
9 Hexagon flange nut M10×1.25 6
10 Slide rail comp.(Right) 2

- 274-
 CHASSIS

No. Part Name Qty Remarks

11 Safety belt placing plate 2
12 Safety belt buckle 2
13 Damping rubber Φ24-11 4
14 Rubber insulation（Left） 1
15 Rubber insulation（Right） 1
16 Head rest 2
17 Backrest assy. 2
18 Seat assy. 2
19 Seat assy. 2
20 Front plug 25×25 4
21 Hexagon flange bolt M8×25 24
22 Rubber plug Φ19×Φ25×10 24

- 275-
 CHASSIS

No. Part Name Qty Remarks

23 Hexagon flange nut M8 20
24 Hexagon flange bolt M8×16 8
25 Hexagon flange bolt M8×40 4
26 Baffle plate 1
27 Pull rod slide rail 2
28 Seat Lock handle bar 2
29 Lock spring seat 2
30 Spring broad seat 2

- 276-
CHASSIS

DISASSEMBLING THE SEAT (Bucket seat)

Remove:
• Driver seat ①
• Passenger seat ②
• Bolt ③
To remove the seat, Remove bolts with socket
wrench, and then remove the seat. Installation is
the reverse of removal.

CAUTION:
·These components should be greased with
butter before assembly.
·The surface of components can not be cracked.

Moving Seat Forward And Backward

• Driver seat handle①
• Passenger seat handle ②
The seat can be moved forward and backward to
fit the height of different drivers. Pull up the handle,
then you can move the seat forward and backward.

CAUTION:

To install the seat, Adjust the four bolts M8

cooperatively to ensure the seat can move forward
and backward normally. Improper installation can
result in seat rail blocked and failure to move the
seat back and forth.

- 277-
CHASSIS

DISASSEMBLING THE SEAT (Bench seat)

Remove:
• Driver seat and passenger seat ①
To open the seat, raise the seat to the forward
position.
To remove the seat, Remove bolts with socket
wrench, and then remove the seat. Installation is
the reverse of removal.

CAUTION:
·These components should be greased with
butter before assembly.
·The surface of components can not be cracked.

- 278-
 CHASSIS
FUEL TANK

No. Part Name Qty Remarks

Removing the fuel tank
1 Fuel tank 1
2 Aluminum foil insulation bellowsΦ14×Φ17-220 2
3 Shock absorbtion rubber Ⅷ 4
4 Fuel pump connector 1
5 Fuel pump cover 1
6 Rubber tube Φ7×Φ11×700 1
7 Plug for fuel outlet 1
8 Clip Φ10 1
9 Clamp 6
10 Triplet joint fuel pipe 1
11 Aluminum foil insulation bellows Φ14×Φ17-470 1
12 Fuel pipe Φ8×Φ14-250 2
13 Fuel pump assy. 1

- 279-
 CHASSIS

No. Part Name Qty Remarks

14 Fuel inlet plug 1
15 Fuel tank cap 1
16 Seal gasket for fuel pump 1
17 Hexagon flange bolt M8×30 2
18 Fuel pipe Φ8×Φ14-250 1
19 Binder plate for fuel tank 2

- 280-
CHASSIS

• Fuel tank cap

Remove the fuel tank cap by turning it
counterclockwise.
Fill fuel tank when fuel gauge shows1/4 or less
fuel in tank.

CAUTION:

 Do not smoke while refueling.

 Be sure to stop the engine before refueling.

• Fuel pump

① Fuel pump
② Fuel line
③ Exit pipe

NOTE:
When the fuel line is disconnected for
maintenance or repair close both ends of the
fuel line with a piece of clean cloth or paper to
prevent dust and dirt from entering in addition
particular, care must be taken not to admit dust
and dirt into the fuel pump entrance of even a
small amount of dust or dirt cause premature
wear and malfunction of the fuel pump and
injector components.

- 281-
 ELECTRICAL COMPONENTS

ELECTRICAL SYSTEM MALFUNCTION INSPECTION

S/N Phenomenon Measure

1、 Check whether switches normal.

1 Abnormal lights 2、 Check whether cables damaged.

3、 Check whether lights damaged.

Fail to shift into 1、 Check whether four wheel drive switch normal.
2 four-wheel-drive or
lock differential. 2、 Check whether front bridge differential mechanical conversion agency
locked or damaged.
1、 Check whether battery undercharge.
2、 Check whether starting motor damaged.
3、 Check whether EFI damaged.
4、 Check whether ignition coil normal.

3 Fail to electric start 5、 Check whether spark plug fouling or ablative.

6、 Check whether crankshaft speedmeter magneto ignition signal normal.

7、 Check whether oilpump damaged.

8、 Check whether air filter plugged.
9、 Check whether oil circuit smooth.

1、 Check whether speedmeter damaged.

Abnormal speed
4 indication between 2、 Check whether meter damaged.
meter and mileage.
3、 Check whether speedmeter surface polluted by iron scrap,

1、 Check whether neutral switch damaged.

Neutral indicator of
5 2、 Check whether meter damaged.
meter is not bright
3、 Check whether cable damaged.

1、 Check whether reverse switch damaged.

Reverse indicator of 2、 Check whether meter damaged.
6
meter is not bright
3、 Check whether cable damaged.

1、 Check whether meter damaged.

Other indicators of
7 2、 Check whether cable damaged.
meter are not bright
3、 Check whether sensor or s witch damaged.

- 282 -
 ELECTRICAL COMPONENTS

ELECTRICAL
ELECTRICALCOMPONENTS(bucket seat)

1. Thermo switch
2. Brake light switch
3. Gear position switch
4. Speed sensor
5. Ignition coil
6. Ignition coil
7. stator assembly
8. Fuel pump
9. Windlass controller
10. Radiator fan
11. Windlass

- 283 -
 ELECTRICAL COMPONENTS

1. ECU unit
2. Rectifier/regulator
3.. Windlass controller switch
4. Ignition switch parts
5. Relay assy
6. Battery
7. Starter relay
8. Lighting switch
9. Low (hight beam) convert switch
10. Driven switch assy
11.. Rear bridge differential convert switch
12. Front bridge differential convert switch
13. Emergency lamp switch
14. Hydraulic control switch assy..
15. Left(Right) turn controller switch
Hydra ulic control switch
16. DC socket
draulic control switch
17. Speedmeter

- 284 -
 ELECTRICAL COMPONENTS

ELECTRICAL
ELECTRICALCOMPONENTS(bench seat)

1. Thermo switch
2. Brake light switch
3. Gear position switch
4. Speed sensor
5. Ignition coil
6. Ignition coil
7. stator assembly
8. Fuel pump
9. Windlass controller
10. Radiator fan
11. Windlass

- 285 -
 ELECTRICAL COMPONENTS

1. ECU unit
2. Rectifier/regulator
3.. Windlass controller switch
4. Ignition switch parts
5. Relay assy
6. Battery
7. Starter relay
8. Lighting switch
9. Low (hight beam) convert switch
10. Driven switch assy
11.. Rear bridge differential convert switch
12. Front bridge differential convert switch
13. Emergency lamp switch
14. Hydraulic control switch assy..
15. Left(Right) turn controller switch
Hydra ulic control switch
16. DC socket
draulic control switch
17. Speedmeter

- 286 -
ELECTRICAL COMPONENTS

CHECKING THE SWITCH

CHECKING THE SWITCH
Use multimeter to check the terminals for
continuity. If the continuity is faulty at any point,
replace the switch.

1NOTE:
• Set the multimeter to “0” before starting the
test.
• The multimeter should be set to the “Ω × 1”
range when testing the switch 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 left. This chart shows the
switch positions in the column and the switch lead
colors in the top row.
For each switch position, “ ” indicates the
terminals with continuity.
The example chart shows that:
① There is continuity between the “Brown/Blue
and Red” leads when the switch is set to “ON”.

- 287 -
 ELECTRICAL COMPONENTS

Checking the switch continuity(bucket)

Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection,
no continuity Correct or replace.
* The coupler locations are circled.

1. Rear bridge differential gear lock switch

2. Driven switch assy.
3. Light switch
4. Brake switch
5. Parking switch
6. Main switch

- 288 -
 ELECTRICAL COMPONENTS

Checking the switch continuity(bench)

Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection,
no continuity Correct or replace.
* The coupler locations are circled.

1. Rear bridge differential gear lock switch

2. Driven switch assy.
3. Light switch
4. Brake switch
5. Parking switch
6. Main switch

- 289 -
 ELECTRICAL COMPONENTS

CHECKING THE BULBS AND BULB

SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity
between the terminals
Damage/wear Repair or replace the bulb, bulb
socket or both.
Improperly connected Properly connect.
Incorrect continuity reading Repair or replace
the bulb, bulb socket or both.

WARNING：
Since the bulb gets extremely hot, keep
flammable products and your hands away from
the bulb until it has cooled down.

CAUTION:
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal
in the coupler.
• Avoid touching the glass part of the bulb to
keep it free from oil, otherwise the
transparency of the glass, the life of the bulb
and the luminous flux will be adversely
affected. If the bulb gets soiled, thoroughly
clean it with a cloth moistened with alcohol
or lacquer thinner.

IGNITION SYSTEM
CIRCUIT DIAGRAM（see 346 page）

- 290 -
 ELECTRICAL COMPONENTS

TROUBLESHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK):

Procedure
Check:
1. Fuses (main, ignition) 7. Main switch
2. Battery 8. Pickup coil resistance
3. Spark plug 9. Wiring connection (the entire ignition system)
4. Ignition spark gap
5. Spark plug cap resistance
6. Ignition coil resistance

NOTE:
1. Cushion
2. Front frame
3. Front fender
Check and repaire with following special tools.

1.Fuses (main, ignition)

NO CONTINUITY
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the fuse(s).
2. Battery
INCORRECT
• Check the battery condition. Refer to
“CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Open-circuit voltage • Clean the battery terminals.
• Recharge or replace the battery.
12.8 V or more at 20 °C (68 °F)

CORRECT
3. Spark plug

• Check the spark plug condition.

• Check the spark plug type.
• Check the spark plug gap.
Refer to “CHECKING THE SPARK PLUG” in
chapter 3.

- 291 -
 ELECTRICAL COMPONENTS

4. Ignition spark gap

• Disconnect the spark plug cap from the INCORRECT

spark plug.
• Connect the pulse ignition spark checker or
ignition checker ① as shown. Repair or replace the spark plug.

② Spark plug cap

• Turn the main switch to “ON”.
• Check the ignition spark gap ○
a .

• Crank the engine by pushing the starter

switch, and increase the spark gap until a
misfiring occurs.

Minimum spark gap MEETS SPECIFICATION

6.0 mm (0.24 in)
OUT OF SPECIFICATION OR
NO SPARK The ignition system is not faulty.

5. Spark plug cap resistance

• Remove the spark plug cap.

• Connect the pocket tester (Ω × 1k) to the
spark plug cap.
• Check that the spark plug cap has the
specified resistance.
Spark plug cap resistance OUT OF SPECIFICATION
10 kΩ at 20 °C (68 °F)

MEETS SPECIFICATION
Replace the spark plug cap.

6. Ignition coil resistance

• Disconnect the ignition coil connector from
the wire harness
• Connect the pocket tester (Ω × 1) to the
ignition coil.
Tester (+) lead Orange lead terminal
Tester (–) lead Ignition coil base
• Check that the primary coil has the specified

- 292 -
 ELECTRICAL COMPONENTS

. resistance
Primary coil resistance
0.18 ~ 0.28 Ω at 20 °C (68 °F)
• Connect the pocket tester (Ω × 1k) to the
ignition coil.
Tester (+) lead Orange lead terminal
Tester (–) lead Spark plug lead
• Check that the secondary coil has the
specified resistance. OUT OF SPECIFICATION
Secondary coil resistance
6.32 ~ 9.48 kΩ at 20 °C (68 °F)
Replace the ignition coil.
BOTH MEET SPECIFICATION

7. Main switch INCORRECT

Refer to “CHECKING THE SWITCH”
CORRECT
Replace the main switch.

8. Pickup coil resistance

0• Disconnect the A.C. magneto coupler from

the wire harness.
• Connect the pocket tester (Ω × 100) to the
pickup coil terminal.
Tester (+) lead White/ Blue terminal ①
Tester (–) lead Green terminal ②
• Check the pickup coil for the specified
resistance. OUT OF SPECIFICATION
Pickup coil resistance
459 ~ 561 Ω at 20 °C (68 °F)
(White/Red – White/Green) Replace the pickup coil/stator assembly.
MEETS SPECIFICATION

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 ELECTRICAL COMPONENTS

9.Wiring connection POOR CONNECTION

• Check the connections of the entire ignition

system. Refer to “CIRCUIT DIAGRAM”.
CORRECT
Properly connect the ignition system.

Replace the ECU unit

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM（see 346 page）

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 ELECTRICAL COMPONENTS

TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO OPERATE:

Procedure 6. Gear position switch

Check: 7. Brake light switch
1. Fuses (main, ignition, signaling system) 8. Diode 1
2. Battery 9. Wiring connection (the entire starting system)
3. Starter motor
NOTE:
4. Starter relay
• Remove the following part(s) before
5. Main switch
troubleshooting:
1. Console
2. Front frame
3. Front fender
• Use the following special tool(s) for
troubleshooting.

NO CONTINUITY
1. Fuses (main, ignition, signaling system)
Refer to “CHECKING THE SWITCH”
CONTINUITY

Replace the fuse(s).

2. Battery
• Check the battery condition. Refer to
“CHECKING AND CHARGING THE
BATTERY” in chapter 3. INCORRECT

Open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Clean the battery terminals.
CORRECT
• Recharge or replace the battery.

3. Starter motor
WARNING：
• Connect the battery (+) terminal ① and
• A wire that is used as a jumper lead must
starter motor cable ② using a jumper lead③
have the equivalent capacity or more as that
• Check the operation of the starter motor.
of the battery lead, otherwise the jumper
lead may burn.
• This check is likely to produce sparks, so
be sure that no flammable gas or fluid is in
the vicinity.

DOSE NOT TURN

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 ELECTRICAL COMPONENTS

TURNS

4. Starter relay Repair or replace the starter motor.

• Remove the starter relay from the wire Small testers and battery and (12V) and start
harness. relay terminal connection
• Connect the pocket tester (Ω × 1) and the Check continuity of the start relay
battery (12 V) to the starter relay terminals.
Battery (+) terminal Yellow/Blue
terminal ①
Battery (–) terminal Blue/Black terminal
②
Tester (+) lead Red terminal ③
Tester (–) lead Black terminal ④
• Check the starter relay for continuity.
CONTINUITY
NO CONTINUITY
5. Main switch Refer to “CHECKING THE
SWITCH”.
CORRECT Replace the starter relay.

6. Gear position switch Refer to “CHECKING INCORRECT

THE SWITCH”.
CORRECT

Replace the main switch.

7. Brake light switch Refer to “CHECKING
INCORRECT
THE SWITCH”.
CORRECT

8. Diode 1 Replace the gear position switch.

㈠ nnect multimeter positive to Yellow/Red INCORRECT
green terminal (1)
Connect multimeter negative to Black/Light
blue②or blue red ③terminal (2) Replace the brake light switch.
Removed from the coupling diodes
Small diode Tester connection terminals, As
shown in the figure
Check the diode continuity

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 ELECTRICAL COMPONENTS

NOTE:

㈠When you switch the tester’s positive

and negative probes, the readings in
the left chart will be reversed.

㈡Connect multimeter positive to Red/Bule

white terminal (1)
Connect multimeter negative to Yellow/Bule
terminal (2)

NOTE:

㈡When you switch the tester’s positive

and negative probes, the readings in
the left chart will be reversed.

CORRECT
POOR CONNECTION

9. Wiring connection
• Check the connections of the entire starting
system. Refer to “CIRCUIT DIAGRAM”. Properly connect the starting system.

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 ELECTRICAL COMPONENTS
STARTER MOTOR

No. Part Name Qty Remarks

Removing the starter motor 1 Remove the parts in the order listed

Flange bolt
1 Starter motor assy.
2

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 ELECTRICAL COMPONENTS

CHARGING SYSTEM
CIRCUIT DIAGRAM

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 ELECTRICAL COMPONENTS

TROUBLESHOOTING
Procedure
IF THE BATTERY IS NOT CHARGED:
Check:
1. Fuse (main) 4. Charging coil resistance
2. Battery 5. Wiring connections(the entire charging system)
3. Charging voltage
NOTE:
Remove some parts before maintenance
1. Cushion
Repair with following special toolings

1. Fuse (main)

Refer to “CHECKING THE SWITCH”. NO CONTINUITY

CONTINUITY

Replace the fuse.

2.Battery
• Check the battery condition. Refer to
“CHECKING AND CHARGING THE
INCORRECT
BATTERY in chapter 3.
Open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Clean the battery terminals.
CORRECT
• Recharge or replace the battery.

3. Charging voltage

• Connect the engine tachometer to the

spark plug lead.
• Connect the pocket tester (DC 20 V) to the
battery.
Tester (+) lead Battery (+) terminal
Tester (–) lead Battery (–) terminal
• Start the engine and accelerate to about
1,000 r/min.
Charging voltage 14 V at 1,450 r/min
MEETS SPECIFICATION
NOTE:
Use a fully charged battery.

OUT OF SPECIFICATION
The charging circuit is not faulty.

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 ELECTRICAL COMPONENTS

4. Charging coil resistance

• Disconnect the A.C. magneto coupler from

the wire harness.
• Connect the pocket tester (Ω × 1) to the
charging coils.
Tester (+) lead White terminal ①
Tester (–) lead White terminal ②
Tester (+) lead White terminal ①
Tester (–) lead White terminal ③
• Measure the charging coil resistance. OUT OF SPECIFICATION
Charging coil resistance
0.32 ~ 0.43 Ω at 20 °C (68 °F)
MEETS SPECIFICATION
Replace the pickup coil/stator assembly.

5. Wiring connections
POOR CONNECTION
• Check the connections of the entire charging
system. Refer to “CIRCUIT DIAGRAM”.
CORRECT
Properly connect the charging system.

Replace the rectifier/regulator.

LIGHTING SYSTEM
CIRCUIT DIAGRAM（see 346 page）

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 ELECTRICAL COMPONENTS

TROUBLESHOOTING
IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON:

Procedure
Check
1. Fuses (main, lighting system) 4. Light switch
2. Battery 5. Wiring connections(the entire lighting system)
3. Main switch
NOTE:
• Remove the following part(s) before
troubleshooting:
1. Console
2. Front luggage carrir
3. Front covering parts
• Use special tool(s) for troubleshooting.
1. Fuses (main, lighting system)

Refer to “CHECKING THE SWITCH”. NO CONTINUITY

CONTINUITY
2. Battery
Replace the fuse(s).
• Check the battery condition. Refer to
“CHECKING AND CHARGING THE
BATTERY” in chapter 3. INCORRECT
Open-circuit voltage
12.8 V or more at 20 °C (68 °F)
CORRECT • Clean the battery terminals.
3. Main switch • Recharge or replace the battery
INCORRECT
Refer to “CHECKING THE SWITCH”.
CORRECT
4.Light switch Replace the main switch.
Refer to “CHECKING THE SWITCH”. INCORRECT
CORRECT
5. Wiring connection

• Check the connections of the entire lighting Replace the light switch.
system. Refer to “CIRCUIT DIAGRAM”. POOR CONNECTION
CORRECT

Check the condition of each of the lighting Properly connect the lighting system.
system’s circuits. Refer to “CHECKING THE
LIGHTING SYSTEM”.

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 ELECTRICAL COMPONENTS

CHECKING THE LIGHTING SYSTEM

1. If the headlights fail to come on:
(1). Bulb and bulb socket
NO CONTINUITY
• Check the bulb and bulb socket for
continuity.
CONTINUITY
(2). Voltage Replace the bulb and/or bulb socket.

• Connect the pocket tester (DC 20 V) to the

headlight couplers. A
Tester (+) lead
Black terminal ① or Yellow terminal ②
Tester (–) lead Green terminal ③
□
A When the light switch is on “ ”.
□
B When the light switch is on “ ” B

• Turn the main switch to “ON”.

• Turn the light switch to “ ” or “ ”.
• Check the voltage (12 V) of the “Green” and
“Yellow” leads on the bulb socket
OUT OF SPECIFICATION
connector.
MEETS SPECIFICATION

The wiring circuit from the main switch to the

bulb socket connector is faulty, repair it.
This circuit is not faulty.

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 ELECTRICAL COMPONENTS

2. If the taillights fail to come on:

(1). Bulb and bulb socket

• Check the bulb and bulb socket for

NO CONTINUITY
continuity.
CONTINUITY

Replace the bulb and/or bulb socket.

(2) . Voltage

• Connect the pocket tester (DC 20 V) to the

tail/brake light couplers.
Tester (+) lead Yellow1 lead terminal ①
Tester (–) lead Black lead terminal ②

• Turn the main switch to “ON”.

• Turn the light switch to“ ” or “ ”.
OUT OF SPECIFICATION
• Check the voltage (12 V) of the “Blue” lead
on the bulb socket connector.
MEETS SPECIFICATION The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.
This circuit is not faulty.

SIGNALING SYSTEM
CIRCUIT DIAGRAM（see 346 page）

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 ELECTRICAL COMPONENTS

TROUBLESHOOTING
IF A BRAKE LIGHT, AN INDICATOR LIGHT, OR THE WARNING LIGHT FAILS TO COME ON:

Procedure 3. Main switch

Check: 4. Wiring connections (the entire signal system)
1. Fuses (main, signaling system) NOTE:
2. Battery • Remove the following part(s) before
troubleshooting:
1. Console
2. Front frame
3. Front pedal
• Use special tool(s) for troubleshooting.
1. Fuses (main, signaling system)
NO CONTINUITY
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the fuse(s).
2. Battery

• Check the battery condition. Refer to INCORRECT

“CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Open-circuit voltage • Clean the battery terminals.
12.8 V or more at 20 °C (68 °F) • Recharge or replace the battery.
CORRECT

3.Main switch
INCORRECT
Refer to “CHECKING THE SWITCH”.
CORRECT
Replace the main switch
4. Wiring connections

• Check the connections of the entire signal

system. Refer to “CIRCUIT DIAGRAM”. POOR CONNECTION

CORRECT

Properly connect the signal system.

Check the condition of each of the signal
system’s circuits. Refer to “CHECKING THE
SIGNAL SYSTEM”.

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 ELECTRICAL COMPONENTS

CHECKING THE SIGNAL SYSTEM

1. If the brake lights fail to come on:
(1). Bulb and bulb socket

• Check the bulb and bulb socket for NO CONTINUITY

continuity.
CONTINUITY
Replace the bulb and/or bulb socket.

(2). Bake light switch

NO CONTINUITY
Refer to “CHECKING THE SWITCH”.

CONTINUITY
Replace the brake light switch.
(3). Voltage

• Connect the pocket tester (DC 20 V) to the

bulb socket connector.
Tester (+) lead Dark/Brown terminal ①
Tester (–) lead Black terminal ②

• Turn the main switch to “ON”.

• Turn the light switch to “ ” or “ ”.
OUT OF SPECIFICATION

• Check the voltage (12 V) of the “Yellow”

lead on the bulb socket connector.
The wiring circuit from the main switch to the
MEETS SPECIFICATION
bulb socket connector is faulty, repair it.

This circuit is not faulty.

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 ELECTRICAL COMPONENTS

2. If L, H, N, R, light is not bright

(1). Gear position switch

Refer to “CHECKING THE SWITCH”. NO CONTINUITY

CONTINUITY

Replace the gear position switch

(2). Wire connection

NO CONTINUITY
Check the main beam connected to the gear
switch connector is strong

Repair the main beam connection with gear

CONNECTION IS FIRM
switch connector

This circuit is not faulty.

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 ELECTRICAL COMPONENTS

3. If the parking brake indicator light fails

to come on:
(1). Brake switch
NO CONTINUITY
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the parking brake switch

(2). Voltage
Set the multimeter to DC12V, test the brake
lamp voltage at both ends
Yellow3 power meter pens ①
Black power meter pens ②

NO VOLATGE DISPLAY

DISPLAY +12V

Replace the fuse F2

This circuit is not faulty.

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 ELECTRICAL COMPONENTS

4. If the reverse indicator light fails to come on:

(1). Directional signal switch
NO CONTINUITY
Refer to “CHECKING THE SWITCH”.

CONTINUITY

Replace the Reverse switch

(2). Voltage

Set the multimeter to DC12V, test the

direction lamp voltage at both ends
Dark/Brown power meter pens ①
Black power meter pens ②

NO VOLATGE DISPLAY

DISPLAY +12V
Replace the fuse F2

This circuit is not faulty.

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 ELECTRICAL COMPONENTS

5. If the coolant temperature warning light does not come on when the main switch to “ON”, or
if the coolant temperature warning light does not come on when the temperature is high
(more than 117 ~ 123 °C (242.6 ~ 253.4 °F):
(1). Bulb and bulb socket
NO CONTINUITY
• Check the bulb and bulb socket for
continuity.
CONTINUITY
Replace the bulb and/or bulb socket.
(2). Thermo switch 1

• Remove the thermo switch 1 from the

cylinder head.
• Connect the pocket tester (Ω × 1) to the
thermo switch 1 ①.
• Immerse the thermo switch 1 in coolant ②.
• Check the thermo switch 1 for continuity.
While heating the coolant use a thermometer
③ to record the temperatures.
□
A The thermo switch 1 circuit is open and the

coolant temperature warning light is off.

□
B The thermo switch 1 circuit is closed and

the coolant temperature warning light is on.

Test Coolant
Continuity
step temperature
Less than 120 ± 3 °C
1 No
(248 ± 5.4 °F)
More than 120 ± 3 °C
2 Yes
(248 ± 5.4 °F)
More than 113 °C
3 Yes
(235.4 °F)
Less than 113 °C
4 No
(235.4 °F)
Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase
WARNING：
Handle the thermo switch 1 with special
care.
BAD CONDITION
Never subject it to a strong shock or allow
it to be dropped. Should it be dropped, it
must be replaced.
Replace the thermo switch 1

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 ELECTRICAL COMPONENTS

6. If the four-wheel drive and front bridge differential lock indicator light fails to come on：

(1). Check the driver combination switch and

front axle differential switch
NO CONTINUITY
Refer to “CHECKING THE SWITCH”.

CONTINUITY
Replace the to drive the combination switch.
(2). Wire connection detection

Detection front axle and transfer line 2 raider NOT CONNECTED WELL

controller cable to connect is complete.

CONNECTED WELL
Will check two connector connect with device.
(3). Voltage

Will the multimeter to DC 12 V, test drive NO +12V VOLATGE DISPLAY

switch and 2WD/4WD controller“Br/R”if
there are +12V voltage.

Replace the fuse F3.

+12V VOLATGE DISPLAY

Replace two all-wheel-drive controller or front

axle thansfer.

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 ELECTRICAL COMPONENTS

COOLING SYSTEM
CIRCUIT DIAGRAM

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 ELECTRICAL COMPONENTS
TROUBLESHOOTING
IF THE FAN MOTOR DOES NOT MOVE:

Procedure 5. Thermo switch 3

Check: 6. Wiring connection(the entire cooling system)
1. Fuse (main)
2. Battery NOTE:
3. Main switch • Remove the following part(s) before
4. Radiator fan motor troubleshooting.
1. Console
2. Front frame
3. Front pedal
• Use special tool(s) for troubleshooting.

1. Fuse (main)
NO CONTINUITY
Refer to “CHECKING THE SWITCH”.

CONTINUITY
Replace the fuse.
2. Battery
• Check the battery condition. Refer to
“CHECKING AND CHARGING THE INCORRECT
BATTERY” in chapter 3。
Open-circuit voltage:
12.8 V or more at 20 °C (68 °F) • Clean the battery terminals.
CORRECT • Recharge or replace the battery

3. Main switch
INCORRECT
Refer to “CHECKING THE SWITCH”.

CORRECT
Replace the main switch.

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 ELECTRICAL COMPONENTS

4.Radiator fan motor

• Disconnect the radiator fan motor coupler.

• Connect the battery (12 V) as shown.
Battery (+) lead Brown terminal ①
Battery (–) lead Blue/Red terminal ②
DOES NOT TURN

Replace the radiator fan motor.

• Check the operation of the radiator fan

motor.

5.Thermo switch 3

• Remove the thermo switch 3 from the

radiator.
• Connect the pocket tester (Ω × 1) to the
thermo switch 3 ①.
• Immerse the thermo switch 3 in coolant ②.
• Check the thermo switch 3 for continuity.
While heating the coolant use a thermometer
③ to record the temperatures.
□
A The thermo switch 3 circuit is closed.

□
B The thermo switch 3 circuit is open.

Test Coolant
Continuity
step temperature
Less than 75±3 °C
1 No
(167 ± 5.4 °F)
More than 75 ± 3 °C
2 Yes
(167 ± 5.4 °F)
More than 68 °C
3 Yes
(154.4 °F)
Less than 68 °C
4 No
(154.4 °F)
Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase

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 ELECTRICAL COMPONENTS

WARNING：
Handle the thermo switch 3 with special
care.
Never subject it to a strong shock or allow
it to be dropped. Should it be dropped, it
must be replaced. BAD CONDITION

Thermo switch 3
28 Nm (2.8 m ·kg, 20 ft ·lb)
Replace the thermo switch 3
GOOD CONDITION

6. Wiring connection
POOR CONNECTION
• Check the connections of the entire starting
system. Refer to “CIRCUIT DIAGRAM”
CORRECT
Properly connect the cooling system.

This circuit is not faulty.

2WD/4WD SELECTING SYSTEM

CIRCUIT DIAGRAM（see 346 page）

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 ELECTRICAL COMPONENTS

TROUBLESHOOTING
1. Check if the 2/4WD switch is working.
a. Turn on the switch, put the gear to position N; keep front and rear wheel off the ground , and then
roll the front wheel to see if the rear wheel is moving together with it or if it is rotatable.
b. After the actions above being done, and the wheels are rotatable, please check the electricity with
multimeter, if has no electricity, please check the fuse.

2. Check if the rear differential is working.

a. Check the sound. When the switch is turned on, the magneto valve will make s sound ‘TA’ to
show that it is working and the rear wheel won’t be able to rotatable at the same direction.
b. If no sound is made, check if the controller of magnetic valve has a output of 12V electricity, and
check if the magnetic valve has a input of 12V electricity,if it has the input, it means the valve doesn't
work, please change for a new one ; if not , please check if the input end of controller has a input, if it
has, change for a new controller, if not , check the fuse.

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 ELECTRICAL COMPONENTS

Check the working state of oxygen sensor:

(1).Diagnostic instrument
• Connect the diagnostic instrument to check NO OXYGEN SENSOR FAULT

whether the EFI system reports the failure

of oxygen sensor.
OXYGEN SENSOR Oxygen sensor works normally.
FAILURE
After clearing the fault, start to test whether NO OXYGEN SENSOR FAULT
the fault occurs again.
OXYGEN SENSOR
FAILURE Oxygen sensor works normally.

(2).Oxygen sensor connector

NOT WELL CONNECTED
Check Whether the Oxygen sensor connector
is well connected.
WELL CONNECTED Make sure the Instrument connector is well
(3).continuity connected，repeat operation (1).
• Connect the pocket tester,Check the EFI line
for continuity as follows.
①
Tester (+) lead A
Tester (–) lead J2-10
②
Tester (+) lead B
Tester (–) lead J2-17
③
Tester (+) lead C
Tester (–) lead J2-7
④
Tester (+) lead D
Tester (–) lead J2-15
The above four test results should continuity INCORRECT
CORRECT

The oxygen sensor is damaged. Replace the The wiring circuit from the ECU to the

oxygen sensor. oxygen sensor connector is faulty, repair it.

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 ENGINE MANAGEMENT SYSTEM

INTRODUCTION
EMS (Engine Management System)
EMS is a self contained set of components including a custom built computer and sensors and
actuators which control the operation of an engine by monitoring the engine speed, load and
temperature and 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 Of EMS(BUCKET)

1. Electronic Control Unit

2. Multec 3.5 Injectors
3.Throttle Body Assembly(with stepper motor)
4. Engine Coolant Temperature Sensor
5. Intake Air Pressure and Temperature Sensor
6. Oxygen Sensor
7. Ignition Coil
8. Fuel Pump Module

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 ENGINE MANAGEMENT SYSTEM

Typical Components Of EMS(BENCH)

1. Electronic Control Unit

2. Multec 3.5 Injectors
3.Throttle Body Assembly(with stepper motor)
4. Engine Coolant Temperature Sensor
5. Intake Air Pressure and Temperature Sensor
6. Oxygen Sensor
7. Ignition Coil
8. Fuel Pump Module

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 ENGINE MANAGEMENT SYSTEM

Layout of EMS Components

Legend:
Dotted line indicates inputs

Solid line indicates outputs

COMPONENTS OF EMS
Electronic Control Unit
1．Description & Working Principle
The ECU continuously monitors the operating conditions of the engine through the system
sensors. It also provides the necessary computation, adaptability, and output control in order to
minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all
operating conditions. The ECU also provides diagnosis when system malfunctions occur.

2．Handling – DOs & DONTs

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 ENGINE MANAGEMENT SYSTEM
ECU Handing
ACTION REASON
DO NOT: Place the ECU close to the exhaust High temperature might reduce the life of the
pipe or Engine when removed ECU and also can damage the ECU
DO NOT: Place the ECU close to or pour ECU is susceptible to water and liquids
water, oil or any other liquids.
DO NOT: Allow mud or other debris to Having mud or debris accumulated on the
accumulate on the surface of the ECU ECU casing reduces its heat dissipation
efficiency.
DO NOT: Apply any voltage relative to any Drastically affects the performance of the
point to the ECU ECU and may lead to ECU damage
DO NOT: Clean ECU with any solvent or any Can damage the housing of the ECU
corrosive liquid
DO: Take extreme care that water droplets or ECU connectors can get short and may
excess moisture should not fall on ECU lead to ECU damage
connectors
DO: Clean the ECU with a moist cloth and Prevents ECU damage
keep it dry

3．Installation requirements
The ECU shall be mounted using M5 machined screws with a torque of 3.9Nm ± 10%. The
mounting surface should also be flat to avoid subjecting the base plate to unnecessary force and
warping the PCB.

4．Maintenance service and Repair

ECU is a non-serviceable part. Once there are problems, it’s important to first determine if the
problem is caused by software/calibration. If it is caused by software/calibration, please refer to
software/calibration reflashing procedure. In the event of ECU hardware failure or malfunction
(during warranty period only) the ECU should be sent back to the vehicle manufacturer giving
complete details of the ECU Part No, Serial number, Vehicle Model & Make, manufacturing Date,
Total kms run on the vehicle, Location of use, Vehicle No, Date of return.

Multec 3.5 Injectors

1．Description and Working Principle
The Multec 3.5 Fuel Injector is an electromechanical device. A magnetic field is generated as
voltage is applied to the solenoid coil. The resulting magnetic force lifts the core assembly,
overcoming manifold vacuum, spring force, and fuel pressure, allowing fuel to pass through the ball
and seat interface to the director. As the fuel passes through the director, an atomized spray is
developed. The injector closes when the voltage is removed, cutting off the fuel flow.

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 ENGINE MANAGEMENT SYSTEM
2．Handling - DOs & DONTs

3.5 FUEL INJECTOR HANDLING

ACTION REASON
DO NOT: Re-use injector seal rings if at all Leakage.
possible. If no other choice exists, take
extra care in inspecting the seal rings for
damage.
DO NOT: Dip injector tips into lubricants. Can plug injector spray orifices.
DO NOT: Cycle injector repeatedly without Damage to internal mechanical components.
fuel pressure.
DO NOT: Pulse (actuate) a suspected high Can dislodge internal contamination if
leak rate injector (leak >50 sccm air). present and preclude root cause analysis.
DO NOT: Allow water to enter fuel system Can damage injectors.
from air lines, etc. during leak checks.
DO NOT: Contact or apply load to the Apply load to 45 deg angle on nylon over
injector tip for installation. mold see
DO NOT: Pound injectors into manifold Can damage injectors or seal rings.
during assembly to engine.
DO NOT: Apply excessive side loads to May cause loss of electrical continuity.
electrical connectors.
DO NOT: Use any dropped unit. Internal damage may have occurred.
DONOT:Store injectors, rails, or External contamination can damage the
subassemblies including engines on which injector electrically and/or mechanically.
the injectors have been installed in an
unprotected environment.
DO NOT: Use the injector as a handle. Do not use the injector to lift assemblies
DO NOT: Rack, stage, or handle parts in a Damage will occur.
manner that allows contact between parts.
DO NOT: Remove packing in a way that Damage could occur due ton contact
allows contact between parts. between parts.
DO NOT: Tap on fuel injectors to correct any Can damage injector.
malfunction.
DO NOT: Replace the injector with other Will severely affect the performance of the
part number not recommended for this injector
application
DO: Take extra care when installing new Prevent tearing seal ring during installation.
fuel seal ring over injector inlet flange.

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 ENGINE MANAGEMENT SYSTEM
DO: Use proper lubricants on seal ring Avoid damage to seal ring during installation.
surfaces to install injector in engine. Avoid contamination at seal.
Minimize time between applying lubricant
and inserting injector / rail.
DO: Pulse (actuate) stuck closed or tip-leak To verify the injector failure
suspected injector (Actuate consists of one
pulse <5 sec duration at 9 to 15V).
DO: Pulse (actuate) injectors prior to a dry Injector valves may not reseat without fuel
fuel system leak test at engine/vehicle after shipping and handling resulting in false
assembly to reseat injector valves. leakage.
DO: Avoid any liquid contamination in the Coil could short circuit.
injector area.
DO: Use care during connection of Avoid terminal damage.
harness to injector.
DO: Use recommended terminal lubricant Minimize potential for terminal fretting
on mating connector. corrosion.
DO: Return any dropped, damaged, or Ensure fast and correct diagnosis of root
suspect material with a tag that describes cause.
the problem.

3. Installation guidelines
Follow these guidelines to prevent damage to the injector and its electrical interface during the
replacement or re-installation process.
 Lubrication: Apply a light coating of lubricant to the lower injector seal ring. ISO 10 light
mineral oil or equivalent is recommended.
 The preferred technique is to apply the lubricant to the sockets the injectors are being
installed into, rather than directly to the seal ring itself. This will help minimize the
possibility of injector contamination.
 Avoid applying lubricant over the director plate holes – this may restrict injector flow. Do
not dip the injector tip in lubricant.
 Multec 3.5 injectors come from the factory with the seal rings attached. The re-use of seal
rings is not preferred when replacing an injector. If an injector is to be re-used, and no new
seal rings are available, take care to inspect each seal ring for signs 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 terminal damage. Listen for a
positive audible click from the connector retention device — this ensures that it is fully
engaged. Shut off ignition.
 Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt
is made to start the engine.
 Disconnect the electrical connector from the injector wiring harness.
 Relieve fuel pressure
 Remove the retaining clip from the fuel injector.

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 Remove the fuel line connection from the injector
 Carefully clean debris from the interface surfaces. Do not damage seal mating surfaces.
 Remove the injector from the manifold
 Apply a light coating of a lubricant to both the upper and lower injector seal ring of the
replacement injector.
 Install the new injector into the manifold. Check that the injector is installed in the original
orientation to maintain proper spray targeting, and that the retaining clip is properly seated
on the injector and the fuel line
 Install 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 electrical connector
 Check for fuel leaks with the key “on” and the engine “off”
 Start engine and verify proper operation.
 or spray pattern, do not rotate the injector in the fuel rail assembly to install the injector
electrical connector. This may dislodge the retaining clip, and result in improper spray
orientation

4．Replacement Techniques

WARNING:
The injector and all associated hardware may be extremely hot.
 Shut off ignition.
 Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt
is made to start the engine.
 Disconnect the electrical connector from the injector 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 damage seal mating surfaces.
 Remove the injector from the manifold
 Apply a light coating of a lubricant to both the upper and lower injector seal ring of the
replacement injector.
 Install the new injector into the manifold. Check that the injector is installed in the original
orientation to maintain proper spray targeting, and that the retaining clip is properly seated
on the injector and the fuel line
 Install 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 electrical connector
 Check for fuel leaks with the key “on” and the engine “off”
 Start engine and verify proper operation.

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5．Plugging
Fuel deposits cause plugging resulting in flow shifts over the life of the injector. Fuel varnish or
gumming, a type of injector deposit, is created when certain types of fuel are heated by high
injector tip temperatures at soak (no fuel flow). Deposit build up in the director holes causes
the flow shifts
 Plugging can cause flow restrictions, frictional changes and the collection of other particles
attracted by the tacky surface. The flow restrictions can degrade emissions and drivability.
 Other fuel and environmental conditions may cause crystal or corrosion growth in the
injector and cause a flow shift.
 Oxidation stability of the gasoline affects the potential for deposit formation and must be
controlled by the fuel supplier.
 Increased levels of detergent additives reduce the rate of injector plugging.
 Incase of plugging of injector follow the injector cleaning procedure mentioned in the section
below

6．Cleaning Procedure
 Electrically disable the fuel pump by removing the fuel pump connection.
 Relieve the fuel pressure in the system and disconnect the fuel connection at the injector.
Plug the fuel feed line.
 Injector cleaner with the specific ratio of the cleaner and gasoline to be mixed in the Injector
cleaning tank.
 Connect the injector-cleaning tank to injector in the vehicle.
 Pressurize the injector-cleaning tank to system pressure.
 Start and idle the engine for 15- 20 minutes.
 Disconnect the injector-cleaning tank from the system and install the fuel pump connections.
Connect the fuel feed line 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)

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 valve system, return spring
system, cable interface system, throttle position sensing system, and the bypass air control
system. The subsystems interact and support each other to provide all the functional
requirements, which are mentioned below -
 Control intake air flow
 Control idle air flow
 Sense throttle position - Provide position feedback to Engine Controller
 Provide reactionary force to the throttle

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2．Handling – DOs and DONTs

THROTTLE BODY ASSEMBLY HANDLING

ACTION REASON
DO: Use care during assembly of harness to throttle
Avoid terminal damage.
body.
DO: Avoid any liquid contamination in the throttle
Ensure proper operation.
body area.
DO: Unload and install units one at a time from
Damage may be done to critical components.
packing trays.
DO: Return any dropped, damaged, or suspect
Ensure fast and correct diagnosis of root
material with a tag that describes the problem.
cause.
(Only warranty cases)
DO: Remove and discard protective caps just before Protects system from contamination, which
assembling mating components. can prevent proper operation.
DO: clean the by pass passage after removing
To ensure good idle stability
bottom cover
Internal damage may have occurred or
DO NOT: Use any dropped or impacted unit.
emissions settings may have been upset.
DO NOT: Store units without protective caps in place. Contamination may impair correct operation.

DO NOT: Ship or store near saltwater without Corrosion buildup may impact proper
protection. operation.
DO NOT: Exposed to environmental conditions
Corrosion buildup may impact proper
(Moisture) prior to complete vehicle
operation.
installation.
DO NOT: Apply any voltage other than system
Damage could occur.
voltage for testing.
DO NOT: Apply excessive band clamp loading Damage could occur.
DO NOT: Remove packing in a way that allows Minimum air leakage could be affected
contact between parts. and/or other damage could occur.
DO NOT: Release the throttle cam abruptly from any
position without the throttle linkage Damage could occur.
attached.
DO NOT: Let the by pass holes be blocked by dirt or
This could effect idle stability
foreign particles.
DO NOT: Rake, stage, or handle parts in a manner
Damage will occur.
that allows contact between parts.
3．Throttle Body Removal
 Disconnect negative terminal of the battery
 Disconnect electric lead wire of throttle position sensor coupler, stepper motor coupler and
MAP/MAT sensor coupler ( if this sensor is mounted on the throttle body)
 Disconnect accelerator cable from throttle body

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 Remove air cleaner outlet hose and throttle body outlet hose

4．Cleaning Procedure
If there is cover on the bottom, it may be removed and cleaned using carburetor cleaner (3M
make recommended). Once the throttle body cover is removed, spray the throttle-body cleaner
inside the shipping air passage, and use the brushes to gently dislodge the dirt, gum and
varnish that are present. Do not let the bye pass holes be blocked by dirt or foreign particles.

5．Throttle Body Installation

 Reverse the procedure for installation noting the following:
 Adjust accelerator cable play
 Check to ensure that all removed parts are back in place.Reinstall any necessary part which
have not been reinstalled

6．Precautions
 Do not submerge TPS in any cleaning fluid.
 Always open the throttle valve using the throttle cable or lever.
 Do not hold the valve at opening position by inserting tools or any sticks into the bore. The
valve may be warped and the bore may be scratched. This type of damage may keep the
throttle from opening easily or fully closing.

Engine Coolant Temperature Sensor

1．Description and Working Principle
This sensor is used in water cooled engines. It provides a resistance that varies as a function of
temperature within prescribed tolerance limits. The sensor has a negative temperature
coefficient of resistance. This is a non-serviceable part.

2．Installation Requirements
 Dynamic Torque Requirement: The sensor shall be hand into the application and then
driven by a driver with a maximum no load speed of 400 rpm or installed to the desired
torque by a hand torque wrench (5/8” hex). The recommended installation torque is:
Minimum: 20 N·m
Maximum: 25 N·m
 Static Torque Requirement: The torque required to remove the sensor from the mating hole
shall be within 200% of the installation torque mentioned above.

3．Sample Cleaning
 When necessary the samples may be cleaned in isopropyl alcohol for one minute with
mating connectors in place and then air-dried

Intake Air Pressure and Temperature Sensor

1．Description and Working Principle
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This sensor has two functions. The first is the intake manifold air temperature, it provides a
resistance that varies as a function of temperature within prescribed tolerance limits. The
second is the intake manifold air pressure; it provides a voltage varies as the intake air
pressure.

2．Sample Cleaning
 When necessary the samples may be cleaned in isopropyl alcohol or gasoline for one
minute with mating connectors in place and then air-dried

Oxygen Sensor
1．Description and Working Principle
This sensor is a device for monitoring the residual oxygen in the exhaust of an internal
combustion engine. It consists of the wide range sensor and stoichiometric sensor. Usually we
use stoichiometric sensor on the small engine. It is the feedback element for engine closed
loop control.

2．Installation Requirements
 Mounting Angle with Level: ≥10 degree
 Tightening Torque Requirement: 40-60 Nm

Ignition Coil
1．Description and Working Principle
This coil provides energy to the spark plug in the combustion chamber. The coil itself doesn’t
have a driver. The high voltage tower of the coil is connected to the spark plug using a high
voltage cable assembly. This is a non-serviceable component.

2．Installation requirements
 The vehicle frame provides the mounting surface and mounting holes.
 Mount coil close to the spark plug and keep the plug wire length very short (less than 6 “).
 Mount coil away from any pick coil device. Especially, a VR type Crank / Cam sensor. Keep
a Min distance of 150 mm (around 6”) between coil and any VR sensor device.
 Never route the coil C- wire with the same bundle as the Crank sensor wires. There is
around 200 V peak potential between C- wire and engine ground. This voltage potential
could cause a noise on sensor cables.

3．DOs and DONTs

Ignition Coil Handing
Action Reason
DO NOT: Install the low voltage connectors with This might cause an unwanted secondary firing,
the power applied possibly leading to personal injury

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 ENGINE MANAGEMENT SYSTEM
DO NOT: Use a screw driver to asset in removing It is possible to damage a secondary lead in
secondary boots from the secondary tower. Use such a manner that creates an electrical path to
tools designed for secondary removal. 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 Damaged components can lead to premature
display physical damage failure.
DO NOT: Scratch or apply any non approved This can jeopardize the seal integrity of the
material to the surface of the high voltage tower mating surfaces which in turn can create a
which mates with the high voltage secondary secondary high voltage leak path.
leads.
DO NOT: Strike any part of the ignition system This can lead to physical damage which can
with a tool or other object. cause a system malfunction or failure.
DO NOT: Permit paint or other sprayed materials Insulating type sprays can create a high
to be sprayed onto the electrical connectors. resistance or open connection. And, a
conductive type spray can create an electrical
short condition.
DO NOT: Support the ignition system by the These leads are not designed to support the
wiring harness or plug wire. weight of the ignition system. It can create a
poor electrical connection Or become
disconnected allowing the system to fall and be
subjected to physical damage
DO NOT: Pierce or probe the secondary This creates an electrical path to outside the
leads. system permitting improper system operation,
misfire, or even possible personal injury if arcing
occurs.
DO NOT: Operate without the spark plug If a technician or mechanic comes in contact
attached. with the high voltage generated during
operation, personal injury may occur. Or, if the
engine is operated under this condition,
unburned fuel may fill the converter area
creating a potential hazard
DO NOT: Share ignition component wiring with This prevents electrical cross talking between
other components, Dedicated wiring is required. components which can lead to component
malfunction.
DO NOT: Apply voltage to the ignition system This can cause reduced performance or an
other than vehicle system voltage for testing electrical malfunction of the ignition system.
purposes.
DO NOT: Use high impact tools to apply the spark Damage to the coil tower, secondary boot, or
plug boot to the ignition secondary towers. mating connection surfaces might occur.
Installation of the high voltage secondary leads
by hand is preferred.

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DO: Install the secondary leads before In the event the low voltage connection has
connecting the primary leads. been made and 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 The high voltage produced by the coil
system. secondary circuit can cause personal injury
and/or damage test equipment
DO: Proper handling and shipping methods need Damaged components can lead to premature
to be in place to reduce the risk of damage due to failure.
impact, moisture, or contamination
DO: Avoid unnecessary disconnecting and The electrical connections are not designed for
connecting of the electrical components. repeated connection and disconnection.
DO: Insure the low voltage connectors are This prevents intermittent electrical connections
entirely seated and the locking mechanism is leading to an improper ignition system
engaged. operation.
DO: Use approved connector breakouts when Connector and/or component damage may
testing the ignition system. occur.
DO: Insure the appropriate seals are included in Liquid intrusion into the terminal connection
the connector system. area might occur causing an electrical
intermittent or short condition. In the event of
severe terminal corrosion, an open condition
might occur.
DO: Operate with gasoline based internal Other fuels or combustion designs may require
combustion engines. additional design considerations.
DO:The power feed line should be fused. This could protect the system in the event of an
electrical short
DO: The module heat sink and back plate must The high level of voltage and current which the
not be used as a connection point when jump module could be subjected to, could cause
starting the engine module performance degradation or failure.
DO: Connection of the module back plate to This greatly reduce potential ground loops and
vehicle ground is desirable whenever possible acts as a heat transfer source from the module.
DO: The ignition system ground wire should be This would greatly reduce the possible of
kept as short as possible. And, when permissible, unwanted electrical ground loops.
should be grounded at the same engine block
position as the engine controller
DO: The electrical wiring to the ignition system Helps prevent electrical intermittent, open or
should be routed so that the conductors are shorted operating conditions.
protected from excessive heat, damage, and
wear.
DO: Ignition secondary leads should not be Voltage spikes can be transmitted from the
routed with the ignition primary harness or any secondary cables into other leads which are in
other electrical harness. close. This could create a component
performance degradation or failure condition
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 ENGINE MANAGEMENT SYSTEM
DO: Spark plug wires(secondary leads) & primary - Spark plug wires carry very high voltage
wiring: (30,000 volt). If the secondary lead loses its
- must not contact sharp surface dielectric characteristics thru being nicked, cut ,
- must not be under tension between fixed points chaffed, then an arc thru to a near by ground
- must be clear of moving parts (belts, fan, etc…) could take place. This kind of condition could
- must be protected from or kept at least 125 mm lead to misfire, no start, or premature failure of
away from radiant heat source exceeding 400 F. ignition system.
- must be protected from environmental damage
(dirt, splash, oils, fluids, etc….)
- must be retained, secured or insulated to
prevent pinching, mis-routing, rattles, and
squeaks
DO: Not all fasteners are designed for repeat use. Adequate retention force might not be achieved
Beware of fastener specifications. All harnesses if the fastener is not designed to be reused.
should be supported within 6" of a mating Mating connections are not designed to support
connection. the weight of the harness assembly.

DO: For removing spark plugs follow the following To remove spark plugs from Aluminum heads,
steps: allow the engine to cool. The heat of the engine,
1- Grasp the spark plug boot and gently in combination with a spark plug that is still hot,
2- rotate 90; and then pull the spark plug boot may cause the spark plug threads to strip the
and cable away from the spark plug cylinder head upon removal
3- Before removing spark plug, brush or air blast Use goggles to protect eyes from dirt when
dirt away from the well areas applying compressed air to spark plug wells
4- Use correct size deep socket wrench to
loosen each spark plug one or two turns
DO: Cleaning a spark plug could be done as -Cleaning a spark plug will reduce the voltage
follow: required for an electrical arc(spark) across the
1- wipe all spark plug surfaces clean….remove electrodes
oil, water, dirt and moist residues. -Cleaning & re-gapping will not restore a used
2- If the firing end of spark plug has oily or wet spark plug to a new condition. It may be more
deposit, brush the spark plug in an approved, economical and efficient to replace used spark
non-flammable and non-toxic solvent. Then plugs with new plugs instead of cleaning.
dry the spark plug thoroughly with -Sooted plugs should be replaced
compressed air -Do not cool by using water or any liquid
3- Use a propane torch to dry wet-fuel fouled -Clean threads permit easier installation and
plugs. Allow the torch flame to enter up the proper seating which will maximize transfer heat
center electrode insulator. Allow plug to cool away from the plug
down
4- If the spark plug threads have carbon & scale
deposits, clean with wire brush, taking care
not to injure the electrode or the
insulator tip

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 ENGINE MANAGEMENT SYSTEM
DO: Regap spark plugs to the exact -Too wide a gap could cause the plug to
measurement specified by the engine misfire(higher required ignition voltage).
manufacturer to keep the best fuel economy and -Too narrow of a gap could affect idle stability
proper engine performance -A flat gauge can’t accurately measure the spark
- Use round wire-type gauge for an accurate plug on used plugs
measure of gap on all used spark plugs
- when gapping a spark plug only the side
electrode is moved. The center electrode must
not be moved
DO: When replacing spark plugs with new ones, -Higher heat range plug(hotter plug) could lead
always use equivalent plugs with same heat to pre-ignition & possible piston damage
range, thread, size, etc…. -Lower heat range (colder plug) could lead to
cold fouling & emission problem

DO: For installing spark plugs follow the following -If the thread is damage, it prevents a good heat
steps: transform from the shell to the cylinder head
1- make sure the cylinder head threads and -Do not use any type of anti-seize compound on
spark plug threads are clean. Make sure the spark plug threads. Doing this will decrease the
spark plug thread is free of dings and burrs. If amount of friction between the threads. The
necessary, use a thread chaser and seat result of the lowered friction is that when the
cleaning tool. spark plug is torqued to the proper specification,
2- Make sure the spark plug gasket seat is the spark plug is turned too far into the cylinder
clean, then thread the gasket to fit flush head. This increases the likelihood of pulling or
against the gasket seat. Tapered seat plugs stripping the threads in the cylinder head
do not require gaskets -Over-tightening of a spark plug can cause
3- Screw the spark plugs finger-tight into the stretching of the spark plug shell and could
cylinder head. Then, use a torque wrench to allow blowby to pass thru the gasket seal
tighten spark plugs following manufacturer’s between the shell and insulator. Over-tightening
recommendation). also results in extremely difficult removal
Torque is different for various plug type & cylinder
head material

Fuel Pump Module

1．Description and Working Principle
Fuel Pump Module supplies fuel to engine at system pressure. Fuel Pump Module is
mounted to fuel tank at bottom and supplies fuel to engine through hoses.
Fuel Pump module consists of Fuel Pump to generate the fuel flow and pressure regulator to
regulate the fuel pressure.
Fuel Pump
When power is supplied to fuel pump, motor in pump assembly rotates the impeller. Impeller in
turn draws the fuel from strainer and pumps the flow to generate the system pressure.
Pressure Regulator

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 ENGINE MANAGEMENT SYSTEM
Pressure Regulator is a diaphragm type mechanical device. Fuel flow from filter
enters in the inlet of pressure regulator. Pressure regulator regulates the fuel
pressure at a set pressure by releasing the excessive fuel flow to fuel tank.

2．Service Procedure:
Precautions:
Before attempting any service on fuel system, following cautions should be always followed for
personal safety and to avoid system damages.
 Disconnect negative cable at battery.
 DO NOT smoke, and place ‘No SMOKING” sign near work area
 Make sure to have fire extinguisher handy.
 Make sure to perform work in well ventilated area and away from any open fire/flames.
 Wear Safety glasses
 To relieve fuel vapor pressure in fuel tank, remove fuel filler cap fuel filler neck and then
reinstall it.
 As fuel lines are at high pressures when the engine is stopped, loosening or disconnecting
fuel line will cause dangerous spout of fuel. Before loosening/ disconnecting fuel lines,
please follow the “Fuel Pressure Relief Procedure” described in this section.
 Small amount of fuel may drip after the fuel lines are disconnected. In order to reduce the
risk of personal injury, cover the pipe/ hose ends with suitable blind with no rust or
contamination.
 After servicing, 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 Procedure’ described in this section.
 After servicing make sure to fill at least 3 liters gasoline before pump is primed (ignition key
should be turned on only after ensuring there is minimum 3 liters of fuel in the fuel tank)

Fuel Module Diagnosis:

Step Action Yes No

Switch on Ignition key. Fuel Pump
primes for 3 seconds when the ignition If fuel pump running If fuel pump running
1 key is ON. noise can be heard, go noise can not be
Check for fuel pump running noise for 3 to step 4. heard, go to step 2.
seconds after ignition key is ON.
Disconnect fuel module coupler. Check
Check the electrical
voltage at harness coupler.
2 Go to step 3 circuit from Ignition
to fuel module.
Is the voltage within 10-14V

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 ENGINE MANAGEMENT SYSTEM
Connect 12V DC power supply
1. Check Fuel
(battery) to fuel module. 1. Check electrical
Pump Harness
Make sure that enough fuel available in circuit from fuel
3 integrity
fuel tank to avoid fuel pump running module to ECU
2. Check Fuel
dry.Is the fuel pump running 2. Check ECU
Pump

Check fuel system pressure at Injector

inlet (with a T-joint) while engine is
running in idle condition. Fuel Module Operation
4 Go to Step 5
Normal
Is the pressure between 220 ~
270kPa?
1. Check for leakages
from hoses, hose 1. Clogged Filter
joints 2. Kink/ Blockage
5 Is the Pressure below 220kPa?
2. Check Fuel Pump in Fuel Hoses
3. Check Pressure 3. Check Regulator
Regulator

3．Fuel Module Removal:

 Relieve fuel pressure in fuel lines referring to the ‘Fuel Pressure Relief Procedure’ provided
in this section.
 Disconnect negative cable at battery.
 Disconnect fuel module wire coupler.
 Drain the fuel in fuel tank thru fuel filler with help of hand pump (siphon). Collect the fuel in
approved container for contamination and safety.
 Disconnect the fuel hoses from fuel module by using standard tools
 Remove the fuel tank from vehicle.
 Place the fuel tank with bottom up condition. Care to be taken not to cause any scratches/
damages on fuel tank.
 Open the fuel module mounting bolts.
 Take out fuel module assembly from fuel tank with care
 Care to be taken not to damage the strainer while removing fuel module from tank.

4. Fuel Module Installation:

 Replace the fuel module gasket in fuel module assembly with a new one. Old/ used gaskets
can cause leakages.
 Fold strainer towards fuel pump and insert fuel module in tank opening with care. Care
should be taken not to cause any damages on strainer.

NOTE
Fuel Module Orientation: Fuel module bolts not symmetrical and can be mounted
only in the intended direction. Regulator side should be facing the Fuel Tank rear
side.Make sure that the fuel tank surface at module mounting area is clean and
free of surface defects.
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 ENGINE MANAGEMENT SYSTEM
 Place the bolts on module cover and tighten the bolts gradually in star pattern sequence to
apply equal compression on gasket. It is shown in figure as below. Bolt Tightening Torque:
3~4 Nm.
Fuel module is installed with special bolts (step bolts). Use designated bolts only. Follow
the tightening torque and tightening sequence instruction.Over torque and
miss-sequence can cause unequal compression of gasket and leakage.
 Install the fuel tank to vehicle.
 Connect for fuel hoses with suitable hose clamps.
 Connect fuel module coupler.
 Follow “Fuel Leakage Check Procedure’ to check any leakage before the engine is started。

Mounting Bolts – Star Tightening Pattern

5. Pressure Regulator Assembly Replacement:

 Remove the regulator retainer from module.
 Apply gradual pull force on retainer to avoid any personal injury due to spring action of
retainer.
 Take out the pressure regulator assembly from module.
 Do not hit/ damage on the regulator dome and crimping portion.
 Lubricate the O-rings in new pressure regulator assembly with recommended lubrication
oils as mentioned in Table no: 3. Lubrication oil is applied only for ease of regulator
assembly.
 Make sure that 2 O-rings (one is bigger diameter the other is smaller diameter) are
assembled in pressure regulator.
 Place the pressure regulator on module at regulator pod. Push the regulator gently in the
pod.
 Do not hit/ damage on the regulator dome and crimping portion. This will disturb the
pressure setting.
 Assemble the retainer on the regulator pod
 Replace the gasket, module with new gasket provided in the kit.

6. Fuel Pressure Relief Procedure:

NOTE
This work must not be done when engine
is hot. If done so, it may cause adverse effect to
catalyst (if equipped)

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 ENGINE MANAGEMENT SYSTEM
After making sure that engine is cold, relieve fuel pressure as follows.
 Place vehicle gear in ‘Neutral’.
 Disconnect fuel module electrical coupler from vehicle harness.
 Start engine and run till it stops due to lack of fuel. Repeat ignition key ON and OFF for 2 ~ 3
times of about 3 seconds each time to relieve fuel pressure in lines. Fuel Connections are
now safe for servicing.
 Upon the completion of servicing, Connect Fuel Module Connector to Vehicle Harness.

7. Fuel Leakage Check Procedure:

After performing any service on fuel system, check to make sure that there are no fuel leakages
as below.
 Fill about 3 ~ 5 liters of fuel in tank.
 Turn Ignition key to ON position for 3 seconds (to operate fuel pump) and then turn to OFF
position. Repeat this for 3 ~ 4 times to apply fuel pressure in fuel lines.
 In this state, check to see that there are no fuel leakage from any part of fuel system (Fuel
Tank, Hoses, Hose Joints, etc)

8. Handling – DOs and DONTs:

FUEL MODULE HANDLING

ACTION REASON
DO NOT: Drop Fuel Module on Floor Could cause internal damage to Fuel
Pump.
DO NOT: Run Fuel Pump Dry (without fuel Caused internal damage to Fuel Pump
at pump inlet/ strainer) ensure atleast 3
litres of gasoline is present in the fuel tank
DO NOT: Damage the strainer during Contamination enters fuel pump thru
servicing, insertion of fuel module in fuel damaged strainer damages the Fuel
tank Pump
DO NOT: Disassemble Fuel Pump and Warranty void.
regulator internal parts out side Delphi
premises.
DO NOT: Do any adjustments on pressure
regulator and pump except for
replacement.
DO NOT: Use module harness for hold/ Wiring Harness Breakage/ Fuel Pump
carry fuel module. Power disconnection
DO NOT: Pull Wiring Harness in vertical
direction to module cover
DO NOT: Use damaged/ distorted hose Can cause fuel seepage/ leakage.
clamps.

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 ENGINE MANAGEMENT SYSTEM
DO NOT: Use Fuel Module if the strainer Contamination enters fuel pump thru
with excessive damage/ cut. damaged strainer damages the Fuel
Pump
DO NOT: Use Fuel Pump for draining duel Not intended function of fuel module.
in fuel tank.
DO NOT: Use module mounting bolts for Affects fuel module sealing.
mounting other components.
DO NOT: Damage fuel pump harness Damaged terminals will cause intermittent/
while servicing fuel module. No contact for power supply.
DO NOT: Force hand pump towards fuel To avoid any damages on fuel module.
module while draining fuel from tank.
DO : Ensure that there are no damages to Can cause fuel seepage/ leakage.
fuel pipes while servicing fuel module
DO: Use genuine module gasket only. Spurious gaskets can cause leakages.
DO: Use designated hose clamps. To ensure no leakages/ seepages thru
hose joint.
DO: Clamp fuel module harness to vehicle Clamp provides mechanical support for
chassis wiring harness in vibrations.
DO: Use only standard gasoline for Fuel Module is intended to run in standard
operating vehicle/ module. gasoline. Adulterated fuel can cause fuel
module premature failures which are not
covered under warranty.
DO: Change the fuel filter at recommended Clogged fuel filter will cause restriction in
intervals. fuel flow and can cause flow reduction.
DO: Use fuel filters supplied/ Spurious fuel filters causes damages to
recommended fuel filters only. injector, regulator and fuel pump
performance.
DO: Ensure that the hoses are routed Improper routing, kinks and fouling of
properly and there are no kinks / rubbing hoses with other components causes hose
with other components. damage
DO: Ensure that always sufficient fuel till Avoids Pump running in dry
the strainer height
DO: Replace two O-rings along with For proper functioning of regulator.
replacement/ re-installation of pressure
regulator.
DO: Use care during connection of Avoid terminal damage.
harness to module coupler.
DO: Return any dropped, damaged, or Ensure fast and correct diagnosis of root
suspect material with a tag that describes cause.
the problem.

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 ENGINE MANAGEMENT SYSTEM

EMS FAULT DIAGNOSIS

EME Fault Diagnosis
When fault comes up, the odometer's clock will turn into a number， which is a fault code, find
out the cause with this numbe;press clock button,then it will turn back to clock mode, and five
second later,the fault code will show again.

Fault code list

System or DTC
DTC Description Related Calibration
Component Number
Manifold Absolute 0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow
Pressure Sensor
(MAP) 0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh
Intake Air 0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow
Temperature Sensor
(IAT) 0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh

Coolant/Oil Temperature Sensor

Coolant/Oil Sensor 0117 KsDGDM_CoolantShortLow
Circuit Low Voltage
Coolant/Oil Temperature Sensor
0118 KsDGDM_CoolantShortHigh
Circuit High Voltage or Open
Throttle Position 0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow
Sensor (TPS) 0123 TPS Circuit High Voltage KsDGDM_TPS_ShortHigh
0131 O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow
Oxygen Sensor
0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh

Oxygen Sensor 0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh

Heater 0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow
0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_Fault
Fuel Injector
0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_Fault
FPR Coil Circuit Low Voltage or
Fuel Pump Relay 0230 KsDGDM_FPP_CircuitShortLow
Open
(FPR)
0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh
Crankshaft
0336 CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal
Position
Sensor (CKP) 0337 CKP Sensor No Signal KsDGDM_CrankNoSignal
Cylinder 1 Ignition Coil
0351 KsDGDM_EST_A_Fault
Malfunction
Ignition Coil
Cylinder 2 Ignition Coil
0352 KsDGDM_EST_B_Fault
Malfunction
Idle Control
0505 Idle Speed Control Error KsDGDM_IdleControl
System

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 ENGINE MANAGEMENT SYSTEM
0562 System Voltage Low KsDGDM_SysVoltLow
System Voltage
0563 System Voltage High KsDGDM_SysVoltHigh

MIL 0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit

1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low
Tachometer
1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High
0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow
Oxygen Sensor 2
0138 O2S 2 Circuit High Voltage KsDGDM_O2_2_ShortHigh
Oxygen Sensor 0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh
Heater 2 0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow
Vehicle Speed
0500 VSS No Signal KsDGDM_VSS_NoSignal
Sensor
Park Neutral
0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch
Switch Diag
0445 CCP short to high KsDGDM_CCP_CircuitShortHigh
CCP
0444 CCP short to low/open KsDGDM_CCP_CircuitShortLow
BLM MaxAdapt 0171 BLM Max Adapt(Kohler Special) KsFDIAG_BLM_MaxAdapt
BLM MinAdapt 0172 BLM Min Adapt(Kohler Special) KsFDIAG_BLM_MinAdapt
PE system Lean P0174 PE syst Lean(Kohler Special) KsFDIAG_PESystLean

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 TROUBLESHOOTING

NOTE:
The following trouble, not including all possible troubles, is a help for trouble guide. Please refer to
relevent contents for the inspection, adjustment and replacement of part.

STARTING FAILURE/HARD STARTING

FUEL SYSTEM

1、No oil
2、Fuel filter is clogged
Fuel tank 3、Fuel pump filter net is clogged
4、Breather tube is clogged
5、Fuel is deteriorated or polluted
1、Clogged fuel hose
Fuel pump
2、Damaged vacuum hose

Air filter Clogged air filter element

Gasoline filter Block up

ELECTRICAL SYSTEM

1、Improper plug gap

2、Worn electrodes
3、Wire between terminals broken
Spark plug 4、Wrong Spark plug heat value
5、Faulty spark plug cap
6. High voltage wires strapped on frame cause shortage of high
pressure ignition energy
1、 Broken ECU
2、 Clogged nozzle or the rupture the line from nozzle to ECU
3、 Damage of engine speed signal sensor
4、 Rupture of the line from engine speed signal sensor to ECU
EFI system
5、 Broken inlet pressure or temperature sensor or damaged line
to ECU
6、 Broken air throttle or damage line to ECU.
7、Broken vice line (cable) of electrical injection

1、 Broken main cable

Switches and wires 2、 Broken main switch

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 TROUBLESHOOTING

1、Faulty starter motor

2、Faulty starter relay
Starter motor 3、Faulty overrunning clutch in engine
4、Broken main switch
5、Broken main fuse
1、Low battery voltage
Battery
2、Faulty battery

COMPRESSION SYSTEM

1、Loose spark plug

2、Loose cylinder head or cylinder
Cylinder and cylinder head 3、Broken cylinder head gasket
4、Broken cylinder gasket
5、Worn, damaged or seized cylinder
1、Improperly installed piston ring
2、Worn, fatigued or broken piston ring
Piston and piston rings
3、Seized piston ring
4、Seized or damaged piston
1、Improperly sealed valve
2、Improperly contacted valve and valve seat
Valve, camshaft and crankshaft 3、Improper valve timing
4、Broken valve spring
5、Seized camshaft

1、Improperly seated crankcase

Crankcase and crankshaft
2、Seized crankshaft

1、Improperly adjusted valve clearance

Valve train
2、Improperly adjusted valve timing

POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE

1、Broken ECU
2、Clogged nozzle or the rupture the line from nozzle to ECU
3、Damage of engine speed signal sensor
EFI system 4、Rupture of the line from engine speed signal sensor to ECU
5、Broken inlet pressure or temperature sensor or damaged line to ECU
6、Broken air throttle or damage line to ECU.
7、Broken vice line (cable) of electrical injection

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 TROUBLESHOOTING

1、Faulty ignition plug

Electrical system 2、The performace of speed sensor become poor
3、Faulty ignition coil

Valve train Improperly adjusted valve clearance

Air filter Clogged air filter element

POOR MEDIUM AND HIGH-SPEED PERFORMANCE

POOR MEDIUM AND HIGH-SPEED PERFORMANCE

1、 Broken ECU
2、 The performance of speed signal sensor become poor
3、 The main nozzle clog or loose
4、 Spoiled or pollute oil
5、 Broken inlet pressure / temperature sensor
EFI system
6、 Air throttle position sensor loose
7、 For two cylinder engine, if the plugs of fuel injector or oxygen
sensor plug in wrong cylinder, the fuel trim will happen mistakes.
After a thin combustion, muffler will appear abnormal high
temperature and then burn down the covering parts
Air filter Clogged air filter element

Muffler Clogged muffler

Set out
The reverse signal error trigger

FAULTY GEAR SHIFTING

SHIFT LEVER DOES NOT MOVE
1、Groove jammed with impurities
2、Seized shift fork
Shift drum, shift forks
3、Bent shift fork guide bar
4、Broken shift guide

1、Seized transmission gear

Transmission
2、Incorrectly assembled transmission

1、Broken shift guide mechanism

Shift guide
2、Broken shift flexible shaft
JUMPS OUT OF GEAR

Shift forks Worn shift fork

1、Improper thrust play

Shift drum
2、Worn shift drum groove

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 TROUBLESHOOTING

Transmission Worn gear dog

ENGINE OVERHEATING
OVERHEATING

1、Improper spark plug gap

Ignition system
2、Improper spark plug heat range

1、Improper fuel level

Fuel system
2、Clogged air filter element

Compression system Heavy carbon deposit

1、Improper oil level

Engine oil 2、Improper oil viscosity
3、Inferior oil quality
Brake Brake drag

1、Low coolant level

2、Clogged or damaged radiator
Cooling system 3、Damaged or faulty water pump
4、Faulty fan motor
5、Faulty thermo switch

Oil cooling system Clogged or damaged oil cooler

FAULTY BRAKE
POOR BRAKING EFFECT
1、Worn brake pads
2、Worn disc
3、Air in brake fluid
4、Leaking brake fluid
Disc brake 5、Faulty master cylinder kit cup
6、Faulty caliper kit sea
7、Loose union bolt
8、Broken brake hose and pipe
9、Oily or greasy disc/brake pads
10、Improper brake fluid level

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 TROUBLESHOOTING

SHOCK ABSORBER MALFUNCTION

Loss of damping function
1、Bent or damaged damper rod
Shock absorber 2、Damaged oil seal lip
3、Fatigued shock absorber spring

UNSTABLE HANDLING
UNSTABLE HANDLING

Steering wheel Improperly installed or bent

1、Incorrect toe-in
2、Bent steering shaft
3、Improperly installed steering shaft
Steering 4、Damaged bearing
5、Bent tie-rods
6、Deformed steering knuckles
7、Over worn or loosen direction linkage ball stud
1、Uneven tire pressures on both sides
Tires 2、Incorrect tire pressure
3、Uneven tire wear
1、Deformed wheel
Rim 2、Loose bearing
3、Bent or loose wheel axle
1、Bent
Frame
2、Damaged frame
1、 Over worn or loosen main knuckle ball stud
2、 Bent rocker
Suspension
3、 Broken shock absorber
4、 Broken buffer rubber of rocker shaft

LIGHTING SYSTEM
HEAD LIGHT IS OUT OF WORK
1、Improper bulb
2、Too many electric accessories
3、Hard charging( broken stator coil and/or faulty rectifier/regulator)
Head light is out of work
4、Incorrect connection
5、Improperly grounded
6、Bulb life expired

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 TROUBLESHOOTING

BULB BURNT OUT

1、Improper bulb
2、Faulty battery
3、Faulty rectifier/regulator
Bulb burnt out
4、Improperly grounded
5、Faulty main and/or lights switch
6、Bulb life expired
ERROR DISPLAY OF METER
1、 Then sensor on rear axle is damaged or polluted by iron powder
Wrong Speed 2、 The connection between sensor to meter is wrong.
3、 Broken meter

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