UTV Junglecross 800 ST and LT Series

Maintenance Manual

Shandong ODES Industry Co.,Ltd

Any copy or without written permission

or authorization of ODES Industry is prohibited to use
the manual (version 2, May 2020).
All rights reserved
Foreword
GROUP INDEX
This manual contains such content as introductions on
overhaul, maintenance, overhauling program,
dismantling, assembling, troubleshooting and service GENERAL INFORMATION 1
data of UTV800

This manual will help you know the vehicle beter so

PERIODIC MAINTENANCE 2
that you can assure your customers of fast and reliable
service.

This manual hass been prepareed on the basis of the ENGINE 3

latest specifications at the time of publication.If
modifications have been made sine then,differences
COOLING SYSTEM 4
may exist between the content of this manual and the
actual vehicle.

Illustrations in this manual are used to show the basic

FUEL SYSTEM 5
principles of operation and work procedures.They
may not represent the actual vehicle exactly in detail. DRIVE TRAIN 6
Manufacturer reserves the right of no prior notice on
product improvement or modification. Repair and
maintenance shall be carried out according to actual
STEERING SYSTEM 7
situation of vehicle.
SUSPENSION SYSTEM 8
WARNING

Inexperienced mechanics or mechanics without BRAKES SYSTEM 9

the proper tools and equipment may not be able
to properly perform the services described in
this manual. CHASSIS 10
Improper repair may result in injury to the
mechanic and may render the vehicle unsafe for
the rider.
ELECTRICAL SYSTEM 11

TROUBLESHOOTING 12
 1.GENERAL INFORMATION

1. GENERAL INFORMATION

PRECAUTIONS ······································ 1-1 TECHNICAL SPECIFICATIONS ·················· 1-3

TIGHTENING TORQUE ···························· 1-6

PRECAUTIONS
1. Do not make engine under operation at a closed place or place with poor ventilation for a long time.

2. If engine stops operation, please do not touch it or silencer to avoid burning.

3. Due to high corrosiveness, battery fluid (dilute sulphuric acid)) may cause burns to skin and eyes. In case of
splashing it to skin, please clean it with water and see the doctor immediately. In case of splashing it to
clothes, please wash it with water immediately. Keep battery fluid far away from Children.

4. Cooling liquid is toxic. Do not drink it or splash it to skin, eyes and clothes. once splashing it to skin, please
wash it with a lot of soapy water. In case of splashing it to eyes, please wash eyes immediately and see the
doctor. In case of drinking cooling liquid, resulting in vomit, please see the doctor. Keep cooling liquid far
away from children.

5. Wear proper working suit, boots and hat. If necessary, please wear long-sleeve working suit and gloves for
operation.

6. Gasoline is highly inflammable. No smoking or firing. At the same time, fire sparks shall be avoided.
Vaporized gasoline is explosive as well. Operation shall be carried out at places with good ventilation.

7. Battery may produce explosive hydrogen in charging. Please ensure charging at places with good
ventilation.

8. Use legal parts, lubricating oil and lubricating grease.

9. Before overhauling, please clean soil and dust.

10. Keep accessories of each part well for correct assembly.
11. Replace dismantled gasket, O-shaped ring, piston pin retainer and cotter pin.
12. Retainer of rubber ring may be deformed after dismantling. So, please do not use loose and soft retainer.
13. Please wash and dry dismantled parts. Use lubricant on the surface of moving parts. For correct installation,
please measure data well in dismantling process.
14. If do not know length of screw, please install screws one by one to ensure their corresponding depth.
15. Pre-tighten bolts and nuts and then tighten them with designated torque from the big to the small and from
the inside to the outside.
16. Check whether rubber parts are aged. If necessary, replace them. Keep rubber parts far away from grease.
17. If necessary, special tools can be used.
18. Rotate inside and outside races of bearing to ensure flexibility of balls.
a) If axial or radial resistance is too large, please replace it. If there is concave-convex on the surface,
please use oil for washing. If no effect is achieved with washing, please replace it.

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 1.GENERAL INFORMATION

b) If bearing cannot be clamped tightly in pressing into machine or axle, please replace bearing.
19. Please install a side dust proof bearing at correct direction. In installation of open or double-face dust proof
bearing, pay attention to that marks of manufacturer shall be outward.
20. In cleaning and drying bearing, please keep bearing support still. Before installation, please carry out
lubrication with oil or lubricating oil.
21. Please correct install elastic retaining ring. Assembling after opening can ensure installation of snap ring into
slot.
22. After assembly, please check whether all parts are of perfect tightening and flexible movement.
23. Brake fluid and coolant may damage shell and plastic and rubber parts. In case of being splashed by them,
please use water for washing.
24. In installing pipeline, please insert them to bottom of connecting pipeline. In installing pipe clamp, please
install them to groove if there is. As for pipeline or pipe clamp that cannot be tightened, please replace them.
25. Do not mix soil or dust into engine and/or hydraulic braking system.
26. Before installation, please clean gasket and spacer of engine shell. Use oil stone to polish scratch of joint
face evenly.
27. Do not twist or bend too much cable. Twisted or damaged cables may cause inflexible operation.
28. In assembling protective caps of parts, insert cap into groove if any.

1-2
 1.GENERAL INFORMATION

TECHNICAL SPECIFICATIONS
Item Parameter
Dimensions UTV800-3A/-3C UTV800-4A/-4C
Overall length 3030mm/3030mm 3830mm/3830mm
Overall width 1730mm/1730mm 1730mm/1730mm
Overall height 2060mm/1950mm 2060mm/1950mm
Seat height 850mm 850mm
Wheelbase 2700mm/1900mm 2020mm/1934mm
Ground clearance 400mm/285mm 400mm/285mm
Engine
Type Two-cylinder, 4-stroke,SOHC, water cooling
Number of valves 8(mechanical adjustment)
Cylinder diameter 91 mm
Piston stroke 61.5 mm
Compression ratio 10.3：1
Displacement 800cc
Maximum power 44Kw/6000rpm
Maximum torque 73N.m/5000 rpm
Idle speed 1250rpm
Type Wet tank lubrication, oil filters can be changed
Oil pressure 0.18-0.3MPa at 1250rpm
Type of oil SAE10W-40/SJ
Lubrication
Oil quantity 2200mL
Replacement of
1850mL
capacity
Type Unleaded gasoline only 93# or higher
Fuel Fuel pressure 350 kpa
Fuel tank capacity 37L/25L
Intake 0.05 to 0.09mm
Valve clearance
Exhaust 0.10 to 0.15mm
New 4.960 to 4.975mm
Diameter of valve rod(IN)
Service limit 4.930mm
New 4.945 to 4.965mm
Diameter of valve rod(EX)
Service limit 4.930mm
New 1.05 to 1.35mm
Valve seat contact width(IN)
Service limit 1.80mm
New 1.25 to 1.55mm
Valve seat contact width(EX)
Service limit 2.00mm
New 5.000 to 5.015mm
Valve guide diameter
Service limit 5.050mm
New 40.5mm
Free length of valve spring
Service limit 39mm
New 12.000 to 12.018mm
Rocker arm bore diameter
Service limit 12.030

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 1.GENERAL INFORMATION

New 11.983 to 11.994

Rocker arm shaft diameter
Service limit 11.97mm
Size “A” 90.955 to 90.962mm
Piston measurement
Size “B” 90.962 to 90.970mm
Size “A” 90.995 to 91.003mm
Cylinder measurement
Size “B” 91.003 to 91.010mm
New 32.15 to 32.25mm
Intake cam height
Service limit 32.09mm
New 31.95mm to 32.05mm
Exhaust take cam height
Service limit 31.92mm
34.95 to 34.975mm(Timing chain side)
New
Crankshaft main journal 21.959 to 21.980mm(Spark plug side)
diameter 34.94mm(Timing chain side)
Service limit
21.95mm(Spark plug side)
Crankshaft radial clearance Service limit 0.06mm
Crankshaft deflection Service limit 0.07mm
Crankshaft pin diameter New 40.009 to 40.025mm
Service limit 39.990mm
Connecting rod big end radial
Service limit 0.09mm
clearance
Connecting rod small end New 20.010 to 20.020mm
diameter Service limit 20.060mm
New 19.996 to 20.000mm
Piston pin diameter
Service limit 19.980mm
Type/manufacturer DCPR8E / NGK
Spark plug
Gap 0.7 to 0.9mm
Transmission type CVT(Continuously Variable Transmission)
Continuously variable ratio 0.71 to 3.1
Drive belt width Service limit 30.00mm
Gearbox type Dual range(H/L) with park, neutral and reverse
Gearbox oil Capacity 420mL(GL-4-90)
H 2.886
Gear ratio L 5.292
R 5.087
Cooling liquid temperature Valve opening 65C◦
thermostat Fan opening 88C◦
Magneto generator output 520W@6000rpm
Crankshaft position sensor value of resistance 774 to 946 Ω@20℃
Tire
Type Tubeless
Pressure 97 to 124KPa
Size Front 27×9–14/29×8–15
Size Rear 27×11–14/29×10–15
Brakes

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 1.GENERAL INFORMATION

System Front and rear unified

Type Front Dual disc brake
Type Rear Dual disc brake
New disk thickness 5.0mm(Front)/4.0mm(Front)
5.0mm(Rear)/3.5mm(Rear)
Minimum disk thickness 5.0mm(Front)/4.0mm(Front)
5.0mm(Rear)/3.5mm(Rear)
Maximum disk warpage 0.2mm
Operation Foot operation
Suspension and shock absorber
Front suspension Double wishbone
Rear suspension Double wishbone
Front shock absorber Coil spring / oil damper
Front shock absorber travel 99mm/126mm
Rear shock absorber Coil spring /oil damper
Rear shock absorber travel 99mm/99mm
Drive train
Front differential Shaft driven/single auto-lock differential
Front differential ratio 3.67:1
Rear axle Shaft driven/single differential
Rear axle ratio 3.67:1
Front differential oil capacity 180mL(GL-4-90)
Rear differential oil capacity 220mL(GL-4-90)
Electrical
Ignition system EFI-DELPHI
Type Maintenance Free
Battery Voltage 12V
capacity 45AH
Reversing Light 10A
Reserve power 15A
EFI system meter 25A
Lock(second shift) 20A
Lighting 30A
Fuses Fan & brake light 30A
EPS 40A
Rear drive control 15A
Electric top 15A
Top light 20A
Seat heating 15A
Head lamp（High beam / low beam） 12V 55W/55W
Fog light Front：12V 0.4W
Rear：12V 0.4W
Stoplight 12V 1.8W
Indicator light Front：12V 0.35W

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 1.GENERAL INFORMATION

Rear：12V 0.4W
Front：12V 5W
Turn light
Rear：12V 1.8W
TIGHTENING TORQUE

Locking devices ( e.g.: locking tabs, elastic stop nuts ,self-locking fasteners ,etc.) must be installed or replaced
with new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed.

In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the following
recommended torque value:

Torque (N·m)
Grade
M6 M8 M10 M12 M14 M16
4.6 4～5 10～12 20～25 36～45 55～70 90～110
5.6 5～7 12～15 25～32 45～55 70～90 110～140
6.8 7～9 17～23 33～45 58～78 93～124 145～193
8.8 9～12 22～30 45～59 78～104 124～165 193～257
10.9 13～16 30～36 65～78 110～130 180～201 280～330
12.9 16～21 38～51 75～100 131～175 209～278 326～434

Torque (lbf.ft)
Grade
M6 M8 M10 M12 M14 M16
4.6 3～3.7 7.4～8.6 14.8～18.5 26.6～33.2 40.6～51.7 66.4～81.2
5.6 3.7～5.2 8.9～11.1 18.5～23.6 33.2～40.6 51.7～66.4 81.2～103.3
6.8 5.2～6.6 12.5～17 24.4～33.2 42.8～57.6 68.6～91.5 107～142.4
8.8 6.6～8.6 16.2～22.1 33.2～43.5 57.6～76.8 91.5～121.8 142.4～189.7
10.9 9.6～11.8 22.1～26.6 48～57.6 81.2～95.9 132.8～148.3 206.6～243.5
12.9 11.8～15.5 28～37.6 55.4～73.8 96.7～129.2 154.2～205.2 240.6～320.3

CAUTION
Be sure to use the proper tightening torque for the proper strength grade. Always torque screws, bolts and / or
nuts in a criss-cross sequence.

Bolt length comparison table

Length(mm) 12 14 16 20 25 30 35 40
Length(in) 0.47 0.55 0.63 0.79 0.98 1.18 1.38 1.57
Length(mm) 45 50 55 60 65 70 75 80
Length(in) 1.77 1.97 2.17 2.36 2.56 2.76 2.95 3.15
Length(mm) 85 90 95 100 105 110 115 120
Length(in) 3.35 3.54 3.74 3.94 4.13 4.33 4.53 4.72
Length(mm) 125 130 135 140 145 150 155 160
Length(in) 4.92 5.12 5.31 5.51 5.71 5.91 6.1 6.3
Length(mm) 165 170 175 180 185 190 195 200
Length(in) 6.5 6.69 6.89 7.09 7.28 7.48 7.68 7.8

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 1.GENERAL INFORMATION

As for important tightening torques , please refer to following standards.

Installation location Specifications (mm) Torque N.m(Ft.lbs)

Fastening bolt of engine M10 60-65(44-47.6)
Fastening nut of suspension arm M12 78-100(57.1-73.3)
Bolt of rear shock absorber M12 78-100(57.1-73.3)
Bolt of front shock absorber M10 60-65(44-47.6)
Fastening nut of wheel rim M12 90-110(65.9-80.6)
Nut of wheel hub M22/M24 280-300(205.1-219.8)
Bolt of rear brake/stop pump (calipers) M10 60-65(44-47.6)
Bolt of brake/stop disc M8 24-28(17.6-20.5)
Bolt of front brake/stop pump (calipers) M10 60-65(44-47.6)
Lock nut of steering rod M12 120-140(87.9-102.6)
Lock bolt of steering gearbox M12 140(102.6)
Bolt of exhaust pipe M8 18-26(13.2-19)
Fastening nut of rear differential M10 80(58.6)
Fastening nut of front differential M10 80(58.6)
Bolt of front propeller shaft flange M8 35-40(25.6-29.3)
Bolt of front propeller shaft flange M10 70-80(51.3-58.6)
Spark plug M12 18(13.2)
Water temperature sensor M12 16(11.7)
Oil pressure switch M10 12.5(9.2)
Adjusting nut of valve clearance M6 12(8.8)
Main pulley bolt M12 100(73.3)
Driven pulley bolt M10 60(44）
Magneto flywheel bolt M16 150(109.9)
Magneto stator bolt M6 12.5(9.2)
One way bolt 单向螺栓 M8 30(22)
Engine oil drain plug M12 20(14.7)
Gearbox oil drain plug M12 20(14.7)
Decompression valve plug M22 20(14.7)
Cylinder head bolt M10 60(44）
Cylinder head bolt M6 12.5(9.2)
Connecting rod bolt M8 50(36.6)
Timing chain wheel bolt M8 30(22)
Front output shaft flange bolt M8 30(22)
Rear output shaft flange bolt M10 60(44)

1-7
 2.PERIODIC MAINTENANCE

2. PERIODIC MAINTENANCE

MAINTENANCE SCHEDULE ······················2-1 AIR CLEANER ·········································2-3

VALVE CLEARANCE ································2-4 SPARK PLUG ···········································2-6
THROTTLE CABLE PLAY ··························2-7 ENGINE OIL ············································2-8
FRONT DIFFERENTIAL OIL ·······················2-10 STEERING SYSTEM ··································2-10
BRAKING SYSTEM ··································2-11 GEAR SHIFT············································2-13
COOLING SYSTEM···································2-13 WHEELS ·················································2-15
ENGINE COMPRESSION PRESSURE ············2-15 ENGINE OIL PRESSURE ····························2-16
SUSPENSION SYSTEM ······························2-17

MAINTENANCE SCHEDULE
In order to maintain the best performance and economical performance of vehicles, suggestions on intervals for
necessary regular maintenance are listed. Following maintenance is calculated in km, mile and hour based on
firstly appeared data.
However, keep in mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals
should be followed.
Items marked with an asterisk should be performed by a dealer as they require special tools and technical skills.
In case of complicated road conditions, regular maintenance shall be carried for vehicles.

INTIAL EVERY
Whichever month 1 3 6 6 12
ITEM ROUTINE Comes first Km 320 1200 2400 2400 4800
(mi) (200) (750) (1500) (1500) (3000)
hours 20 75 150 150 300
● Check vale clearance.
Valves* O O O O
● Adjust if necessary.
● Check coolant leakage.
Cooling system ● Repair if necessary. O O O O O
● Replace coolant every 24 months.
● Check condition.
Spark plug ● Adjust gap and clean. O O O O O
● Replacement every 24 months
● Clean. Every 20-40 hours
Air filter elements
● Replacement every 24 months (More often in dusty areas)
Crankcase breather ● Check breather hose for cracks or damage.
O O O
system* ● Replace if necessary.
● Check for leakage.
Exhaust system* ● Tighten if necessary. O O O
● Replace gasket(s) if necessary.
● Check fuel hose for cracks or damage..
Fuel line* ● Replacement fuel hose every 48 months O O O
● Replacement fuel filter every 24 months
Engine oil ● Replace (Check oil level every month) . O O O O
Engine oil filter ● Replace. O O O
Differential and ● Check oil level/oil leakage.
O O
gearbox oil ● Replacement every 24 months.
●Check operation/brake pad wear/fluid
Brake* O O O O O
leakage.
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 2.PERIODIC MAINTENANCE

●Brake fluid needs to be above the lowest

position.
●Correct if necessary. Replace pads/disk if
worn to the limit.
Accelerator pedal* ●Check operation and free play. O O O O O
●Check balance/damage/ run out
Wheels* O O O O
●Repair if necessary.
●Check bearing assemblies for looseness or
Wheel bearings* damage.. O O O O
●Replace if damaged.
Front and rear ●Check no deformation and looseness.
O O
Suspension* ●Correct if necessary.
●Check operation and no looseness.
Steering system* ●Repair if damage. O O O O O
●Check toe-in/Adjust if necessary.
Rear knuckle pivots
●Lubricate with lithium-soap-based grease. O O O
and suspension arms*
Drive shaft
●Lubricate with lithium-soap-based grease. O O O
universal joint*
●Check for cracks or damage.
Engine mount* O O O
●Correct bolt tightness.
Front and rear axle ●Check operation.
O O
boots* ●Replace if damage.
Stabilizer bushings* ●Check for cracks or damage. O O O
Fittings and ●Check all chassis fittings and fasteners.
O O O O O
fasteners* ●Correct if necessary.
Battery ●End connection O O O O
Lamp and steering
●Operation O O O O O
indication

2-2
 2.PERIODIC MAINTENANCE

AIR CLEANER
In case of driving in dusty environment, air filter shall be cleaned regularly. It is of great possibility to
accelerate wear to engine if there is not filtering element or worn filtering element is used. So, please keep air
filter under good conditions all the time. If vehicle is used in dusty area, inspect more frequently than specified in
MAINTENANCE SCHEDULE.
If the air cleaner is clogged with dust,intake resistance will be increased,with a resultant decrease in power
output and an increase in fuel consumption. never remove or modify any component in the air filter housing. The
engine management system is calibrated to operate specifically with these components. Otherwise, engine
performance degradation or damage can occur.Check and clean the air cleaner element in the following manner:

Remove left and right seats, then remove the engine intake cover
(fixed with 2-plastic fastener).

Release the rear Φ 73-Φ 95 clamp,remove the top fixed screw,

and the remove the engine air intake.

Remove the gear shift handle,remove all the plastic fastener and rear fixed
screws,pull the parking brake lever up to end, then remove the engine
shield.

Loosen clamp and remove air filter.

Blow low pressure compressed air on filter element to clean it.

Properly re-install removed parts in the reverse order of their removal.

pay attention to the engine breather hose insert into the intake pipe.

Properly re-install removed parts in the reverse order of their removal.

pay attention to the engine breather hose insert into the intake pipe.
CAUTION
1.If liquid /deposits are found, squeeze and dry the foam filter. Replace filter element if damaged.
2.Do not start engine if liquid or deposit are found. If there is oil in the air filter housing, check engine oil level.
Oil level may be too high.
3.Inspect the air cleaner element for tears, a torn element must be replaced.

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 2.PERIODIC MAINTENANCE

VALVE CLEARANCE
Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced
power.
Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to
specification,if necessary.
Valve clearance is to be checked when the engine is cold.The intake and exhaust valves must be checked an adjusted
when the piston is at TOP-DEAD –CENTER(TDC) on the compression stroke.

Remove left and right seats, gear shift handle and engine shield.

Remove spark plug cable and spark plug of both cylinders.

Remove the valve cover of both cylinders .

1. screws
2. Valve cover

Remove the plug screw and O-ring of magneto cover.

Remove the crankshaft position sensor.

1. Crankshaft position sensor
2. Screw

Valve clearance of cylinder 2

Use a 14 mm Allen key to turn crankshaft until piston 2,
rear is at TDC ignition.

When rear piston is at TDC ignition, marks on magneto

flywheel “2” and on the magneto cover are aligned.
1. Mark “2” on magneto flywheel
2. Notch on magneto cover
3. Crankshaft position sensor location

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 2.PERIODIC MAINTENANCE

At TDC ignition, the printed marks on the camshaft

timing gear have to be parallel to cylinder head base. If
not, use Allen key to turn crankshaft 360°
1. Printed marks on camshaft timing gear
2. Cylinder head base

Insert the feeler gauge between the valve stem end and
adjusting screw on the rocker arm to check the clearance.
If the valve clearance is out of specification, adjust valves
as follows.
Valve clearance
Intake 0.06 to 0.10mm(0.00236 to 0.00394 inches)
Exhaust 0.11 to 0.15mm(0.00433 to 0.00591 inches)
Use mean valve of exhaust/intake to ensure a proper valve
adjustment.
Hold the adjustment screw at the proper position and
torque the locking nut.
Repeat the procedure for each valve.
1. Adjustment screw
2. Adjustment nut
3. Feeler gauge

CAUTION
Securely tighten the locknut after completing adjustment.
Valve clearance adjustment locknut: 12N.m(8.856Lbf.ft)

Valve clearance of cylinder 1

Using a 14 mm Allen key, turn crankshaft 280 °
counterclockwise.
1. Allen key 14mm
2. Turn crankshaft 280°counterclockwise

Until marks on magneto flywheel “1” and magneto

cover are aligned.
1. Mark “1” on magneto flywheel
2. Notch on magneto cover
3. Location of crankshaft position sensor

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 2.PERIODIC MAINTENANCE

At TDC ignition, the printed marks on the camshaft

timing gear have to be parallel to cylinder head base as
per following illustration.
TYPICAL
1. Printed marks on camshaft timing gear
2. Cylinder head base

Insert the feeler gauge between the valve stem end and
adjusting screw on the rocker arm to check the clearance.
If the valve clearance is out of specification, adjust valves
as follows.
Valve clearance
Intake 0.06 to 0.10mm(0.00236 to 0.00394 inches) U
s
Exhaust 0.11 to 0.15mm(0.00433 to 0.00591 inches) e
mean valve of exhaust/intake to ensure a proper valve
adjustment.
Hold the adjustment screw at the proper position and
torque the locking nut.
Repeat the procedure for each valve.
1. Adjustment screw
2. Adjustment nut
3. Feeler gauge
Valve clearance adjuster locknut: 12N·m(8.856Lbf.ft)
CAUTION
Securely tighten the locknut after completing adjustment.

Install the valve cover of both cylinders, spark plug cable and spark plug of both cylinders, the plug screw and
O-ring of magneto cover and the crankshaft position sensor.

SPARK PLUG
In case of serious wear or burn to electrode or burn to insulator by spark plug or damage to thread etc, please replace
it with new spark plug
In case of carbon deposit, please use proper tools for cleaning.

Spark plug gap

Use clearance gauge to measure clearance of spark
plug.
In case of exceeding designated range, then adjust the
gap.
0.7-0.9mm(0.028-0.035inches)

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 2.PERIODIC MAINTENANCE

Spark plug heat range

Check the spark plug heat range by observing the electrode color. If the electrode of the spark plug is
appearing wet or dark color, replace the spark plug with a hotter type one. If it is white or appearing glazed,
replace the spark plug with a colder type one.
Standard type: DCPR8E / NGK
Colder type: DCPR9E / NGK
Hotter type: DCPR7E / NGK

CAUTION
In order to avoiding damaging cylinder cap thread, firstly use hands to tighten spark plug and then use
spark plug wrench to tighten cylinder cap with designated torque.

THROTTLE CABLE PLAY

Before starting the engine, check the gas pedal to be sure it is operating correctly. Make sure the gas pedal fully
returns to the idle position as soon as it is released.
Check the free play and adjust if needed. Press the throttle to make sure it moves smoothly without sticking and
snaps back automatically when it is released Check to see that the gas pedal operates correctly. It must operate
smoothly and fully spring back to the idle position when released. Have a dealer repair if necessary for proper
operation.

Check throttle pedal free play:

3 - 5mm(0.118-0.197inches)
In case of out of range: → adjustment

Remove left and right seats, the engine air intake and engine shield.

Loose throttle cable (bracing cable).Turn adjuster to

adjust free play of throttle pedal.

After adjustment, tighten nut.

If free play after adjustment cannot reach designated requirement
or there is viscosity for throttle valve, replace it with new throttle
cable.

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 2.PERIODIC MAINTENANCE

ENGINE OIL
Oil level verification
Strictly follow this procedure, otherwise wrong oil
level may be indicated.

1. Ensure vehicle is on a level surface.

2. Start engine and let idle for a few minutes.

3. Stop engine. Wait a few minutes to allow oil to flow

down to crankcase then check oil level.

4. Remove passenger side seat.

5. Remove the inspection cover on the engine shield.

6. Remove dipstick and wipe clean stem.

7. Fully screw in dipstick to check oil level.

8. Remove dipstick and read oil level. Oil level must be

between minimum(2) and maximum(1) marks on
dipstick.

9. There is a capacity of 300 ml between the two marks.

Refill oil as necessary. Do not overfill.

10. Re-install dipstick.

Replace engine oil

Prior to change the oil, ensure vehicle is on a level surface. Oil and oil filter must be replaced at the same time.
Oil change and oil filter replacement should be done with a warm engine.

WARNING

The engine oil can be very hot. Wait until engine oil is warm.

CAUTION

Dispose oil and filter as per your local environmental regulations.

2-8
 2.PERIODIC MAINTENANCE

1. Ensure vehicle is on a level surface.

2. Start engine and let idle for a few minutes.
3. Stop engine. Wait a few minutes to allow oil to flow down
to crankcase then check oil level.
4. Remove left and right seats, the engine air intake.
5. Remove engine shield.
6. Remove dipstick.
7. Raise the vehicle, support it securely. Place a drain pan
under the engine drain plug area.
8. Clean the drain plug area.
9. Unscrew drain plug then remove dipstick.

1) Drain plug
2) Gasket ring
10. Allow oil to drain completely from crankcase.
11. Clean the magnetic drain plug from metal shavings and
residue.
12. Install a new gasket ring on drain plug. Torque drain
plug to 20 N.m(14.76Lbf.lt).
13. Remove oil filter screws, oil filter cover and oil filter.
1) Oil filter screw
2) Oil filter cover
3) ring
4) Oil filter
14. Check and clean the oil filter inlet area for dirt and
other contamination.
15. The installation is the reverse of the removal procedure.
Pay attention to install a new gasket on oil filter cover.
16. Refill engine with a SAE 10W-40 API SJ classification
engine oil, Oil change capacity with filter 1850mL.
17. Check the oil level with the dipstick. Refer to OIL
LEVEL VERIFICATION above.
18. Run engine to ensure oil filter and drain plug areas are
not leaking.

CAUTION

In order to expand service life of vehicle, please use grade SJ standard engine
oil conforming to API with its viscosity indication being SAE10W/40. If viscosity
of engine does not reach SAE 10W/40, make corresponding selection according to
drawing

Replace gearbox oil

Prior to change the gearbox oil, ensure vehicle is on a level surface, should be done with a warm engine.

2-9
 2.PERIODIC MAINTENANCE

1. Drive vehicle for a few minutes.

2. Ensure vehicle is on a level surface.
3. Stop engine and wait a few minutes.
4. Remove left and right seats, the engine air intake.
5. Remove engine shield

6. Remove the oil level check plug.

7. Place an oil pan under the gearbox case, and then
drain oil completely by removing the drain plug.
8. Tighten the drain plug to 20 N.m(14.76Lbf.lt).
9. Pour the specified oil(GL-4-90) about 360~450mL
Drain Plug
by syringe through the oil level check plug hole until
the oil over flows.
10. Tighten the oil level check plug to 20
Oil level
N.m(14.76Lbf.lt).
check plug

FRONT DIFFERENTIAL OIL

To change the front differential oil, locate the vehicle Oil level
check plug
on a level position and carry out the following steps.
Clean the oil level check plug area and remove the oil
level check plug.

Clean the drain plug area.

Place an oil pan under the front reducer case,and then Drain Plug
drain oil completely by removing the drain plug.
Tighten the drain plug to 20 N.m. (14.76Lbf.lt)

Pour the specified oil(GL-4-90) about 150~180mL by

syringe through the oil level check plug hole until the
oil over flows.
Tighten the oil level check plug to 20
N.m(14.76Lbf.lt).

STEERING SYSTEM
Park vehicle at flat ground and hold steering wheel for wobbling to up, down, left and right.Check whether
there is loosing. In case of wobbling, tighten nut or dismantle steering column for further inspection.

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 2.PERIODIC MAINTENANCE

Park vehicle at flat ground and turn handle left or right slowly to see whether it can be turned flexibly. In case
of obstacles, check whether it is caused by main cable or other wiring installation. If it is not caused by above
situations, please check the bottom of steering tie rod and see whether steering column bearing is damaged or
not.
Park vehicle on flat ground, make sure the tire
pressure for right and left tires is same and set to the
proper specification, set the front wheels in the straight
position, then place a load of 75kg on the seat.

Measure the distance A and B of the front wheels

and calculate the difference.

Toe-in.:B -A= 5mm(0.197inches)

A: front of front wheel

B: rear of front wheel

Out of range of toe-in: →Adjust nut of tie rod

CAUTION
After adjusting toe-in, fist rotate steering wheel from center position to the left and right
completely, to ensure that is the same corner, then slowly run vehicle to see whether its
direction can be controlled.

BRAKING SYSTEM
Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir. Apply the brakes
firmly for one minute. If there is any leakage, have the vehicle inspected by an authorized dealer.

Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not
provide proper braking performance, inspect the brake system. If needed, have the vehicle inspected by an
authorized dealer.

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 2.PERIODIC MAINTENANCE

Brake fluid level

Check the brake fluid level by observing the lower limit
line on the brake fluid reservoir.
When the brake fluid level is below the lower edge,
replenish with brake fluid DOT4.

Brake pedal adjustment

The brake pedal stroke is 30～40mm(1.18~1.57inches). If less than
equal 30mm, it will be a hidden dangers, must adjust the brake pin
connecting the brake pedal.

Parking brake adjustment

Pull the parking brake lever up to engage the parking
brake. To release the unit, press button on front end of
parking lever then push the parking lever to the bottom.

The free play is 15～20mm(0.59~0.79inches),

the travel is 7 teeth.

Parking brake
If necessary, slacken the cable by loosening the caliper
locknut and screwing the adjuster on the brake holder.
After adjusting the play, tighten the locknut. Or
screwing the adjustment nut on the parking brake caliper Adjustment nut

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 2.PERIODIC MAINTENANCE

GEAR SHIFT
Check the shift lever as to change gearshift from P to R N H L and reverse smoothly. Also the meter display is
correct.
The shift lever should be vertical when the gear is in neutral. If not, only remove the the engine air intake and
adjust rear side of the shift cable and then tighten the nuts of the shift cable.

COOLING SYSTEM
To prevent rust formation or freezing condition, always replenish the system with the premixed coolant or
with 50% antifreeze and 50% water. Do not use tap water, straight antifreeze or straight water in the system.
Tap water contains minerals and impurities which build up in the system. During cold weather, straight water
causes the system to freeze while straight antifreeze thickens and does not have the same efficiency. Always
use ethylene glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines.

Cooling liquid may be reduced by natural evaporation. Regularly check horizontal position of cooling liquid

Coolant level verification

Park vehicle at flat ground,lift the front hood and then check horizontal line of cooling liquid.

Check the level of cooling water in fluid reservoir

(auxiliary radiator) is between upper and lower critical
levels.

CAUTION

To avoid potential burns, do not remove the radiator cap or loosen the cooling drain plug if
the engine is hot. Never drain or refill cooling system when engine is hot.

Coolant replacement
Park vehicle at flat ground and lift the front hood.

2-13
 2.PERIODIC MAINTENANCE

Remove the radiator cap.

radiator
cap

Partially unscrew coolant drain plug located below

water pump housing. Water pump
housing
When coolant is drained completely, remove cooling
drain plug completely and install a new gasket ring.
Screw the coolant drain bolt and torque it to 10
N.m(7.38Lbf.lt). Coolant
drain bolt

Bleed
Unscrew bleed screws on top of screw
thermostat housing.Both cylinders must be bled.

Unscrew bleed bolt on top of raditor.

Fill up the radiator with coolant, when the coolant comes out
by the thermostat housing hole, install the bleed screws with
its gasket ring and torque to 10 N.m(7.38Lbf.lt).

Start the engine and let idle.

Refill coolant to radiator, when the coolant comes out by the radiator bleed hole, install the bleed bolt with its
gasket ring and torque to 10 N.m(7.38Lbf.lt).

Press and relax the throttle pedal five times to bleed air bubbles completely.

Refill coolant to radiator, and install the the radiator cap.

Run engine until radiator fan opens.

Stop the engine. When engine has completely cooled down, recheck coolant level in the coolant tank, Top up if
necessary

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 2.PERIODIC MAINTENANCE

WHEELS
Lift wheels up at horizontal position and ensure no
load to each wheel.

Shake wheels to left and right to see whether their

connecting parts are installed tightly and check whether
they can be swung.

No adequate tightening: → tightening

Swing: → replace rocker arm

Tire pressure

Improper tire pressure will lower comfort of operation

and driving and may lead to wear to side edges of tires.

Tire thread.

When the tire groove decreases to 6 mm (0.24 in) due to

wear, replace the tire.

ENGINE COMPRESSION PRESSURE

The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to
overhaul the cylinder is often based on results of a compression test.

Before measuring cylinder pressure, ensure installation and tightening of cylinder cap bolt with designated
torque and reasonable clearance of valve.
Standard cylinder pressure: 0.9～1.2Mpa(130.5PSI~174PSI)

Too low cylinder pressure may cause the following:

 Excessive wear to cylinder;
 Wear to piston or piston ring;
 Blockage of piston ring in groove;
 Close valve seat;
 Damage to cylinder lining or faults of other parts
Measure engine compression pressure:
1. Warm up engine.
2. Ensure full charging of battery.
3. Remove left and right seats, gear
shift handle and engine shield
4. Dismantle spark plugs.
5. At spark plug hole, install cylinder pressure meter.

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 2.PERIODIC MAINTENANCE

6. Press button of start for several seconds. Record

indication of maximum cylinder pressure.

ENGINE OIL PRESSURE

Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts.
The engine oil pressure test should be done with a warm engine 90℃ and the recommended oil.

Remove left and right seats, the engine air intake and
engine shield.

Remove the oil pressure switch wire connector and

switch on the right of engine.

Install oil pressure gauge and adapter hose. Oil pressure 1250 RPM 6000 RPM
Start engine on idle speed. The engine oil pressure 70kPa 300kPa
should be within the following values. Minimal
(10.2PSI) (43.5PSI)
150kPa 350kPa
Nominal
(21.8PSI) (50.8PSI)
Remove oil pressure gauge and adapter hose. 250kPa 450kPa
Maximal
(36.3PSI) (65.3PSI)

Installation oil pressure switch to 12 N.m(8.86Lbf.lt) and

the oil pressure switch wire connector.
Install engine shield gear shift handle globe and left and
right seats.

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 2.PERIODIC MAINTENANCE

SUSPENSION SYSTEM
Lubricate both suspension arms with lithium-soap based grease. There are two grease fittings on each suspension
arm. Check operation and for leakage.

Grease fitting location of front suspension arms.

Grease fitting location of rear suspension arms.

Lubricate rear knuckles with lithium-soap based grease.

There are two grease fittings on each rear knuckle.

2-17
 3.ENGINE

3. ENGINE
ENGINE REMOVAL··································· 3-2 VALVE COVER ········································· 3-2
TIMING CHAIN TENSIONER ······················ 3-3 CAMSHAFT TIMING GEAR ························ 3-4
ROCKER ARM ········································· 3-5 CYLINDER HEAD ····································· 3-6
CAMSHAFT ············································· 3-8 VALVE SPRING ········································3-12
VALVE····················································3-13 VALVE GUIDE ··········································3-15
CYLINDER ··············································3-16 PISTON AND RINGS ··································3-17
PISTON RINGS ·········································3-20 DRIVE SHAFT ··········································3-21
PTO COVER·············································3-22 DRIVE GEARS ·········································3-25
TIMING CHAIN ········································3-25 CRANKCASE ···········································3-26
CRANKSHAFT ·········································3-30 OLL PRESSURE REGULATOR ·····················3-33
OLL PUMP ··············································3-33 MAGNETO COVER ···································3-35
STATOR ··················································3-36 ROTOR ···················································3-37
SPRAG CLUTCH·······································3-38 SPRAG CLUTCH GEAR ······························3-39
TRANSMISSION ·······································3-39 DRIVE BELT ············································3-40
DRIVE PULLEY ········································3-41 DRIVEN PULLEY ······································3-42
CVT AIR GUIDE ·······································3-43 GEARBOX ···············································3-43
GEARBOX OLL DRAIN ······························3-44 POSTION INDICATOR SWITCHES ················3-45
OLL SEALS ·············································3-46 OUTPUT SHAFT ·······································3-47
GEARS ···················································3-50 PRESS SHAFT IN THE DIRECTION AS
SHOWNBYTHE ARROW ·························3-53
ENGINE INSTALLATION ····························3-62

Components witch are identical for both cylinders/cylinder heads are identified in the two exploded views by
the same number. Components which are different or which are, for instance, present of one of the
cylinders/cylinder heads but not on the other, have different numbers. The information given below always
relates as a general rule.
Special reference is made in the text to work instructions which are not the same for cylinder no. 1 and
cylinder no. 2.

! WARNING
Torque wrench tightening specifications must
strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic stop
nuts, self-locking fasteners, cotter pin, etc.) must
be installed or replaced with new ones where
specified. If the efficiency of a locking device is
impaired, it must be repaired.

1. Cylinder 1
2. Cylinder 2

When diagnosing an engine problem, always perform a cylinder leak test. This will help pin-point a problem.
Refer to the instructions included with your leak tester and to LEAK TEST section for procedures.
Always place the vehicle on level surface.

3-1
 3.ENGINE

NOTE: For a better understanding, the many illustrations are taken with engine out of vehicle. To perform the
following instructions, it is not necessary to remove engine from vehicle.
Always disconnect BLACK (- ) cable from the battery, then RED (+ ) cable before working on the engine.
Even if the removal of many parts is not necessary to reach another part, it is recommended to remove these
parts in order to check them.

When disassembling parts that are duplicated in the engine, (e.g.: valves), it is a strongly recommended to note
their position (PTO/MAG side, front/rear cylinder) and keep them as a “group”. If you find a defective
component, it would be must easier to find the cause of the failure among it group of parts (e.g.: you found a
worn valve guide. A bent spring could be the cause and it will be easy to know which one among the springs is
the cause to replace it if you grouped them at disassembly). Also, since used pars have matched together during
the engine operation, they will keep their matched fit when you reassemble them together within their “group”.

ENGINE REMOVAL
To avoid potential burns, let engine and exhaust system cool down before performing any servicing.
Place vehicle on a work station that will have access to an engine-lifting hoist. Then start with initial
preparation of vehicle.
Disconnect the BLACK(-) cable from battery, then the RED(+) cable.
Drain coolant from engine cooling system. Drain engine oil only if engine overhaul is necessary. To work
on gearbox the removal is necessary but do not drain engine oil.

VALVE COVER
Cover Removal
Remove:
 distance screws of valve cover

1. Distance screws
2. Valve cover

 valve cover and gasket.

1. Valve cover
2. Gasket

Repeat the procedure for the other valve

cover if required.

Cover Inspection
Check the gasket on the valve cover if it
is brittle, cracked or hard. If so, replace
the gasket.

Cover Installation
For installation, reverse the removal
procedure.
Torque the valve cover distance screws in
a criss-cross sequence.

3-2
 3.ENGINE

TIMING CHAIN TENSIONER

NOTE: Before removal and installation, make sure that the respective cylinder is set to TDC ignition.
Refer to CAMSHAFT.

Tensioner removal
! WARNING
Timing chain tensioner is spring loaded. Never perform this operation immediately after the engine has been
turn because the exhaust system can be very hot. Wait until exhaust system is warm or cold.

Remove:
chain tensioner plug
O-ring
Spring
Chain tensioner plunger

1. Chain tensioner plug

2. O-ring
3. Spring
4. Chain tensioner plunger

Screws retaining chain tensioner housing

Chain tensioner housing with O-ring

1. Chain tensioner screws

2. Chain tensioner housing
3. O-ring

Tensioner Inspection
Check the housing for cracks or other
damages.
Replace if necessary.
Check chain tensioner plunger for free
movement and/or scoring.
Check if O-rings are brittle, cracked or hard.
Replace if necessary.
Check spring condition. Replace if broken or
worn.

Tensioner Installation
For installation, reverse the removal
procedure. However, pay attention to the
following.
NOTE: Before installing the chain tensioner
make sure, that the camshaft timing gear can
be moved back and forth.
Apply engine oil on the plunger before
installing.

NOTE: Slightly screw in the plunger until the timing chain allows no more back and forth movement of the
camshaft timing gear. Then screw in the plunger an additional 1/8 turn to reach the required torque of 0.1
N.m.
CAUTION: Improper adjustment of the timing chain will lead to severe engine damage.
Fit the spring on one side into the slot of the plug screw and on the other side into the plunger. Turn spring
only clockwise in order to fit the spring end into the notch of the plunger and to avoid loosening the plunger
during spring installation. Do not preload the spring.
NOTE: Do not forget to place the O-ring on chain tensioner plug.
Then compress the spring and screw in plug screw.
Finally, tighten the plug screw to 4.5 N.m.

3-3
 3.ENGINE

CAMSHAFT TIMING GEAR

Gear Removal
Turn crankshaft to TDC ignition of the
respective cylinder.
Unscrew timing chain tensioner.
Remove camshaft timing gear screw.

1. Camshaft timing gear screw

2. Camshaft timing gear

Remove the camshaft timing gear.

NOTE: Secure timing chain with a retaining
wire.

Gear Inspection
Check camshaft timing gear for wear or
deterioration.
If gear is worn or damaged, replace it as a set
(camshaft timing gear and timing chain).

Gear Installation
For installation, reverse the removal
procedure. Pay attention to the following
details.
Clean mating surface and threads of camshaft,
prior to assemble camshaft timing gear.

1. Mating surface on camshaft

2. Threads for camshaft screw

Camshaft timing gear and crankshaft must be

at TDC ignition position before installing the
timing chain.
CAUTION: Crankshaft and camshaft must
be locked on TDC ignition position to place
camshaft timing gear and timing chain in the
proper position.
Install camshaft timing gear so that the timing
gear tabs are located into the flat zone of the
camshaft.
The printed marks on the camshaft timing
gear must be parallel to the cylinder head
base. See the following illustration for a
proper positioning.

1. Printed marks on camshaft timing gear

2. Cylinder head base
3. Camshaft timing gear
4. Timing gear tab

Install trigger wheel on camshaft timing gear

of cylinder 1.

1. Camshaft timing gear screw

2. Camshaft timing gear

3-4
 3.ENGINE

When the camshaft timing gear and the timing chain are installed, remove the crankshaft locking bolt as well as
the camshaft locking tool.
NOTE: Before installing the camshaft screw adjust the chain tension and check again if marks on the timing gear
are parallel to cylinder head base.
Reinstall all other removed parts.

ROCKER ARM
Rocker Arm Removal
Remove:
valve cover
chain tensioner
camshaft timing gear
Allen screw and camshaft retaining plate

1. Cylinder head
2. Allen screw
3. Camshaft retaining plate
Rocker arm shafts
Rocker arm assembly (exhaust side and
intake side) with adjustment screws and nuts.

1. Rocker arm shaft

2. Rocker arm (exhaust side)
3. Rocker arm (intake side)
4. adjustment screw
5. Locking nut

 Thrust washer

CAUTION: Pay attention not to lose thrust

washers or drop them into the timing chain
compartment.

Rocker Arm Inspection

Inspect each rocker arm for cracks and scored
friction surfaces. If so, replace rocker arm
assembly.
Check the rocker arm rollers for free
movement, wear and excessive radial play.
Replace rocker arm assembly if necessary.

1. Rocker arm (exhaust side)

2. Roller
3. Bore for rocker arm shaft

Measure rocker arm bore diameter. If

diameter is out of specification, change the
rocker arm assembly.

Rocker arm bore diameter

new 12.000 to 12.018 mm
Service limit 12.030 mm

3-5
 3.ENGINE
Check adjustment screws for free movement,
cracks and/or excessive play.

1. Free movement of adjustment screw top

Rocker arm shaft

Check for scored friction surfaces, if so,
replace parts.
Measure rocker arm shaft diameter.

A: Measure rocker arm shaft diameter here

Rocker arm shaft diameter

New 11.983 to 11.994 mm
Service limit 11.970 mm

Any area worn excessively will require parts

replacement.

Rocker Arm Installation

NOTE: use the same procedure for exhaust
and intake rocker arm.
Apply engine oil on rocker arm shaft.
Install the rocker arm shafts with the
chamfered edge first and use following
procedure:
Insert a rocker arm pin through rocker
arm pin bore.
Install a thrust washer then the proper
rocker arm.
Push in rocker arm shaft until its chamfer
reaches the end of rocker arm bore.

1. Rocker arm shaft

2. Thrust washer (timing chain side)
3. Thrust washer (spark plug side)

Place the other thrust washer and push

rocker arm shaft to end position.
Install the camshaft retaining plate no. 5.

CYLINDER HEAD
Cylinder Head Removal
The removal procedure is the same for both
cylinder heads.

Drain coolant.
CAUTION

Before removing cylinder head, blow out remaining coolant by air pressure. During cylinder head removal,
the remaining coolant in cylinder head could overflow into the engine and a little quantity of coolant could
drop into the engine. In this case, the engine oil will be contaminated.ccontrolled.

3-6
 3.ENGINE

Disconnect:
spark plug wire
temperature sensor connector, located at
rear cylinder head
Remove:
exhaust pipe spring
exhaust pipe nuts
radiator inlet hose
air filter box and throttle body
air intake manifold
chain tensioner
valve cover and gasket
camshaft timing gear
cylinder head screws M6
cylinder head screws M10 retaining
cylinder head and cylinder to cylinder base.

1. Cylinder head screws M10

2. Cylinder head screws M6

Pull up cylinder head.

Remove:
chain guide
cylinder head gasket and scrap it.

1. Cylinder head
2. Timing chain
3. Chain guide
4. Cylinder head gasket

Cylinder Head Inspection

Inspect timing chain guide for wear, cracks or
other damages. Replace if necessary.
Check for cracks between valve seats, if so,
replace cylinder head.
Check mating surface between cylinder and
cylinder head for contamination. If so, clean
both surfaces.
Clean oil support through the cylinder head
from contamination.

1. Oil port to lubricate camshaft lobes

intake/exhaust
2. Oil supply to camshaft bearing journal
timing chain side
3. Oil supply to camshaft bearing journal
spark plug side

Cylinder Head Installation

NOTE: The cylinder heads are not identical in design. Do not invert the cylinder heads at assembly.
For installation,reverse the removal procedure.Pay attention to the following details.Ensure dowel pins are in
place

3-7
 3.ENGINE

CAUTION: Chain guide has to be fixed

between cylinder and cylinder head.

1. Chain guide (fixed between cylinder and

cylinder head)

2. Chain tensioner guide (mounted in

crankcase)

Install a new cylinder head gasket.

First, torque cylinder head screws M 10 in

crisscross sequence to 20 N.m then finish by
tightening to 60 N.m.

Install cylinder head screws M6.

1. Cylinder head screws M10

2. Cylinder head screws M6

Check chain guide for movement.

Remove crankshaft locking bolt and reinstall plug screw with sealing ring

CAMSHAFT
NOTE: The engine is equipped with two
different camshafts.

1. Camshaft of cylinder 1
2. Camshaft of cylinder 2

Camshaft timing cylinder 2

Turn crankshaft until piston is at TDC ignition as follows.

Remove:
spark plug cable and spark plug of both
cylinders
valve cover of both cylinders
plug screw and O-ring of magneto cover

1. Plug screw
2. O-ring

3-8
 3.ENGINE

crankshaft position sensor

1. Crankshaft position sensor

2. Screw

Use a 14 mm Allen key to turn crankshaft

until piston 2, rear is at TDC ignition.

1. Allen key 14 mm

When rear piston is at TDC ignition,

marks on magneto flywheel “2” and on
the magneto cover are aligned.

1. Mark “2” on magneto flywheel

2. Notch on magneto cover
3. Crankshaft position sensor location

At TDC ignition, the printed marks on the

camshaft timing gear have to be parallel to
cylinder head base.

1. Printed marks on camshaft timing gear

2. Cylinder head base

To lock crankshaft at TDC ignition, proceed

as follows.
Remove from crankcase plug screw with
sealing ring.

1 Plug screw
2 Sealing ring
3 Crankcase PTO side, front side

3-9
 3.ENGINE

Lock crankshaft with crankshaft locking bolt.

1. Crankshaft locking bolt

NOTE: Make sure the locking bolt engines in

the groove of the crankshaft.

Camshaft Timing Cylinder 1

Using a 14 mm Allen key, turn crankshaft 280 °

counterclockwise, until marks on magneto
flywheel “1” and magneto cover are aligned.

1. Allen key 14mm

2. Turn crankshaft 280°counterclockwise

1. Mark “1” on magneto flywheel

2. Notch on magneto cover
3. Location of crankshaft position sensor

NOTE: At TDC ignition, the printed marks

on the camshaft timing gear have to be
parallel to cylinder head base as per following
illustration.

1. Printed marks on camshaft timing gear

2. Cylinder head base

CAUTION: Crankshaft can not be locked at

cylinder 1 TDC ignition.

Camshaft Removal
The removal procedure is the same for both
camshafts.
Each camshaft is different in design. Thus, it
is important not to mix up any parts of the
camshaft assembly with that of the other
cylinder. Keep parts as a group.
Remove:
valve cover (see VALVE COVER above)
chain tensioner (see CHAIN
3-10
 3.ENGINE

TENSIONER above)
camshaft timing gear (see CAMSHAFT
TIMING GER above)
camshaft retaining plate

1. Cylinder head
2. Allen screw
3. Camshaft retaining plat

rocker arms (see ROCKER ARM above)

camshaft.

NOTE: For removal rotate camshaft so that

intake/exhaust lobe shows to upper side of
cylinder head.

1. Area for camshaft lobes

2. Camshaft
3. Camshaft retaining

Camshaft Inspection
Check each lobe and bearing journal of
camshaft for scoring, scuffing, cracks or
other signs of wear.
Measure camshaft bearing journal diameter
and lobe height using a micrometer.

A. Camshaft lobe (exhaust valves)

B. Camshaft lobe (intake valves)
C. Camshaft journal timing chain side
D. Camshaft journal spark plug side

Camshaft lobe (exhaust) Camshaft journal(timing chain side)

New 31.95 to 32.05mm New 34.95 to 34.975 mm
Service limit 34.94mm
Service limit 31.92mm
Camshaft journal (spark plug side)
Camshaft lobe (intake)
New 35 to 35.025 mm
New 32.15 to 32.25 mm
Service limit 35.04 mm
Service limit 32.09 mm

Measure clearance between both ends of

camshaft and cylinder head. Replace
parts that are not within specifications.

A. Cylinder head camshaft bearing timing

chain side
B. Cylinder head camshaft bearing spark
plug side

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 3.ENGINE

Cylinder head camshaft bearing(timing chain side)

New 35.000 to 35.025 mm
Service limit 35.040 mm
Cylinder head camshaft bearing(spark plug side)
New 22.000 to 22.021 mm
Service limit 22.040 mm

Camshaft Installation
For installation, reverse the removal
procedure. Pay attention to the following
details.
CAUTION: the camshafts are not identical in
design. Do not invert the camshafts during
assembly. Any mix-up of the components will
lead to engine damage.
Place the camshaft retaining plate in the slot
of the camshaft.

1. Camshaft retaining plate position

2. Slot retaining camshaft
3. Direction of movement

For other parts, refer to proper installation procedure.

VALVE SPRING
Valve Spring Removal

Remove:
rocker arms (see ROCKER ARM above)
cylinder head (see CYLINDER HEAD
above).
Compress valve spring; use valve spring
compressor clamp and vale spring
compressor cup.

! WARNING
Always wear safety glasses when disassembling
valve springs. Be careful when unlocking valves.
Components could fly away because of the strong
spring preload .

Remove valve cotters.

1. Valve spring compressor clamp

2. Valve spring compressor cup
3. Valve cotter

Withdraw valve spring compressor, valve

spring retainer and valve spring .

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 3.ENGINE

Valve Spring Inspection

Check valve spring for visible damages. If so,
replace valve spring.
Check valve spring for free length and
straightness. Replace valves springs if not
within specifications.

A. Valve spring length

Valve spring free length

Nominal New 40.5 mm

Service limit 39.00 mm

Valve Spring Installation

For installation, reverse the removal
procedure. Pay attention to the following
details.
Colored area of the valve spring must be
placed on top.
To ease installation of cotters, apply oil or
grease on them so that they remain in place
while releasing the spring.
NOTE: Valve cotter must be properly
engaged in valve stem grooves.

1. Position of the spring

2. Valve cotter
After spring is installed, ensure it is properly
locked by tapping on valve stem end with a
soft hammer so that valve opens and closes a
few times.
CAUTION: An improperly locked valve
spring will cause engine damage

VALVE
VALVE Removal
Remove valve spring, see VALVE SPRING
above.
Push valve stem, then pull valves (intake and
exhaust) out of valve guide.

1. Intake valves 31mm

2. Exhaust valve 27mm
Remove valve stem seal with Snap-On pliers
and discard it.

Valve Inspection
Valve Stem seal
Always install new seals whenever valves are
removed.
Valve
Inspect valve surface, check for abnormal stem wear Valve out of round(intake and exhaust valves)
and bending .If out of specification, replace by a new New 0.006 mm
one. Service limit 0.06 mm

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 3.ENGINE

Valve Stem and Valve Guide Clearance

Measure valve stem and valve guide in three
places using a micrometer and a small bore
gauge.
NOTE: Clean valve guide to remove carbon
deposits before measuring.
Change valve if valve stem is out of
specification or has other damages such as
wear or friction surface.

A. Valve steam diameter

Valve stem diameter

Exhaust valve
New 4.945 to 4.965 mm
Service limit 4.930 mm
Intake valve
New 4.960 to 4.975 mm
Service limit 4.930 mm

Replace valve guide out of cylinder head if valve guide

Valve guide diameter(intake and exhaust valves)
or out of specification or has other damages such as
New 5.006 to 5.015 mm
wear or friction surface (see VALVE GUIDE
Service limit 5.050 mm
PROCEDURE below)

Valve Face and Seat

1. Valve seat
2. Exhaust valve contaminated
3. Valve face (contact surface to valve seat)
Check valve face and seat for burning or
pitting. and replace valve or cylinder head if
there are signs of damage.
Ensure to seat valve properly. Apply some
lapping compound to valve face and work
valve on its seat with a lapping tool (see
VALVE GUIDE PROCEDURE below).
Measure valve face contact width.
Valve seat contact width
NOTE: The location of contact area should Exhaust valve
be in center of valve seat. New 1.25 to 1.55 mm
Measure valve seat width using a caliper. Service limit 2.00 mm
If valve seat contact width is too wide or has Intake valve
dark spots, replace the cylinder head New 1.05 to 1.35 mm
Service limit 1.80 mm

A. Valve face contact width

B. Valve seat contact width

Valve installation
For installation, reverse the removal
procedure. Pay attention to the following
details.
Install a NEW valve stem seal. Make sure
thrust washer is installed before installing
seal.
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 3.ENGINE

Apply engine oil on valve stem and install it.

CAUTION: Be careful when valve stem is
passed through sealing lips of valve stem seal.

1. Thrust washer
2. sealing lips of valve stem seal.

To ease installation of cotters, apply oil or

grease on them so that they remain in place
while releasing the spring.
After spring is installed, ensure it is properly
locked by tapping on valve stem end with a
soft hammer so that valve opens and closes a
few times.
CAUTION: An improperly locked valve spring will cause engine damage.

VALVE GUIDE
Valve Guide Removal
Remove:
cylinder head (see CYLINDER HEAD
above)
valve spring (see VALVE SPRING
above)
valves (see VALVE above)
NOTE: Clean valve guide area from
contamination before removal.
Using valve guide remover, remove valve
guide with a hammer.

1. Valve guide remover

2. Valve guide

Valve Guide Inspection

Always replace valve stem seals whenever
valve guides are removed.
Clean the valve guide bore before reinstalling
the valve guide into cylinder head.
Valve Guide Installation
For installation, reverse the removal
procedure. Pay attention to the following
details.
Use vale guide installer to install valve guide.

NOTE: Apply LOCTITE 767 on valve guide

prior to install it into the cylinder head.
Valve guide to be adjusted in diameter by using a
reamer. Valve guide diameter
(intake and exhaust valves)
new 5.006 to 5.015 mm
NOTE: Ensure to turn reamer in the right direction. Service limit 5.050mm
Using cutting oil and make brakes to clean
reamer/valve guide from metal shavings .
Apply some lapping compound to valve face
and work valve on its seat with a lapping tool.

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 3.ENGINE

1. Valve seat
2. Valve face (contact surface to valve seat)
3. Turn valve while pushing against
cylinder head
A. Valve seat angle 45°。

NOTE: Ensure to seat valves properly. Apply

marking paste to ease checking contact patter.
Repeat procedure until valve seat/valve face
fits together.

CYLINDER
Cylinder removal
Remove:
Chain tensioner (see CHAIN
TENSIONER)
camshaft timing gear (see CAMSHAFT
TIMING GEAR)
cylinder head (see CYLINDER HEAD)

Pull cylinder.
Discard cylinder base gaskets.

1. Cylinder
2. Piston assembly
3. Cylinder base gasket
4. Camshaft timing chain
Cylinder Inspection
Check cylinder for cracks, scoring and wear,
ridge on the top and bottom of the cylinder. If
so, replace cylinder.
Cylinder taper
Measure cylinder bore and if it is out of
specifications, replace cylinder and piston
rings.
Measure cylinder bore at 3 recommended
positions. See the following illustration.

1. First measuring of diameter

2. Second measuring of diameter
3. Third measuring of diameter Cylinder taper in diameter
A. 7mm from cylinder bottom New (maximum) 0.033-0.048 mm
B. 68mm
Service limit 0.090 mm
C. 32mm
Distance between measurements should not exceed the service limit mentioned above

Cylinder out of Round

Measure cylinder diameter in piston axis
direction from top of cylinder. Take another
measurement 90 °from first one and compare.
NOTE: Take the same measuring points like
described in CYLINDER TAPER above.
A. Perpendicular to crankshaft axis
B. Parallel to crankshaft axis
Cylinder out of round
New (maximum) 0.003 mm
Service limit 0.020 mm

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 3.ENGINE

Cylinder Installation
For installation, reverse the removal
procedure. Pay attention to the following
details.
CAUTION: Always replace cylinder base
gasket before installing the cylinder.
First mount cylinder 2. then remove
crankshaft locking bolt. Crank the engine
further and position piston 1 at TDC. Mount
cylinder 1. The cylinder can not be pushed
fully over the piston unless the piston is
located at TDC.
Apply engine oil in the bottom area of
cylinder bore and also on the band of the
piston ring compressor tool.

1. Piston ring compressor

2. Piston
3. Cylinder

NOTE: Put timing chain through the chain

pit then put the cylinder in place.
CAUTION: Chain guide has to be fixed
between cylinder and cylinder head.
NOTE: After both cylinders are installed, turn
crankshaft until piston of cylinder 2 is at TDC
ignition and lock crankshaft. Install cylinder
head and the other parts in accordance with the
proper installation procedures.

PISTON AND RINGS

Piston removal
Remove:
cylinder head (see CYLINDER HEAD
above)
cylinder (see CYLINDER above).
Place a rag under piston and in the area of
timing chain compartment.

Remove one piston circlip and discard it.

NOTE: The removal of both piston circlips is

not necessary to remove piston pin.

Push piston pin out of piston.

1. Piston
2. Piston Pin
Detach piston from connecting rod.

Piston Inspection
Inspect piston for scoring, cracking or other
damages. Replace piston and piston rings if
necessary.
Using a micrometer, measure piston at 8 mm
perpendicularly (90°) to piston pin.

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 3.ENGINE

1. Measuring perpendicularly to piston pin

A. 8 mm
The measured dimension should be as described
in the following tables. If not, replace piston.
Piston measurement
Size “A”
New 90.955 to 90.962mm
Service limit 90.930mm
Size “B”
New 90.962 to 90.970 mm
Service limit 90.940mm

Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston
dimension .

1.Micrometer set to the piston dimension

With the micrometer set to the dimension,

adjust a cylinder bore gauge to the
micrometer dimension and set the indicator to
0 (zero).

1. Use the micrometer to set the cylinder

bore gauge
2. Dial bore gauge

1. Indicator set to 0
Position the dial bore gauge 20 mm above
cylinder base, measuring perpendicularly (90°)
to piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder
wall clearance.
Piston/cylinder clearance
v-800
New 0.033 to 0.048 mm
Service limit 0.09 mm
NOTE: Make sure used piston is not worn.
If clearance exceeds specified tolerance; replace piston
by a new one and measure piston/cylinder clearance
again. Make sure the cylinder bore gauge indicator
is set exactly at the same position as the micrometer,
otherwise the reading will be false.

Connecting Rod/Piston Pin clearance

Using synthetic abrasive woven clean piston pin from deposits.
Inspect piston pin for scoring, cracking or other damages.
Measure piston pin. See the following illustration for the proper measurement positions.

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 3.ENGINE

A. Piston pin diameter

Piston pin diameter
New 19.996 to 20.000 mm
Service limit 19.980 mm

Replace piston pin if diameter is out of

specifications.

Measure inside diameter of connecting rod

small end bushing .

1. Bore gauge

2. Connecting rod

Connecting rod small end diameter

New 20.010 to 20.020 mm
Service limit 20.060 mm

Replace connecting rod if diameter of connecting rod small

end is out of specifications.

Piston Installation

For installation, reverse the removal

procedure. Pay attention to the following
details.

Apply engine oil on the piston pin.

Insert piston pin into piston and connecting
rod.

1. Piston of cylinder 1

2. Mark on piston must show to exhaust side

of cylinder1

3. Piston of cylinder2

4. Mark on piston must show to exhaust side of cylinder 2

CAUTION: Take care that pistons will be

installed with the punched arrow on piston
top direction to the rear side of the engine.
Front cylinder: Mark on top of piston must
show to intake side.
Rear cylinder: Mark on top of piston must
show to exhaust side.

1. Piston of cylinder 1
2. Mark on piston must show to intake side of
cylinder 1
3. Piston of cylinder 2
4. Mark on piston must show to exhaust
side of cylinder 2

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 3.ENGINE

CAUTION: Always replace disassembled

piston circlip(s) by new ones. Place a rag on
cylinder base to avoid dropping the circlip
inside the engine.

NOTE: Take care that the hook of the piston

circlip is positioned properly.

PISTON RINGS
Ring Removal
Remove:
cylinder head
cylinder
piston pin.

Ring Inspection
Ring/piston Groove Clearance
1. Piston
2. Feeler gauge

Using a feeler gauge measure each ring/piston groove

clearance. If the clearance is too large, the piston and
the piston rings should be replaced.

Ring/piston groove clearance Ring end gap

Upper compression ring Upper compression ring
New 0.030 to 0.070 mm New 0.25 to 0.40 mm
Service limit 0.150 mm Service limit 1.50 mm
Lower compression ring Lower compression ring
New 0.020 to 0.060 mm New 0.35 to 0.50 mm
Service limit 0.150 mm Service limit 1.50 mm
Oil scraper ring Oil scraper ring
New 0.010 to 0.045 mm New 0.20 to 0.80 mm
Service limit 0.150 mm Service limit 1.50 mm

To measure the ring end gap place the ring in the cylinder in the area of 8 to 16 mm from top of
cylinder.
NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher.
Using a feeler gauge, check ring end gap. Replace ring if gap exceeds above described specified
tolerance.

Ring Installation
For installation, reverse the removal
procedure. Pay attention to the following
details.
NOTE: First install spring and then rings of
oil scraper ring. Install the oil scraper ring
first, then the lower compression ring with the
word “N and TOP” facing up, then the upper
compression ring with the word “N and TOP”
facing up.

1. Upper compression ring

2. Lower compression ring
3. Oil scraper
3-20
 3.ENGINE

CAUTION: Ensure that top and second rings are not interchanged.
NOTE: Use a ring expander to prevent breakage
during installation. The oil ring must be installed by
hand.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120 apart and do not
align the gaps with the piston pin bore or the thrust side
axis.

1. DO NOT align gap with piston thrust side axis

2. DO NOT align ring with piston pin bore axis
A. 120°.

DRIVE SHAFT
Oil Seal Removal
To remove the front oil seal , no need to remove the engine. Lift the front of vehicle to avoid engine oil
spillage. Separate the front propeller shaft from engine.
For the rear oil seal the gearbox removal is necessary.

Engine Drive Shaft Removal

NOTE: The engine drive shaft is located
inside the engine and comes through it to
drive the front differential.
Separate gearbox from engine.
To the rear of engine, remove the bearing
cover and its O-ring.

1. bearing cover
2. o-ring

Pull out drive shaft.

CAUTION: check ends of the circlip for sharp edges or
burr before removing the drive shaft, to avoid damaging
the oil seal.

1. bearing cover gearbox side

2. drive shaft
3. circlip

Remove the other bearing cover at the front of engine

Engine Drive Shaft Inspection

Replace oil seals and/or O-ring if they are brittle, hard or damaged.
Check drive shaft bearings for contamination and/or metal shavings. Check if bearings turn freely and
smoothly. Replace if necessary.
Check drive shaft for cracks, bend, pitting or other visible damages.
Check drive shaft splines for wear or damages.
Check oil seal running surface of the drive shaft for scratches. Replace if necessary.

3-21
 3.ENGINE

Engine Drive Shaft Installation

The installation is reverse of removal procedure. Pay attention to the following details.
Clean all metal components in a solvent.
Crankcase surface and bearing covers are best cleaned using a combination of LOCTITE chisel and a
brass brush. Brush a first pass in one direction then make the final brushing perpendicularly (90°) to
the first pass cross (hatch).

CAUTION: Do not wipe with rags. Use a

new clean hand towel only.
Then install drive shaft oils with the oil seal
installer.
Use a suitable installer for installing bearings.
Use LOCTITE 5910 on mating surfaces.
IMPORTANT: When beginning the
application of the bearing cover sealant, the
assembly and the first torquing should be
done within 10 minutes. It is suggested to
have you need on hand to save time.
Use a plexiglass plate and apply some sealant
on it. Use a soft rubber roller (50-75 mm)
available in arts products suppliers for
printing, and roll the sealant to get a thin
uniform coat on the plate (spread as
necessary). When ready, apply the sealant on
bearing cover surfaces.
Do not apply in excess as it will spread out
inside crankcase.
NOTE: It is recommended to apply this
specific sealant as described here to get a
uniform application without lumps. If you do
not use the roller method, you may use your
finger to uniformly distribute the sealant
(using a finger will not affect the adhesion.
To install bearing cover no. 6, fit oil seal
protection sleeve into oil seal.
1. Protection sleeve
2. Bearing cover
3. O-ring
4. Drive shaft
Install bearing cover then place O-ring inside
cover.
Finally check for axial play of the drive shaft

PTO COVER
Cover Removal
Remove
CVT and air guide. Refer to TRANSMISSION
Disconnect vent hose
PTO cover screws and pull PTO cover.

1. PTO cover
2. PTO cover screws
3. vent hose nipple

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 3.ENGINE

Cover Inspection
Check the PTO cover for cracks or other
damage.
Replace PTO cover if damaged.
Clean oil breather bore in PTO cover from
contaminations with part cleaner then use an
air gun to dry it.

1. oil breather bore

Check oil seal running surface of crankshaft

PTO side for grooves. Replace if necessary.

Oil Seal Installation

The installation is the reverse of the removal
procedure.
Pay attention to the following details.
CAUTION: Oil seal must be installed with
sealing lip toward the engine.
Push oil seal in place by using the oil seal installer

1. PTO cover
2. oil seal
3. oil seal installer

Check plain bearings for scorings or other damages.

NOTE: Measure plain bearing inside
diameter and compare to crankshaft journal
diameter (PTO support bearing). Refer to
CRANKSHAFT in this section. Replace if the
measurement is out of specification.

1. plain bearing
2. oil bore
A. measure plain bearing inside diameter

Plain bearing inside diameter

(PTO side support bearing)
Service limit 34.080 mm

Plain Bearing Replacement Procedure

Plain Bearing Removal
Carefully remove the oil seal no. 9 with a
screwdriver, without damaging the PTO cover.
Push-out the plain bearings from the outside
towards the inside using the plain bearing
remover/installer.

The PTO cover has to be supported from below

with suitable support with straight surface, in
order to prevent damage of the sealing surface.
1. PTO cover
2. plain bearing remover/installer

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 3.ENGINE

Plain Bearing Installation

CAUTION: Unless otherwise instructed, never use hammer to install plain bearings. Use press only.
Install plain bearings with the proper plain bearing remover/installer in a cool PTO cover. Do not lubricate plain
bearings and/or PTO cover for installation.
Carefully press-in the plain bearings in the same direction as during disassembly, from the outside towards the
inside. Support PTO cover with suitable support with straight surface, in order to prevent damage of the sealing
surface.
CAUTION: Mark position of oil bore on PTO cover and on plain bearing remover/installer. Align mark on plain
bearing remover/installer with mark on PTO cover.

1.mark position of oil bore on PTO cover

2.mark position of oil bore on plain bearing remover/installer

NOTE: Wrong oil bore position will stop oil

supply to plain bearings and will damage the
engine.
CAUTION: The partition of the plain
bearings must be positioned near to oil bore
in counterclockwise direction (refer to no.3 in
next illustration).

1. PTO cover (inside)

2. partition
3. oil bore

Cover Installation
For installation, reverse the removal
procedure.
Pay attention to the following details.
NOTE: At installation, replace PTO cover
gasket and oil seal.
Tightening sequence for screws on PTO cover
is as per following illustration.

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 3.ENGINE

DRIVE GEARS
The drive gears are located on the engine
PTO side behind the PTO cover.

1. intermediate gear
2. oil pump gear
3. water pump gear
4. breather gear

Drive Gear Removal

Remove:
PTO cover (refer to PTO COVER )
Intermediate gear
Oil pump gear
Water pump gear

To remove water pump gear, pull the shaft

assembly a bit out and turn it about one
teeth until it stays out.
Now you can push water pump gear down.
Remove needle pin and pull water pump gear
out.
Remove breathe gear.

Drive Gear Inspection

Intermediate Gear/Oil Pump Gear/Water
Pump Gear.
Inspect gears for wear or other damage.
Replace if damaged.

Breather Gear
The engine is equipped with a breather gear
which prevents engine oil coming out through
the breathing system into the air box.

1. breather gear
2. V-ring

Inspect gear for wear or other damage.

Check ball bearing for excessive play and smooth operation. Replace breather gear assembly if necessary.

Drive Gear Installation

The installation is essential the reverse of the removal procedure, but pay attention to the following details.
NOTE: At installation replace the V-ring no. 16 of the breather gear.
Adequately oil the ball bearing of the breather gear.

TIMING CHAIN
The engine is equipped with two timing chains. One of the timing chain is located on engine MAG side behind
the magnet cover. The second timing chain is located on engine PTO side behind the PTO cover.
Removal of Magneto Side Timing Chain
Remove:

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 3.ENGINE

valve cover, chain tensioner and

camshaft timing gear (refer to CYLINDER
AND HEAD)
magneto cover and rotor (refer to
MAGNETO SYSTEM)
timing chain guide and lower timing
chain guide.

1. Timing chain
2. Timing chain guide
3. Lower timing chain guide
Carefully pull the timing chain sideward and
down from the crankcase.
NOTE: Mark the operating direction of the
timing chain before removal.

Removal of PTO Side Timing Chain

Remove:
valve cover, chain tensioner and camshaft timing gear (refer to CYLINDER AND HEAD section)
PTO cover (refer to PTO COVER)
Intermediate gear and breather gear (refer to DRIVE GEARS)
Timing chain guide and lower timing chain guide (see illustration above).
Carefully pull the timing chain sideward and down from the crankcase.
NOTE: Mark the operating direction of the timing chain before removal.

Timing Chain Inspection

Inspection is the same for both timing chains.

NOTE: Check timing chain on camshaft

timing gear for excessive radial play.
Check chain condition for wear and teeth
condition.
If chain is excessively worn or damaged,
replace it as a set (camshaft timing gear and
timing chain).

Timing Chain Installation

Installation is the same for both timing chains.
The installation is essential the reverse of the removal procedure, but pay attention to the following details.
NOTE: Ensure to perform proper valve timing. Lock crankshaft (see CRANKSHAFT) and camshaft at TDC
ignition (refer to CYLINDER AND HEAD section).
Install timing chain with camshaft timing gear then, adjust chain tension (refer to CYLINDER AND HEAD
section).
CAUTION: Improper valve timing will damage engine components.

CRANKCASE
Crankcase Disassembly
Remove:
 drive shaft (refer to ENGINE DRIVE SHAFT)
 PTO cover (refer to PTO COVER)
 Drive gears (refer to DRIVE GEARS)
NOTE: Oil pump removal from crankcase is
not necessary, but recommended to see
condition of oil pump (refer to
LUBRICATION SYSTEM section).
electric starter

1. electric starter
2. screw

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 3.ENGINE

magneto cover and rotor (refer to

MAGNETO SYSTEM section)
electric starter drive gears (refer to
MAGNETO SYSTEM section)
water pump housing (refer to COOLING
SYSTEM section)
oil filter (refer to LUBRICATION
SYSTEM section)
cylinder head and cylinder (refer to
CYLINDER AND CYLINDER HEAD
section)
timing chains and timing chain guides
(refer to TIMING CHAIN and TIMING
CHAIN GUIDE).
Remove retaining screws of crankcase.

1. 4 screws M8 x 65
2. 12 screws M6 x 75
3. 1 screw M6 x 35

Carefully split crankcase halves by using a

screw driver and a soft hammer.

NOTE: During disassembly, do not damage

the sealing surfaces of the crankcase halves.
Pull crankshaft out of crankcase.
Remove the water pump intermediate shaft
and the water pump gear.

1. water pump intermediate shaft

2. water pump gear

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 3.ENGINE

Remove engine oil strainer.

1. engine oil strainer

2. retaining plate
3. screws

Crankcase Inspection
NOTE: Remove all remaining parts from the
crankcase halves; they could get damaged
during repair work.
Clean crankcase halves from contaminations
and blow the oil supply lines with
compressed air.
Check crankcase halves for cracks or other
damage. Replace if damaged.
Check plain bearings no. 17 and no.18 for
scorings or other damages.
NOTE: Measure plain bearing inside
diameter and compare to PTO/MAG side
journal diameters of crankshaft (refer to
CRANKSHAFT ). Replace if the
measurements are out of specification.

1. plain bearing
2. oil bore
A. measure plain bearing inside diameter
plain bearing inside diameter
service limit 42.070 mm

Plain Bearing Replacement

Plain bearing Removal

CAUTION: Always support crankcase halves

properly when ball bearing or plain bearings
are removed. Damages to crankcase halves
may occur if this procedure is not performed
correctly.

NOTE: Always use a press for removal of

plain bearings.
Remove plain bearings with the proper plain
bearing remover/installer.
Carefully push the plain bearings out, from the
crankcase half inside towards the outside.

NOTE: Place the proper crankcase support

sleeve under crankcase halves before
removing plain bearings. During disassembly,
make sure not to damage the surfaces of the
crankcase halves.

1.Crankcase half
2.Plain bear remover/installer
3.Crankcase support sleeve

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 3.ENGINE

Plain Bearing Installation

CAUTION: Unless otherwise, instructed,
never use hammer to install ball bearings or
plain bearings. Use press only.
Install plain bearings with the proper plain
bearing remover/installer in a cool crankcase.
Do not lubricate plain bearings and/or
crankcase for installation.
NOTE: Place the proper crankcase support
sleeve under crankcase halves before
installing the plain bearings.
Carefully press-in the plain bearings in the
same direction as during disassembly, from
the crankcase inside toward the outside.
During reassembly, make sure not to damage
the sealing surface of the crankcase halves.
CAUTION: Mark position of oil bore on
crankcase half and on plain bearing
remover/installer. Align mark on plain
bearing remover/installer with mark on
crankcase half.

1. oil bore position marked on crankcase

2. oil bore position marked on plain bearing
remover/installer

NOTE: Wrong oil bore position will stop oil

supply to plain bearings and will cause engine
damage.
CAUTION: the partition of the plain bearings
in crankcase half MAG side must be positioned
near to oil bore in clockwise direction (refer to
no. 3 in next illustration).

CAUTION: The partition of the plain bearings in crankcase half PTO side must be positioned near to oil bore in
counterclockwise direction (refer to no. 3 in next illustration).

1. crankcase half PTO (inside)

2. oil bore
3. partition

NOTE: Use an O-ring (φ42x1 or 1.5 mm thickness) to hold plain bearings in place during installation. The
O-ring will disappear in the groove, of the plain bearing remover/installer.

Crankcase Assembly
The assembly of crankcase is essentially the reverse of removal procedure. However, pay attention to the
following details.

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 3.ENGINE

NOTE: Clean oil passages and make sure

they are not clogged.
Clean all metal components in a solvent.
At installation, replace crankcase gasket.
Oil the plain bearings before mounting the
crankshaft.

CAUTION: Correctly reinstall crankshaft

(refer to CRANKSHAFT).
Reinstall engine oil strainer.
Reinstall water pump shaft shafts /gears.
Tightening sequence for screws on crankcase
is as per following illustration.

CRANKSHAFT
Crankshaft Removal
Refer to CRANCASE.
Crankshaft Inspection
NOTE: Check each bearing journal of
crankshaft for scoring, scuffing, cracks or
other signs of wear.
NOTE: Replace crankshaft if the gears are
worn or otherwise damaged.
CAUTION: Components with less than the
service limit always have to be replaced. If
this is not observed, severe damage may be
caused to the engine.

1. Crankshaft timing gears

Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between
butting face of connecting rods and crankshaft
counterweight. If the distance exceeds specified
tolerance, replace the crankshaft.

1. Crankshaft
2. Connecting rods
3. Feeler gauge

Connecting rod big end axial play

New 0.200 to 0.500 mm
Service limit 0.6 mm

Connecting Rod/Piston Pin Clearance

NOTE: Prior to remove connecting rod from crankshaft, mark big end halves together to ensure a correct
reinstallation (cracked surface fits in only one position).

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 3.ENGINE

Remove connecting rods from crankshaft.

CAUTION: Always replace connecting rod
screws no. 19 if removing the connecting rod.
It is recommended to replace plain
bearings no. 20, in case of installing the
connecting rod.

1. Connecting rod screws.

Measure crankpin Compare to inside

diameter of connecting rod big end.

1. Micrometer
2. Crankpin area for plain bearing

To measure the rod big end diameter, use the

OLD screws .
Install the OLD plain bearings as they were
mounted initially.
Do the torque procedure as described further.
Crankshaft pin diameter
new 40.009 to 40.025 mm
Service limit 39.990 mm
Connecting rod big end diameter
Service limit 40.100 mm
Connecting rod big end radial clearance
Service limit 0.09 mm

Crankshaft Radial Play MAG/PTO Side

Measure crankshaft on MAG/PTO side.
Compare to inside diameter of MAG/PTO
plain bearing (refer to CRANKCASE).

1. Micrometer
2. Crankshaft area for MAG plain bearing

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 3.ENGINE

1. Micrometer
2. Crankshaft area for PTO plain bearing

Crankshaft main journal diameter

New 42.024 to 42.040 mm
Service limit 42.000 mm
Crankshaft deflection
Service limit 0.07mm
Crankshaft radial clearance
Service limit 0.06 mm

Crankshaft Radial Play

(PTO side support bearing)
Measure crankshaft journal of PTO support
bearing. Compare to inside diameter of PTO
support bearing in PTO cover (refer to PTO
COVER).

Crankshaft pin journal diameter ( PTO

support bearing )
new 34.024 to 34.040 mm
Service limit 34.010mm

Crankshaft PTO support bearing radial clearance

Service limit 0.01 mm

Crankshaft Assembly
For assembly, reverse the disassembly procedure.
Pay attention to following details.
NOTE: Use NEW plain bearings no. 20, when
connecting rod big end diameter is out of specification.
Put plain bearings correctly in place and clean the split
surface on both sides (cracked area) carefully with
compressed air.

1. Haif plain bearing of connecting rod big end

2. Split surface of the connecting rod
3. Nose of plain bearing in line with connecting rod groove

NOTE: Oil the plain bearing surface of the connecting rod and crank pin before installation.
Torque NEW connecting rod screws as per following procedure:
First, install screws with half of the recommended torque. Do not apply any thread locker.
Secondly, torque connecting rod screws to 20 N.m.

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 3.ENGINE
Finish tightening the screws with an additional 60°turn using an angle torque wrench.
CAUTION: failure to strictly follow this procedure may cause screw to loosen and lead to engine damage. The
plain bearing tapered end must be against the counterweight. Besides, as the “crankpin” has been stretched from
the previous installation, it is very important to use a new screw at assembly.
The running direction of big end bearings and of the piston pins must not change.

Crankshaft Installation
For installation of crankshaft in crankcase reverse the removal procedure. Pay attention to the following details.
CAUTION: Observe the correct installation position when fitting the crankshaft with the connecting rods. The
connecting rod MAG side has to face to cylinder 1.

OIL PRESSURE REGULATOR

The oil pressure regulator is located the engine
magneto side ( inside magneto cover).

1. Engine pressure regulator

NOTE: The oil pressure regulator system works when

the oil pressure exceeds 450kPa (65ps).

Removal
Remove plug screw and pull oil pressure regulator out.

1.Plug screw
2.Gasket ring
3.Pressure regulator housing
4.Spring
5.Pressure regulator valve

Inspection
Inspect pressure regulator hosing and valve for
scoring or other damages.
Check spring for free length. SPRING FREE LENGTH
New nominal 39 mm(1.535 in)
NOTE: Replace worn or damaged components. Service limit 37 mm(1.457in)
Clean bore and thread in the magneto housing from metal shavings and other contaminations.

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: At installation, always replace the gasket ring no. 3 of the plug screw.

OIL PUMP
The oil pump is located on the engine PTO side
(behind cover).

1. Oil pump

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 3.ENGINE

Removal
Remove parts to access the engine crankcase PTO
cover.
Remove the engine crankcase PTO cover. .
Remove:
retaining ring
oil pump gear
needle pin
thrust washer
oil pump cover screws and pull oil pump cover
oil pump shaft with inner rotor and outer rotor.

1.Retaining ring
2.Oil pupm gear
3.Needle pin
4.Thrust washer

1.Retaining screws
2.Oil pump cover

Inspection
Inspect oil pump for marks or other damages.
Check for scratches in crankcase between outer rotor
and oil pump bore. If so, replace damaged parts.

1. Oil pump bore

2. outer rotor
3. Oil pump shaft
4. Needle pin
5. Inner rotor

Check inner rotor for corrosion

pin holes or other damages. If so, replace oil pump
shaft assembly.

1. Pitting on the teeth

Using a feeler gauge, measure the clearance of inner

and outer rotors as shown.

1. Outer rotor
2. inner rotor
A. SERVICE LIMIT:0.25mm(0.09in)

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 3.ENGINE

If clearance of inner and outer rotors exceeds the tolerance, replace oil pump shaft assembly. Ensure to also check
oil pump cover. If damaged, replace the complete oil pump assembly.
If clearance between outer rotor and its bore in crankcase exceeds the tolerance, replace the complete oil pump
assembly and/ or the crankcase.

Using a depth gauge, measure the axial clearance of

the oil pump as shown..

Oil PUMP-MEASUREMENT “A”

Oil PUMP COVER - MEASUREMENT “B”

Difference between measurements should not exceed

0.2 mm. if so, replace the complete oil pump
assembly.
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure decreases.

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: The outer rotor and inner rotor are marked.
When installing, make sure both markings are on the
upper side.

1.Markings

After reinstallation of the remaining parts, check for

smooth operation of the oil pump assembly.
Final Test
After engine is completely reassembled, start engine and
make sure oil pressure is within specifications .

MAGNETO COVER

Magneto Cover Removal

Lock crankshaft at TDC.
Drain engine oil.
Disconnect crankshaft position sensor (CPS) connector
and cut tie rap.
Remove magneto cover retaining screws.

1. magneto cover
2. retaining screws
3. crankshaft position sensor
Pull magneto cover.

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 3.ENGINE

Magneto Cover Inspection and Cleaning

Check magneto cover for cracks or other damage. Replace if necessary.

Magneto Cover Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
NOTE: At installation replace magneto cover gasket.
Apply Drei Bond sealing compound on stator cable
grommet as shown in the illustration.

1. Apply drei bond sealing compound

Tightening sequence for screws on magneto cover is

as per following illustration.

STATOR
Stator Removal
Remove magneto cover.
Remove screws securing holding strip.
Remove stator retaining screws then the stator.

1. Stator
2. Stator retaining screws
3. holding strip
4. holding strip screws

Stator Inspection
Check stator condition. If damaged replace it.
Check if stator wires are brittle, bard or otherwise damaged.
For electrical inspection, refer to CHARGING SYSTEM.

Stator Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
CAUTION: When installing the stator take care that
the cable is in place (guide for wire).
NOTE: There is only one position for the stator (notch
in the magneto housing cover).

1. Threads for cable holding strip

2. Notch for stator

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 3.ENGINE

ROTOR
Rotor Removal
Lock crankshaft with crankshaft locking bolt.
Remove magneto cover. Refer to MAGNETO COVER
above.
Remove screw and washer securing rotor to
crankshaft.

1. Screw M16
2. Washer
3. Rotor

Install magneto puller and crankshaft then remove

rotor.
NOTE: Use grease to place protector on crankshaft
end prior to screw on the magneto puller.

1. Rotor
2. Magneto puller

Screw magneto puller bolt to remove rotor.

Rotor Inspection
Check inner side of rotor for scratches or other
damage.
Check keyway of the rotor for wear or damages.
Check if trigger wheel teeth are bent or otherwise
damaged.

1. Rotor with trigger wheel

Check woodruff and keyway on the crankshaft for

wear or damages.
Replace parts as necessary.

Rotor Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
Clean crankshaft taper and rotor with pulley flange
cleaner.
CAUTION: Taper on crankshaft and rotor must be free
of grease.
Oil sprag clutch in sprag clutch housing and install
sprag clutch gear.

1. Sprag clutch
2. Sprag clutch housing
3. Sprag clutch gear
4. Apply engine oil here

Slide rotor onto crankshaft. The woodruff key and the keyway must be aligned.

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 3.ENGINE

Rotate starter double gear counterclockwise to align

intermediate gear teeth with sprag clutch gear.

1. Starter double gear

2. Sprag clutch gear
3. intermediate gear

SPRAG CLUTCH
Sprag Clutch Removal
Remove magneto cover
Loosen sprag clutch housing screws located inside
rotor.
Remove rotor (refer to ROTOR above)
Remove sprag clutch gear.
Remove sprag clutch housing screws and sprag clutch
housing.

1. Sprag clutch housing screws

2. Rotor
3. Sprag clutch
4. Sprag clutch housing

Sprag Clutch Inspection

Inspect sprag clutch and sprag clutch housing for wear
and damage.
Also check the collar of the sprag clutch gear.
Perform a functional test of the sprag clutch. To do so,
rotate sprag clutch gear in sprag clutch.
NOTE: Sprag clutch must lock in counterclockwise
direction.

1. Lock

NOTE: Sprag clutch, housing and gear must be

replaced at the same time, if damaged.
Sprag Clutch Installation
For installation, reverse the removal procedure. Pay
attention to the following details.
Apply LOCTITE 648 (green) on threads of sprag
clutch housing screws.
Install screw but do not torque yet.
Apply engine oil on sprag clutch and inside sprag
clutch gear hole.

1. Sprag clutch
2. sprag clutch housing

Install rotor then torque sprag clutch housing screws to 30 N.m.

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 3.ENGINE

SPRAG CLUTCH GEAR

Sprag Clutch Gear removal
Remove rotor .
Pull sprag clutch gear from rotor.

1. Rotor
2. Sprag clutch gear

Sprag Clutch Gear Inspection

Inspect gear, especially teeth and sprag clutch collar,
for wear and other damage.
Check needle bearing condition. Replace sprag clutch
gear if necessary.

INSPECT
1. Teeth
2. Collar
3. Needle bearing

Sprag Clutch Gear Installation

The installation is the reverse of the removal procedure.
NOTE: Apply engine oil on needle bearing and collar
of sprag clutch gear.

TRANSMISSION

Never touch CVT while engine is running.

never drive vehicle when variator cover is removed.
Subcomponent installation and assembly tolerances require strict adherence to procedures detailed.
Never use any type of impact wrench at drive pulley removal and installation.
The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch assembly
These pulleys have metric threads. Do not SAE threads puller. Always tighten puller by hand to ensure that the
drive pulley has the same type of threads prior to fully tightening.

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 3.ENGINE

DRIVE BELT
Removal
Remove:
 Distance screws
 remove variator cover and gasket.

1. Variator cover
2. Distance screw
3. Gasket

NOTE:
Remove the center top screw last. This screw allows to
support the cover during removal.
Open driven pulley with the driven pulley expander.

Screw tool in the threaded hole of driven pulley and

tighten to open the pulley.

1. Driven pulley expander

2. Fixed sheave of driven pulley

To remove belt, slip the belt over the edge of fixed sheave
as shown.

INSPECTION
Inspect belt for cracks, fraying or abnormal wear.
Replace if necessary.
Drive belt width
Service limit 30.00mm(1.181 in)

Installation
For installation, reverse the removal procedure. Pay
attention to following details.

1. Word printed on belt

2. Drive pulley (front)
3. Driven pulley (rear)
4. Rotation direction
The maximum drive belt life span is obtained when the
drive belt has the proper rotation direction. Install it so
that the arrow printed on belt is pointing towards front of

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 3.ENGINE
the vehicle, viewed from top.

Install variator cover gasket.

Install the center top screw in first.
Tighten the distance screw as per following sequence.

DRIVE PULLEY

1. Belt
2. Drive pulley
3. Driven pulley

Removal
 remove variator cover and gasket.
 Remove belt
Block the drive pulley as followed.

Block drive pulley with the pulley holding tool.

1. Pulley holding tool

2. Torque wrench

When the drive pulley is blocked, mark sliding sheave

and governor cup to ensure correct reinstallation.

Unscrew the drive pulley screw (right hand thread), then

remove it as well as the conical spring washer and thrust
washer.

1. Drive pulley
2. Thrust washer
3. Drive pulley screw

Inspection
Drive pulley should be inspected annually for wear or
damages.
Check drive pulley for cracks and sliding contact surface
for excessive wear. Replace it if necessary.
Check one-way clutch bearing for excessive play and smooth operation. Replace one-way clutch if necessary.

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 3.ENGINE

Installation
For installation, reverse the removal procedure. Pay attention to the following details.
Do not apply any lubricant on crankshaft and drive pulley tapers.
Clean pulley faces and shaft with dry cloth.
Install drive pulley on crankshaft extension.
Do not forget to place thrust washer
Never substitute conical spring washer and/ or screw with jobber ones. Always use genuine parts for this
particular case.
Install thrust washer with its concave side towards drive pulley then install drive pulley screw.
To torque the drive pulley screw, block the drive pulley. Refer at the beginning of this section.
When the drive pulley is blocked, torque screw to 100N.m.

DRIVEN PULLEY
Removal
 remove variator cover and gasket.
 Remove belt

Using the pulley holding tool, hold the driven pulley

during the removal of the driven pulley screw, do not
remove screw completely.

Put in tow STUD to Driven Pulley

1. Driven Pulley holding tool

2. Torque wrench

When the driven pulley is blocked, unscrew the driven

pulley screw.

1. Driven pulley
2. Thrust washer
3. Driven pulley screw

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 3.ENGINE

Inspection
Driven pulley should be inspected annually for wear or damages.
Check sliding and fixed sheave for cracks and sliding contact surface for excessive wear. Replace sliding sheave
if necessary.
Check sliding sheave bushings for cracks, scratch and for free movement when assembled to sliding sheave.
Check ball bearing for free play and smooth operation. Replace if necessary.

Installation
For installation, reverse the removal procedure. Pay attention to the following details.
Chamfer on inside diameter of the spacer must face engine side.
Clean pulley faces and shaft with dry cloth.
Driven pulley is a spring loaded system.
Always place washer at the time of driven pulley installation.
When the driven pulley is blocked, torque screw to 60N.m.

CVT AIR GUIDE

Removal
Remove:
 Variator cover
 Drive belt
 Drive pulley
 Driven pulley

Unscrew the clamps retaining the CVT air hoses

Remove CVT air guide.

Inspection
Clean CVT air guide from contamination.
Check O-rings if brittle, hard or damaged. Replace if
necessary.

1. CVT air guide

2. O-rings

Installation
For installation, reverse the removal procedure.

GEARBOX

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 3.ENGINE

To remove gearbox, the engine removal is necessary. First remove drive and driven pulley and CVT air guide.
After unscrew the three (3) nuts attach the gearbox to the engine. Then pull gearbox to separate it from engine.
Always drain the gearbox oil before working on.

1.Right housing
2.Center housing
3.Left housing
4.Output shaft
5.Bearing cover
6.Countershaft
7.Shift shaft
8.Cover

GEARBOX OIL DRAIN

Prior to change the oil, ensure gearbox is on a level surface.
Place a drain pan under the gearbox drain plug area.
Clean drain plug area and remove magnetic drain plug with
its sealing ring to drain gearbox oil.
Remove oil filler screw including its o-ring.
CAUTION: Pay attention not to loose O-ring on drain plug
screw.
Wait a while to allow oil flow out of gearbox.

1. Magnetic drain plug

2. Sealing ring
3. Oil filler screw

Dispose gearbox oil as per your local environmental regulations.

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 3.ENGINE

Inspection
Oil condition gives information about the teeth condition inside the gearbox.
Clean the magnetic drain plug from metal shavings and dirt. Presence of debris gives an indication of failure
inside the gearbox. Check gearbox to correct problem.
Change gasket ring on the magnetic drain plug if damaged.
Replace o-ring if brittle, hard or otherwise damaged.

POSTION INDICATOR SWITCHES

NOTE: The gearbox removal is not necessary to reach the gearbox position indicator switches.

Removal
To reach the gearbox position indicator switches, remove the
rear engine cover.
Remove screw retaining indicator switch wire.

1. Gearbox position indicator switches

2. BROWN/ GREY wire
3. WHITE/ GREY wire
4. ORANGE/ GREY wire

Unscrew switch.

Test
Check if gearbox position indicator switches work properly
as per following procedure:
NOTE: Remove insulating paint to obtain correct readings.
Put gearbox in park, reverse, neutral, high and low position.
Corresponding switch wires
Use a multi meter to measure the resistance from the
Shifter
indicator switch to engine ground. Compare results with the Brown/ White/ Orange/gr
position
logic table below. grey grey ey
An “x” indicates switch is making ground contact, thus there
L x x
should be continuity (R is close to 0 ohms)
A blank space indicates switch is not making contact, there H x
should be no continuity (R = infinite). If the indicator switch N x x
is good, check the vehicle harness and /or indicator lights. R x
P x x

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Take care do not damage shifting indicator switched threads
during installation.
If all switches are removed, make sure to put the wires back
in the right location.

1. Gearbox position indicator switches

2. BROWN/ GREY wire
3. WHITE/ GREY wire
4. ORANGE/ GREY wire

Spray a layer of electrical insulating paint or varnish over switches to prevent shorts and corrosion.

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 3.ENGINE

OIL SEALS
Removal
Replace oil seals if they are brittle, hard or damaged.
A small flat screwdriver can be used to remove most of these
oil seals.
CAUTION: Avoid scoring housings, bearing cover, shift
shaft, distance sleeve of countershaft or output shaft during
oil seal removal.
Countershaft oil seal
The countershaft oil seal can be removed without removing
gearbox from vehicle. Remove drive and driven pulley and
CVT air guide.
NOTE: When oil seal is removed also inspect O-ring

1. Countershaft oil seal

2. Distance sleeve
Shift shaft oil seal
The shift shaft oil seal can be removed without removing the
gearbox from the vehicle.
Remove side panel and the shifting plate from shift shaft to
reach the oil seal.
Output shaft oil seal
Removal of output shaft oil seal requires that the rear
propeller shaft is separated from the output shaft. The
removal of the gearbox or bearing cover is not necessary.
NOTE: When oil seal is removed also inspect O-ring

1. Shift oil seal

2. Output shaft oil seal

Inspection
Check bearings behind each oil seal for contamination and / or metal shavings.
Check oil seal running surfaces for scratches. Replace if necessary.
Check if the countershaft O-ring and the output shaft O-ring are brittle, hard or damaged. Replace if necessary.

Installation
The installation is the reverse of removal procedure. Pay
attention to the following details.
Output shaft and countershaft oil seal
Install output shaft oil seal and countershaft oil seal with the
oil seal installer.
1. output shaft oil seal
2. oil seal installer

1. countershaft oil seal

2. oil seal installer

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 3.ENGINE

Shift shaft oil seal

Using a suitable tube with the proper diameter to install the
shift shaft oil seal.
If gear housing is apart, the oil seal installer and installer
handle can be used for shift shaft oil installation.

CUTION: Oil seal must be installed with sealing lip

toward gearbox.

OUTPUT SHAFT
Remove gearbox.
Before removing the right housing and output shaft measure
the back lash on output shaft. This measure will indicate if
output shaft adjustment is necessary.

Output Shaft Back lash Procedure

Engage PARK position on the gear shaft to block gearbox.
Remove:
bearing cover with oil seal

1. bearing sleeve
2. oil seal

distance sleeve
 o-ring

NOTE: It is recommended to apply this specific sealant as

described here to get a uniform application without lumps. If
you do not use the roller method, you may use your finger to
uniformly distribute the sealant (using a finger will not
affect the adhesion).
Install all the screws on right housing then the O-ring and
the distance sleeve on end of output shaft. Chamfered bore
of distance sleeve has to face the engine.

1. distance sleeve
2. O-ring

Install the backlash measurement tool at the end of output

shaft.

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 3.ENGINE

From center of tool bolt, measure 47 mm and place a mark

on the tab.

1. back lash measurement tool

2. mark on tab
A 47 mm

Position the head of the dial indicator, against the tab at a

90° angle and on the line. Then, gently rotate the output
shaft.
This reading gives the back lash measurement.
Refer to the following table for backlash specifications.
Output shaft backlash
New 0.10 to 0.20 mm
Service limit 0.25 mm
If back lash is not within the specification, remove the
output shaft and select the next larger or smaller shim to
meet the specifications.

NOTE: Use next lager shim to increase back lash and next
small shim to reduce backlash.

Removal
Remove the bearing cover with oil seal.
Unscrew all bolts retaining the right housing to the center
housing.
To remove right housing, use 2 big screwdrivers.

Remove output shaft.

CAUTION: Use a soft hammer to remove output shaft from
center housing.

1. output shaft
2. coupling sleeve
3. soft hammer

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 3.ENGINE

Continue removal procedure by removing:

 coupling sleeve, O-ring, ball bearing and shim.

1. coupling sleeve
2. O-ring
3. ball bearing
4. shim

ball bearing and thrust washer

1. ball bearing
2. thrust washer

Inspection
Check output shaft and its gear for cracks, bend, pitting or
other visible damages.
Check output shaft splines for wear or other damages.
CAUTION: Always replace output shaft and bevel gear
shaft at the same time. Adjust these components upon
replacement.
Check if the output shaft bearings and turn freely and
smoothly. Replace if necessary.
Replace oil seal if brittle, hard or damaged.
Replace O-rings and if brittle, hard or damaged.
Check splines of coupling sleeve for wear or other damages.

1. inspect splines

Installation
Install shim, bearing, O-ring and coupling sleeve onto the output shaft.
Install thrust washer and ball bearing.
O-ring and distance sleeve are not installed at this time.
Place the output shaft into the center housing.
Use soft hammer to put bearing exactly in place against center housing.

Clean the bearing cover location then attach bearing cover with oil seal to the housing.
Temporarily install the right housing with the four (4) M8
screws beside bearing seats.

NOTE: prior to tightening the screws, tap on the gear end of output shaft with a soft hammer to take up all gear
free play.
Verify output shaft backlash. Refer to OUTPUT SHAFT BACK LASH PROCEDURE in this section. Adjust as
required.
If back lash is with in specifications, remove dial indicator, backlash measuring tool, bearing cover and right
housing.
Clean all metal components in a solvent.
Housing mating surfaces are best cleaned using a combination of chisel (gasket remover) and a brass brush. Brush
a first pass in one direction then make the final brushing perpendicularly (90°) to the first pass cross (hatch).
CAUTION: Do not wipe with rags. Use a new clean hand towel only.
Important: When beginning the application of sealant, the assembly and the first torquing should be done within
10 minutes. It is suggested to have all you need on hand to save time.
3-49
 3.ENGINE

Use LOTITE 5910 on mating surfaces.

Use a plexiglass plate and apply some sealant on it. Use a soft rubber roller (50-75 mm), available in arts products
suppliers for printing, and roll the sealant to get a thin uniform coat on the plate (spread as necessary). When ready,
apply the sealant on housing mating surfaces.
Do not apply in excess as it will spread out inside housing.
NOTE: It is recommended to apply this specification without lumps. If you do not use the roller method, you
may use your finger to uniformly distribute the sealant (using a finger will not affect the adhesion).

Install all other screws on right housing then the O-ring no.
4 and the distance sleeve on end of output shaft. Chamfered
bore of distance sleeve has to face the engine.

1. O-ring
2. distance sleeve

NOTE: To install the right housing align the coupling fork

no. 10 with the groove in the coupling sleeve no. 9.
First, torque the four (4) M8 screws in a crisscross sequence
by hand then retighten to 25 N.m.

Tighten all M 6 screws to 10 N.m.

Before installing bearing cover, apply Loctite 5910 on the
housing and Super Lube grease on seal.
Once this is done, complete final assembly.

GEARS
Removal
Unscrew the three (3) nuts attach the gearbox to the
engine.
Pull gearbox to separate it from engine.

Disassembly
NOTE: During gearbox disassembly, inspect the condition
of each part closely.
Remove the output shaft.
Push bevel gear with a pin lightly down and measure the
axial clearance of bevel gear with a feeler gauge.
NOTE: Bevel gear axial clearance must be measured before
center and left housings separation.

1. bevel gear

Unscrew the left housing screws.

Place the left housing on a wood stand, center housing
pointing upwards.
Using 2 big flat screwdrivers, lift the center housing.

3-50
 3.ENGINE

Remove center housing completely.

Remove:
shift shaft assembly

1. shift shaft assembly

shift fork shaft

 disengage shift fork from shift drum
1. shift fork shaft
2. shift fork
3. shift drum

bevel gear shaft with low range gear assembly and

thrust washer

1. bevel gear
2. low range gear
3. thrust washer

sliding gear with shift fork

1. sliding gear
2. shift fork

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 3.ENGINE

 thrust washer, needle bearing and reverse gear

1. thrust washer
2. needle bearing
3. reverse gear

thrust washer CVT side

1. thrust washer CVT side

countershaft with low range gear and high range gear

assembly.

1. countershaft
2. low range gear
3. high range gear

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 3.ENGINE

Insert a flat screwdriver in the slot of index lever. Turn

screwdriver clockwise and remove shift drum.

1.index level
2.shift drum

Continue by removing the following:

parking lock lever

1.parking lock level


index lever with washer, step ring and spring

1. index lever
2. washer
3. step ring]
4. index spring

 support flange.

To remove intermediate gear and needle bearing, use a

press bench to push out the intermediate gear shaft.

PRESS SHAFT IN THE DIRECTION AS SHOWN

BY THE ARROW

1.intermediate gear shaft

2.left housing

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 3.ENGINE

Bearing removal in Housing

If necessary heat housing up to 100℃ before removing ball
bearings or needle bearings.
CAUTION: Always support gearbox housings properly
when ball bearings or needle bearings are removed. Housing
damages may occur if this procedure is not performed
correctly.
To remove bevel gear needle bearing use a punch.

1.bevel gear needle bearing

2.punch
3.center housing

To remove ball bearings of bevel gear and needle bearing of

countershaft, use a blind hole bearing puller.

For countershaft ball bearing, remove screw and

intermediate gear shaft, then push with a suitable puller from
outside in.

1.screw
2.intermediate gear shaft
3.ball bearing countershaft
4.bevel gear ball bearing

Inspection
Always verify for the following when inspecting gearbox
components:
 gear teeth damage
 worn or scoured bearing surfaces
 worn or scoured shift fork
 worn or scoured shift fork shaft
 rounded engagement dogs and slots
 bent shift forks
 bent shift fork shaft
 worn shift fork engagement pins
 worn tracks on shift drum
 worn shift fork engagement groove
worn splines on shafts and gears.

Bearing
Check if bearings as well as needle bearings turn freely and
smoothly.
Check all bearings, bearing points, tooth flanks, taper
grooves and annular grooves. Annular grooves must have
sharp edges.

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 3.ENGINE

Shift Forks
Check both shift forks for visible damage, wear or bent shift
fork claws.
Measure the shift fork claw thickness.

1. micrometer
A. shift fork claw thickness

Shift fork claw thickness

New 4.95 to 5.05 mm
Service limit 4.80mm

Measure shift fork pins.

1. micrometer
A. shift fork pin diameter

Shift fork pin diameter

New 6.942 to 7.00 mm
Service limit 6.850 mm

Shift Drum
Check shift drum tracks for scouring or heavy wear, like
rounded engagement slots.
Replace isolating washer if there are signs of wear or visible
damages.

1. track for the low/reverse gear shift fork

2. track for the high gear shift fork
3. isolating washer on the shift drum

Levers
Check parking lever for cracks or other damages.
Index lever with roller must move freely.
Gears
NOTE: Replace gears only together with the corresponding meshing gears. Always replace circlips and use
special pliers to install them.

Measure the width of shift fork engagement groove.

1. main gear
2. caliper
A. width for engagement of shift fork

gear for high gear shifting.

Width of shift fork engagement groove

(high gear shifting)
New 5.10 to 5.17 mm
Service limit 5.20 mm

gear for low/ reverse gear shifting.

Width of shift fork engagement groove

(low/reverse gear shifting)
New 5.10 to 5.17 mm
Service limit 5.20 mm

3-55
 3.ENGINE

Check free pinion for wear.

1. micrometer
2. free pinion

Diameter free pinion

New 29.007 to 29.028 mm
Service limit 29.030 mm

Shafts
Check shaft for worn splines and gears.
Check intermediate shaft for wear.
1. intermediate gear bearing
Intermediate gear shaft
New 24.980 to 24.993 mm
Service limit 24.977 mm

Check countershaft for wear.

1. MAG side
2. free pinion bearing
3. CVT side
Countershaft
Service limit
MAG side 17.974 mm
Free pinion bearing 24.970 mm
CVT side 24.970

Check bevel gear shaft.

1. free pinion bearings
Bevel gear shaft
Service limit
Free pinion bearing 24.972 mm

Shims
Always replace shim by a new one with the same thickness,
when reassembling the gearbox with existing output shaft
and bevel gear shaft.
1. thrust washer for adjusting the bevel gear on center
housing side
2. area where wear signs appear
3. thickness of the washer

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 3.ENGINE

Bevel Gear Adjustment

NOTE: Only necessary if backlash and axial clearance of the bevel gear is out of specification or if parts are
changed (output shaft, bevel gear shaft or housing).
There are 2 adjustments to perform on the bevel gear.
bevel gear backlash on center housing
bevel gear axial clearance on left housing.
The bevel gear backlash is adjusted by finding the proper thrust washer thickness E as per following illustration.
The bevel gear axial clearance is adjusted by finding the proper thrust washer thickness J as per following
illustration.
Clean mating surface of housing before taking measurements.
CAUTION: Do not wipe with rags. Use a new clean hand towel only.

Bevel Gear Back lash Procedure

Use the following course of calculation to determine the theoretical thrust washer thickness D:
D = B – C –A

B = the distance between the thrust surface of the bevel

gear and the theoretical center of its taper. This is defined
by manufacturer and is written on the bevel gear shaft.
This bevel gear reference number could be between -10
and + 10.

1. bevel gear
2. bevel gear reference number

Use following formula to find out value B.

B= ( bevel gear reference number ) + 37.8
100
For example: Bevel gear reference number = -3.
B = (-3/100) + 37.8 = 37.77
C = Distance between the shim thrust surface in the center
housing and the mating surface to left housing.

1.deep gauge – measurement C

2.thrust washer surface in center housing
3.mating surface to left housing

3-57
 3.ENGINE

A = 2 mm nominal thickness of axial needle bearing . Theoretical Thrust Washer Thrust Washer
Thickness Number
When the measurements are taken, calculate the D E
theoretical thrust washer thickness D using the formula
( D = B – C –A) 1.20 mm to 1.29 mm 120
Take the obtained theoretical thrust washer thickness D
and choose the corresponding thrust washer number E 1.30 mm to 1.39 mm 130
according to the following table. 1.40 mm to 1.49 mm 140
NOTE: For example, if the theoretical thrust washer
thickness D is 1.53 mm, choose the corresponding thrust 1.50 mm to 1.59 mm 150
washer number 150 E. the thrust washer number 150
1.60 mm to 1.69 mm 160
represents a nominal value equal to 1.50 mm.
1.70 mm to 1.79 mm 170
1.80 mm to 1.89 mm 180
Bevel Gear Axial Clearance Procedure
Use the following course of calculation to determine the theoretical thrust washer thickness I:
I = F+ G– H –A-E

F = Distance between mating surface of left housing to ball

bearing inner race.

1. ball bearing inner race

2. mating surface of left housing
3. depth gauge

G = Distance between mating surface of center housing and

thrust washer surface.

1. mating surface of center gear housing

2. thrust washer surface

H = Distance between thrust surface of bevel gear shaft.

A = 2mm nominal thickness of axial needle bearing no.

12 .
E = the thrust washer number nominal value as found in
the BEVEL GEAR BACKLASH PROCEDURE. For
example, thrust washer number 150 represents a value of
1.50 mm.

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 3.ENGINE

When the measurements are taken, calculate the THEORETICAL THRUST THRUST WASHER
theoretical WASHER THICKNESS NUMBER
thrust washer thickness I using the formula I J
(I = F + G – H – A – E )
Take the obtained theoretical thrust washer thickness I and 1.22 mm to 1.31 mm 120
choose the corresponding thrust washer number J 1.32 mm to 1.41 mm 130
according to the following table.
For example, if the theoretical thrust washer thickness I is 1.42 mm to 1.51 mm 140
1.53 mm, choose the corresponding shim number 150 J.
Bevel gear axial clearance of 0.02 to 0.11 mm is included 1.52 mm to 1.61 mm 150
in the table.
1.62 mm to 1.71 mm 160

1.72 mm to 1.81 mm 170

1.82 mm to 1.91 mm 180

Assembly
The assembly of gearbox is essentially the reverse of disassembly procedure. However, pay attention to the
following details.
Bearing Installation in Housing
Unless otherwise instructed, never use hammer to install ball bearings or needle bearings. Use press machine only.
If necessary heat housings up to 100℃ before installing ball bearings or needle bearings.
Place new bearing in freezer for 10 minutes before installation.
Use a suitable installer for installing ball bearings of countershaft and bevel gear.
NOTE: Place gearbox housings on a wood stand before
installing bearings.
Install countershaft needle bearing with the main shaft
needle bearing installer and the installer handle in right
housing.

1. needle bearing installer

2. installer handle

1. countershaft needle bearing

2. right housing
3. needle bearing installer
4. installer handle

Install bevel gear needle bearing using the bevel gear

needle bearing installer and the installer handle.

1. bevel gear needle bearing

2. center housing
3. needle bearing installer
4. installer handle

3-59
 3.ENGINE

Install new oil seals with the proper installer.

Other Gearbox Components
Fit intermediate gear with needle bearing on intermediate
gear shaft.
NOTE: Fit gear with collar face to housing side on the
intermediate shaft.

1. intermediate gear
2. collar facing housing
3. needle bearing
4. intermediate gear shaft

Press intermediate gear shaft in the left housing.

1. intermediate gear shaft

Fit support flange in the left housing and install index

lever.
NOTE: Fit step ring into index lever.

1.shim
2.index lever
3.step ring
4.index spring

Install parking lock level, teeth showing to

countershaft.

1. parking lock lever

Place thrust washer CVT side on bearing.

1. thrust washer CVT side

3-60
 3.ENGINE

Place reverse gear with needle bearing and thrust

washer.
NOTE: Check if the screw to secure countershaft
bearing is installed.

1.reverse gear
2.needle bearing
3.thrust washer
4.countershaft bearing screw

Install countershaft with low gear and high gear assembly.

1. countershaft
2. low gear
3. high gear

Install a new shim onto bevel gear shaft, fork side.

Install bevel gear with sliding gear assembly together with
shift fork.
NOTE: If a new bevel gear and output shaft are used, it is
necessary to verify the shim adjustment prior to

finalize assembly. Refer to ADJUSTMENT above in this

section. If the existing bevel gear is used, it is mandatory
to use a new shim with the same thickness, a new needle
bearing and thrust washer .

1. bevel gear
2. sliding gear
3. shift fork

Install a new needle bearing and thrust washer.

1. needle bearing
2. thrust washer

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 3.ENGINE

Insert a flat screwdriver in the slot of the index lever, turn

screwdriver clockwise and install shift drum on neutral
position as per following illustration.

1. index lever
2. shift drum
3. neutral position

1. parking stop location

2. reverse stop location
3. neutral stop location
4. high gear stop location
5. low gear stop location

Install shift shaft assembly.

NOTE: Marks on shift drum/isolating washer and shift
shaft must align.
1. shift shaft assembly
2. isolating washer
3. marks

Install shift fork then engage both shift fork pins in their
corresponding groove on the shift drum.
NOTE: move sliding gears to facilitate engagement of
pins inside grooves.
1. shift fork pin
2. sliding gear

Install shift fork.

NOTE: Run all gears as a final function check before
installing center housing.
Now, close the housings by doing the following:
Clean all metal components in a solvent.
Gearbox housing mating surfaces are best cleaned.
CAUTION: Do not wipe with rags. Use a new clean hand towel only.

3-62
 3.ENGINE

IMPORTANT: When beginning the application of the gear housing sealant, the assembly and the first torquing
should be done within 10 minutes. It is suggested to have all you need on hand to save time.
Use Loctite 5910 on mating surfaces.
Use a plexiglass plate and apply some sealant on it. Use a soft rubber (50-75 mm), available in arts products
suppliers for printing, and roll the sealant to get a thin uniform coat on the plate (spread as necessary). When
ready, apply the sealant on gear housing mating surfaces.
Do not apply in excess as it will spread out inside gear housing.
NOTE: It is recommended to apply this specification without lumps. If you do not use the roller method, you may
use your finger to uniformly distribute the sealant (using a finger will not affect the adhesion).
Hand-torqued gear housing screws in a crisscross sequence. Repeat procedure, retightening all screws to 10 N.m.
Install O-ring including distance sleeve on countershaft CVT side.
CAUTION: Place O-ring including distance sleeve right away. Chamfered bore of distance sleeve has to face the
gearbox.

Installation
The installation is the reverse of the removal procedure.

Filling Procedure
Make sure that magnetic drain plug is reinstalled and tight.
With the gearbox on a level surface, fill the gearbox through the oil filler hole with GL-4-90 or with an equivalent
product until the oil reaches the lower threads of the oil filler hole (about 420 ml).

ENGINE INSTALLATION
The engine installation is the reverse of the removal procedure. However, pay attention to the following.
1. Prior to install engine, inspect condition of engine mounts. If necessary, replace the engine mounts, you can
insert a punch in hole of engine mount bushing and push the other bushing out of the housing.
2. Make sure coolant and oil drain plugs are reinstalled and tight.
Refill engine oil and check the oil level with the dipstick.

3-63
 4.COOLING SYSTEM

4. COOLING SYSTEM

FAULT OVERHAULING ·····························4-1 COOLING SYSTEM TEST ···························4-2

THERMOSTAT ·········································4-3 RADIATOR AND CAP ································4-3
COOLANT TANK ······································4-5 RADIATOR FAN········································4-5
WATER PUMP HOUSING ····························4-7 WATER PUMP IMPELLER ···························4-7
WATER PUMP SHAFT AND SEALS ···············4-8

FAULT OVERHAULING
1. If cover of radiator is open and temperature of cooling liquid is over 100℃, pressure of cooling liquid will
be reduced rapidly and boiled. Vapor injection may cause danger and injuries. After drop of temperature
of cooling liquid, use one cloth to cover the cover of radiator and then slowly open the cover. Cooling liquid
can only be tested after complete cooling.
2. Cooling liquid is toxic. Do not drink it or splash it to skin, eyes or clothes. In case of splashing cooling liquid
to your eyes, use clean water to wash your eyes completely and see the doctor. In case of splashing cooling
liquid to your clothes, use soapy water to wash it rapidly. In case of drinking cooling liquid, vomit will be
caused immediately. Please see the internist physician immediately. Store cooling liquid well and keep it out
of reach of children.
3. Check whether soil of fins is blocked or damaged. Correct curved fins。 Use water and compressed air to
clean soil. If damaged area reaches 20%, please replace radiator.
4. Pump overhauling can be carried out before dismantling engine.
5. Add cooling liquid to water tank. In addition to adding or exhausting cooling liquid, please do not open
cover of radiator.
1. Do not splash cooling liquid to plastic parts. Once splashed, please use clean water for washing.
2. After dismantling cooling system, check leakage situation of joint.

Sharp rise of water temperature

 Faults of radiator cover
 There is air in cooling system.
 Faults of water pump
 Faults of thermostat (thermostat is not open)
 Blockage of radiator tube or cooling tube
 Damage or blockage to radiator
 Incomplete cooling liquid
 Failure or faults of fan motor

No rise or slow rise of water temperature.

 Faults of thermostat (thermostat is not closed)
 Faults of line of water temperature display

Leakage of cooling liquid

 Faults of water seal
 Aging, damage or improper sealing to O-shaped ring.
 Aging, damage or improper sealing to gasket
 Improper installation of pipe or hose
 Aging, damage or improper sealing to pipe and/or hose

！Warning
Never start engine without coolant. Some engine parts such as the rotary seal on water pump shaft can be
damaged.

4-1
 4.COOLING SYSTEM

COOLING SYSTEM TEST

！Warning
To avoid potential burns, do not remove the
radiator cap or loosen the cooling drain plug if
the engine is hot.
Open the upper cover of engine hood and remove the
radiator cap.
Install the test cap and a small hose pincher on
overflow hose.
Using pressure/ vacuum pump, pressurize system to 100 kPa.

Check all hoses, radiator and cylinder(s)/base for

coolant leaks or air bubbles.

Inspection
Check general condition of hoses and clamps
tightness.

Check the leak indicator hole if there is oil or coolant.

NOTE: Flowing coolant indicates a defective rotary
seal. Oil indicates a defective inner oil seal. If either
seal is leaking, both seals must be replaced at same
time. Refer to WATERPUMP SHAFT ANDSEAL in
this section.

1. leak indicator hole

Another leak indicator hole is visible on the PTO side.

It indicate if the PTO gasket is in good condition. If a
liquid leaks by this hole, the PTO gasket replacement
is necessary.

4-2
 4.COOLING SYSTEM

THERMOSTAT

The thermostat is a single action type. The thermostat is located on the top of cylinder head, on intake side.
Remove:

 thermostat housing screws and pull thermostat cover

1. Thermostat cover
2. Screws
 thermostat with gasket out of the hole.

Thermostat Test
To check thermostat, put in water and heat water.
Thermostat should open when water temperature
reaches 65℃(149°F).
Check if the gasket is brittle, hard or damaged. If so
replace gasket.

Thermostat Installation
For installation, reverse the removal procedure, pay
attention to the following details.
Install the thermostat cover then torque screws to
6N.m.
Check coolant level in radiator and coolant tank and
top up if necessary.
Do not forget to bleed the cooling system. Refer to
COOLANTREPLACEMENT.

RADIATOR AND CAP

Using a pressure cap tester, check the efficiency of
radiator cap. If the efficiency is feeble, install a new
100 kPa cap (do not exceed this pressure).

Radiator Inspection
Check radiating fins for clogging or damage.
Remove insects, mud or other obstructions with
compressed air or low pressure water.

Radiator Removal
Drain cooling system.
Remove front fascia and radiator shroud.
Remove:
 Radiator inlet and radiator outlet hoses
 Overflow hose.
Remove radiator.

4-3
 4.COOLING SYSTEM

Remove the connector of temperature controller on the

radiator and the radiator water outlet hose A.

Remove the fill hose B and the top mounting bolt C on C

the left side.

Unplug the connectors of cooling fan.

A
Temperature controller

Connector of fan
Pull out upward the radiator from the lower mounting
holes on the frame, remove the radiator from the left
side of the vehicle.

4-4
 4.COOLING SYSTEM

Radiator Installation

For installation, reverse the removal procedure.

Pay attention to the following detail.
Fill up the radiator. Refer to COOLANT
REPLACEMENT, in this section.
Check for any coolant leakage from radiator and hoses.

COOLANT TANK
The coolant expands as the temperature (up to
100-110℃) and pressure rise in the system. If the
limiting system working pressure cap is reached
110kPa, the pressure relief valve in the pressure cap is
lifted from its seat and allows coolant to flow through
the overflow hose into the overflow coolant tank.

COOLANT Tank Removal

Remove:
 The upper cover of engine hood.
 Coolant tank support bolt and.
 Overflow hose and clamp.

Tank Installation
The installation is the reverse of the removal procedure.

RADIATOR FAN

Radiator Fan Removal

Remove radiator shroud.
Remove bolts.
Remove the radiator fan.

Radiator Fan Test

NOTE: The ECM controls the radiator fan via the input of the coolant temperature sensor (CTS). The
radiator fan should turn on when coolant temperature reaches 98℃ and should turn off when the coolant
cools down at 95℃.(203°F).

Connect the vehicle to B.U.D.S. Refer to ENGINE MANAGEMNT for procedure and connector location.
In ACTIVATION folder, press COOLANT FAN button.
If fan turns, check CTS, wiring harness and connectors. If all parts are good, replace the ECM.
If fan does not turn when COOLANT FAN button is pressed, use the following troubleshooting chart to resolve
the problem.

4-5
 4.COOLING SYSTEM

Radiator Fan Installation

For the installation, reverse the removal procedure

4-6
 4.COOLING SYSTEM

WATER PUMP HOUSING ! WARNING

To avoid potential burns, do not remove
It is located on the engine MAG side. the radiator cap or loosen the cooling
Water Pump Housing Removal drain plug if the engine is hot .

Drain cooling system.

Remove radiator outlet hose from water pump
housing.
Remove screws retaining water pump housing.

1. Screws
2. Water pump housing
3. Sealing ring
Pull water pump housing to remove it.

Water Pump Housing Inspection

Check if gasket is brittle, hard or damage and
replace as necessary.

1. Gasket

Water Pump Housing installation

The installation is the opposite of the removal
procedure.
CAUTION: To prevent leaking, take care that the
gasket is exactly in groove when you reinstall the
water pump housing.
Tighten screws of water pump housing in a
criss-cross sequence.

WATER PUMP IMPELLER

Impeller Removal
Remove water pump housing.
Unscrew impeller.

1. Impeller

CAUTION:
Water pump shaft and impeller have right-hard
threads. Remove by turning counterclockwise and
install by turning clockwise.
Check impeller for cracks or other damage.
Replace impeller if damaged.

Impeller Installation
The installation is the opposite of the
removal procedure. Be careful not damage
impeller wings during installation.

4-7
 4.COOLING SYSTEM

WATER PUMP SHAFT AND SEALS

Shaft/Seal Removal
NOTE: It is not required to split crankcase to
replace the water pump shaft and seals, but engine
removal is necessary.

Drain engine oil.

Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION section.
Detach gearbox from engine.
Remove engine drive shaft and engine PTO cover.
Remove water pump housing and impeller. See
procedures in this section.
Pull out water pump gear to disengage the inner
drive gear.

1. water pump gear

2. Inner drive gear

Sharply strike water pump shaft out with a plastic

hammer
.

Pull out water pump shaft through the engine drive

shaft opening.
NOTE: Pay attention to hold thrust washer to
prevent it from falling in crankcase.

1. Thrust water here

CAUTION: If thrust washer is not on water pump

shaft, use a magnet to retrieve it inside crankcase.
Using appropriate pliers remove and discard the
retaining ring securing water pump gear on water
pump shaft.

To remove plastic gear from water pump shaft

place gear between your fingers and briskly tap
shaft end.

4-8
 4.COOLING SYSTEM

Using 2 screwdrivers, pry out inner part of the

rotary seal.

To remove outer part of rotary seal, use an

expander from puller kit.
Install expander snugly against outer part and pull
rotary seal out.

Remove inner oil seal.

1. Inner seal
2. Rotary seal surface
CAUTION: Be careful not to damage the rotary
seal surface in crankcase.

Part Inspection
Inspect water pump gear for wear and damage on
the snap mechanism to the needle pin. Replace if
damaged.

Shaft/Seal Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
NOTE: For installation use the torque values.
Ensure to use multipurpose grease oil seal.
CAUTION: Always replace rotary seal and water
pump shaft together. Also, install a new inner oil
seal (behind rotary seal) at the same time.
Apply engine oil on the water pump shaft and
intermediate shaft.
NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.

Use the oil seal pusher and the installer

Handle to install inner oil seal.

1. Handle
2. Pusher
4-9
 4.COOLING SYSTEM

Apply MOLYKOTE inside lips oil seal when

installing the oil seal on the pusher, make sure
sealing lip points outside.
Push inner oil seal in place.

1. Inner oil seal

2. Installer handle with oil seal pusher

Slide water pump shaft with the new rotary seal

into crankcase.
To properly install water pump shaft with rotary
seal, use the rotary seal installer.

Use a plastic hammer and drive rotary seal into

crankcase.

From engine drive shaft opening. Insert thrust

washer pump shaft in crankcase.
Using a flashlight and a mirror, position the shaft
hole so that pin can be installed.
Position pin between your fingers, push in water
pump

shaft to fully expose hole then install pin.

Position pin equal distance out of shaft hole so gear
can be installed.
Install water pump shaft gear.

NOTE: Ensure gear properly snaps on pin.

A screwdriver may have to be used to push gear in
place.
Use a 45°snap-ring pliers and install a NEW
retaining ring on pump shaft end.

4-10
 4.COOLING SYSTEM

CAUTION: Never use the retaining ring a second

time. Always install a new one.

After installation, water pump shaft with rotary seal

must rotate freely.
Carefully push in water pump gear while turning to
mesh with the inner drive gear.

1. Water pump gear

2. Inner drive gear

Tighten Screws of the water pump housing crosswise.

Refill all fluids

4-11
 5.FUELSYSTEM

5. FUEL SYSTEM

FUEL PRESSURE TEST ······························ 5-2 FUEL FILTER ··········································· 5-3

FUEL PUMP ············································· 5-3 FUEL TANK ············································· 5-4

The fuel system of a fuel injection system holds much more a pressure than on carbureted vehicle. Prior to
disconnecting a hose or to removing a component from the fuel system, follow the recommendation described her
Fuel lines remain under pressure at all times. Always proceed with care and use appropriate safety equipment when
working on pressurized fuel system. Wear safety glasses. Proceed with care when removing/installing pressure test
equipment or disconnecting fuel line connections. Cover the fuel line connection with an absorbent shop rag.
Slowly disconnect the fuel hose to minimize spilling. Wipe off any fuel spillage in the

5-1
 5.FUELSYSTEM

on injection system high pressure hoses. Replace any damage or deteriorated fuel lines.
When the repair is completed, ensure that all hoses are connected and secured.
Always perform the fuel pressure test if any component has been removed. A pressure test must be done before
turning the ignition key to ON and setting the engine stop switch to RUN. The fuel pump is activated each time in
these conditions.
To locate a leak, pressurize the system. Check for leaking fuel or fuel odor. Spray soapy water on all hose
connections and injectors. Air bubbles will show the leaking area.
Inspect the fuel lines, fuel tank, fuel tank cap for damage, clogging and leakage of fuel. If any damages are found,
replace the defective parts with the new ones.

FUEL PRESSURE TEST

The pressure test will show the available pressure at the fuel pump outlet. It validates the pressure regulator, the
fuel pump and leaks in the system.
Before proceeding to the pressure test ensure the battery is fully charged. Battery voltage must be over 12 volts.
Ensure there is enough gas in fuel tank.

Remove left seat.

Disconnect outlet hose.

Install fuel pressure gauge and T-fitting between
disconnected hoses.
Turn ignition key ON and set engine stop switch to
RUN and observe fuel pressure. Turn ignition key off
then back on. Repeat the test.

Standard fuel pressure: 350kpa.

A rapid pressure drop indicates leakage is from the fuel rail, If there is not leaking then replace fuel pump.
A slow pressure drop indicates leakage either from the fuel injector or from the fuel pressure regulator. Check fuel
injector and the fuel pressure regulator for leaks. If it is not leaking then replace fuel pump module.
If no leakage, start engine and observe fuel pressure. The fuel pressure should be the same as above.
If pressure is within limits, fuel pump and the fuel pressure regulator are working adequately.

Remove pressure gauge from inlet hose. Reconnect inlet hose.

5-2
 5.FUELSYSTEM
FUEL FILTER
Replace fuel filter as per amintenance schedule.

Filter Removal
Remove oetiker clamps and pull hoses off. Detachfilter
from body.

Filter inspection
If fuel filter is suspected to be clogged, it may be checked as follows:
Using low compressed air, check if fuel filter is clogged. Air should flow easily through filter. In doubt, install a
new filter.
Filter installation
Use arrow on filter to position it according to fuel flow.

FUEL PUMP
Fuel pump electrical test.
When turning ignition key ON, the fuel pump should
run for 5 seconds to build up the fuel pressure in the
system.

If the pump does not work, disconnect the connector

from the fuel pump.
Install a temporary connector to the fuel pump
connector. Apply 12V to this test harness.
CAUTION
Running the fuel pump a few minutes with
reverse polarity can damage the pump.

If pump does not run, replace a new pump.

Other wise, check fuse and if good, probe terminals of fuel pump connector on vehicle harness or its connector,
Repair or replace appropriate part.

Fuel pump removal

Remove fuel pump outlet hose and harness.
Remove fuel pump retaining screws.
Gently push pump up.
CAUTION
While pulling out the fuel pump, pay attention
to fuel sensor float arm. Float arm can get stuck
and bend which can reduce the fuel sensor
capabilities.

Fuel pump installation

For installation, reverse the removal process but pay attention to
the following.
Install a new gasket.
Pay attention to pump orientation.
Tighten retaining screws as per illustrated sequence.
Install hose properly on OUT nipples and harness.
5-3
 5.FUELSYSTEM
FUEL TANK
Fuel tank draining
Never perform this operation when the engine and/or the exhaust system is/are hot.
Never sue a hose pincher on injection system high pressure hoses.

Remove fuel tank cap and siphon gas in an approved fuel container.

Fuel tank removal

Remove
Disconnect vent line from body.

Fuel tank inspection

Inspect fuel tank for any damage or cracks which may result in fuel leaks. If so replace tank with a new one.
Inspect tank and protector attachment points for damage. Inspect protector for damage.

5-4
 6. DRIVE TRAIN

6. DRIVE TRAIN

FRONT WHEEL HUB ································· 6-1 REAR WHEEL HUB ··································· 6-2
TIRES AND WHEELS ································· 6-3

FRONT WHEEL HUB

Front drive disk

Place the vehicle at the parking rack position and lift
the front of the vehicle with a jack.
Remove the nuts, cotter pins and other standard
parts from the front wheel, pull the rim outward
and place the rim and the front drive disc on one
side.
Check whether or not the rim is broken and
cracked, etc., and check whether the spline in
the front drive disc is damaged. If so, please
replace it.

Front axle
Remove the half shafts on both sides from the front
axle, check the outer splines of the half shafts for
damage, cracks, etc. Check whether the connecting
rubber sleeves are pulverized, cracked, etc. If any,
please replace them in time.

Front reducer assembly

Remove the front axle mounting bolts, lift the front
axle straight up, and remove it from the front of the
frame to check whether the airbag is worn or damaged.
Check whether the rubber sleeve is firmly connected. If
yes, please replace it with a new one
Check the gear box, cover, bearing, oil seal and dust

6-1
 6. DRIVE TRAIN
seal for wear or damage. If any damage or wear is
found, replace with a new oil seal or dust seal.
Check the internal spline meshing with the half shaft
for damage, cracks, etc. If so, please replace it with a
new one.

Front drive shaft

Remove the engine shield and set it aside, then remove
the connecting bolts of the engine and front drive shaft
front axle and front drive shaft respectively, and take
them out from the side of the frame.

Check the drive shaft for wear or damage. If any

defects are found, replace them with new drive shafts.
Check if the U-shaped joint moves freely in all
directions.
Check the bellows for holes or brittleness.

Installation
The installation is the reverse of the removal
procedure.
Ensure tighten the bolts to specified torque.

Installation location Specifications (mm) Torque N.m(Ft.lbs)

Mounting nut of wheel rim M10 60(44)
Nut of wheel hub M22 300(220.6)
Fastening nut of front differential M10 80(58.8)
Bolt of front propeller shaft flange M8 40(29.4)
Bolt of front propeller shaft flange M10 80(58.8)

REAR WHEEL HUB

6-2
 6. DRIVE TRAIN
Rear drive
Place the vehicle at the parking rack position and lift
the front of the vehicle with a jack.
Remove the nuts, cotter pins and other standard
parts from the front wheel, pull the rim outward
and place the rim and the front drive disc on one
side.
Check whether or not the rim is broken and
cracked, etc., and check whether the spline in
the front drive disc is damaged. If so, please
replace it.

Rear axle
Remove the half shafts on both sides from the rear axle,
and check the outer splines of the half shafts for
damage, cracks, etc.
Check whether the connecting rubber sleeve is
pulverized, cracked, etc. If any, please replace it in
time

Rear reducer assembly

Remove the rear axle mounting bolts, lift the rear axle
vertically upwards, and remove it from the rear of the
frame.
Check whether the rubber sleeve is firmly connected. If
so, please replace it with a new one.
Check the gear box, cover, bearing, oil seal and dust
seal for wear or damage.
If any damage or wear is found, replace with a new oil
seal or dust seal.
Check the internal spline meshing with the half shaft
for damage, cracks, etc., replace with new ones if there
are any.

Rear drive shaft

Remove the engine shield and set it aside, then remove
the engine and rear drive shaft separately
The connecting bolts of the front axle and the rear
drive shaft are taken out from the side of the frame.

An examination
Check the drive shaft for wear or damage. If any
defects are found, replace them with new drive shafts.
Check if the U-shaped joint moves freely in all
directions.
Check the bellows for holes or brittleness.

TIRES AND WHEELS

Tire thread
When the tire groove decreases to 6 mm (0.24 in) due
to wear, replace the tire.

When the tires are replaced, never install a bias tire with
a redial tire. such a combination could create handling
and/or stability problems.
Dot mix tires of different size and/or de-sign on the same axle.
Front and rear tire pairs must be the identical model and manufacturer.
For unidirectional tread pattern, ensure that the tires are installed in the correct direction of rotation.
The radial tires must be installed as a complete set.

6-3
 6. DRIVE TRAIN
In dismantling tires, use special crowbar and rim protection device.

Tire replacement
Use jack to support vehicle and ensure its no dropping.
Remove the wheels.
After removing the air valve cap, release the tire pressure
by depressing the valve.
Dismount the bead from the rim completely.

Separate the tire from the rim by using a set of tire levers
and rim protectors.

CAUTION
When using the tire lever, do not scratch or hit
the sealing portion of the wheel or it may cause air
leakage.

Apply tire lubricant to the new tire bead and the flange of
the rim. But never apply grease, oil or gasoline to the tire
bead because they will deteriorate the tire.
CAUTION
The standard tire fitted on this vehicle is
AT26×9–14 for the front and AT26×11–14 for the
rear.
The use of tires other than the standard may
cause instability. It is highly recommended to use
the specified tire.
Inspect the sealing portion of the rim for
contamination and distortion before installing the
tire on the rim.
Mount the new tire on the rim.
CAUTION
When installing each tire, make sure the arrow
on the tire points in the direction of rotation. Also
make sure the outer side of the wheel rim is facing
outward.

Inflate the tire to seat the tire bead.

Check the rim line cast on the tire side walls. It must be
equidistant from the wheel rim all the way around. If the
distance between the rim line and the wheel rim varies
this indicates that the bead is not properly seated. If this is
so, deflate the tire completely, and unseat the tire bead on
bosh sides. Then coat the bead with clean water and
re-seat the tire.

Adjust the tire pressure to specification

6-4
 7. STEERING SYSTEM

7. STEERING SYSTEM

STEERING ALIGNMENT ···························· 7-2

Inspect the tie rod for distortion or damage. If any damage are found, replace the tie rod with a new one.
Inspect the tie ends for smooth movement. If there are any abnormalities, replace the tie rod end with a new one.
Inspect the tie rod end boot for wear or damage.If any damage are found, replace the tie rod end with a new one.

Tie rod installation

1. For the installation, reverse the removal

procedure.
2. Tighten tie rod lock nuts finger tight.
3. Install tie rod on steering knuckle..
4. Torque tie rod retaining nut to 60N.m.
5. Install new cotter pins. Both ends of cotter pins
must be folded around nut.

7-1
 7. STEERING SYSTEM

STEERING ALIGNMENT

Park vehicle on flat ground, make sure the tire pressure for right and left tires is same and set to the proper
specification, set the front wheels in the straight position, then place a load of 75kg on the seat.

Steering wheel looseness check

Move the steering wheel as shown in the figure,

check the steering column bearing wear, steering
shaft reverse joint clearance, loose steering wheel
and loose steering column. Replace or repair if
necessary.

Steering wheel clearance check

At the position directly in front of the steering wheel, lightly turn the steering wheel to the left and right to adjust
the clearance to within the specification. If the clearance exceeds the specified range, whether the steering shaft
universal joint is worn or the steering gear clearance is too large, it should be corrected.

7-2
 7. STEERING SYSTEM

Steering assist check

Check whether the steering power assist case is damaged. If the damage is serious, replace the new steering assist
according to the actual situation.
Check whether the steering assist click is working normally under the working state of the engine. If the required
steering force is too large or there is a stuck phenomenon, repair or replace it according to the situation.

Measurethe distance A and B of the front wheels and

calculate the difference.

Toe-in.:B -A= 5mm

A: front of front wheel

B: rear of front wheel

Out of range of toe-in: →Adjust nut of tie rod

CAUTION
After adjusting toe-in, fist rotate steering wheel
from center position to the left and right competely,
to ensure that is the same corner, then slowly run
vehicle to see whether its direction can be
controlled.

7-3
 8. SUSPENSION SYSTEM

8. SUSPENSION SYSTEM

FRONT SUSPENSION ································ 8-1 REMOVAL AND DISASSEMBLY ·················· 8-1

INSPECTION············································ 8-2 REASSEMBLY ·········································· 8-2
REAR SUSPENSION ·································· 8-3 REMOVAL AND DISASSEMBLY ·················· 8-3
INSPECTION············································ 8-3 REASSEMBLY ·········································· 8-4

FRONT SUSPENSION

The procedure explained below is the same for the RH and LH sides unless otherwise noted. During assembly or
installation, use the torque values and service products as in the torque table.
In order to prevent collapse of vehicle, please do not dismantle left and right suspensions simultaneously.
Before overhauling front suspension system, please ensure stable support of vehicle

REMOVAL AND DISASSEMBLY

Loosen wheel nut of the appropriate.
Install a jack stand under the frame to lift the front of vehicle off the ground until shock absorber is fully extended then.

Remove wheels, brake caliper and hub

remove steering knuckle from ball cage tie rod

8-1
 8. SUSPENSION SYSTEM
INSPECTION

Shock absorber
Inspect the shock absorber for oil leakage or damage,
inspect the bushing for wear or damage. If any damage
are found, replace the front shock absorber with a new
one.

Extend and compress the piston several times over its

entire stroke. Check that it moves smoothly and with
uniform resistance with rod up. Any of the following
conditions will denote a defective shock:
 A skip or hang up when reversing stroke at
mid-travel.
 Seizing or binding conditions except at extreme end
of either stroke.
 A gurgling noise after completing one full
compression and extension stroke.
Replace shock if any these conditions are found.

Knuckle
Inspect the knuckle for damage. If any damages are
found, replace the knuckle with a new one.

Lower Suspension Arm

Inspect the suspension arm and for damage or
distortion. If any damages or distortion are found,
replace the suspension arm with a new one.

Move suspension arm from side to side. There should

be no noticeable loose. Replace bushing if necessary.
Move suspension arm up and down.There should be no
noticeable loose. Replace bushing if necessary.

Upper Suspension Arm

Inspect the suspension arm and for damage or
distortion. If any damages or distortion are found,
replace the suspension arm with a new one.

Move suspension arm from side to side. There should

be no noticeable loose. Replace bushing if necessary.
Move suspension arm up and down.There should be no
noticeable loose. Replace bushing if necessary.

Check ball joint for damage, pitting, looseness and

roughness. If so ,replace it.
Checl ball joint bellows for cracks. Change if
necessary.

REASSEMBLY
Reassemble and remount the front suspension in the
reverse order of removal and disassembly. Pay
attention to the following points.
1. Install the washers and tighten the knuckle
nuts to the specified torque.
2. Replace the removed cotter pins with new
cotter pins.

8-2
 8. SUSPENSION SYSTEM
REAR SUSPENSION

During assembly or installation, use the torque values and service products as in the torque table

REMOVAL AND DISASSEMBLY

Loosen wheel nut of the appropriate.
Install a jack stand under the frame to lift the rear of vehicle off the ground until the shock absorber is fully extended.

Remove wheels, brake caliper and hub

remove steering knuckle from ball cage tie rod

INSPECTION

Shock absorber
Inspect the shock absorber for oil leakage or damage,
inspect the bushing for wear or damage. If any damage
are found, replace the rear shock absorber with a new
one.

Extend and compress the piston several times over its

entire stroke. Check that it moves smoothly and with
uniform resistance with rod up. Any of the following
conditions will denote a defective shock:
 A skip or hang up when reversing stroke at
mid-travel.
 Seizing or binding conditions except at extreme end
of either stroke.
 A gurgling noise after completing one full
compression and extension stroke.
Replace shock if any these conditions are found

8-3
 8. SUSPENSION SYSTEM

Knuckle
Inspect the knuckle for damage. If any damages are
found, replace the knuckle with a new one.

Lower Suspension Arm

Inspect the suspension arm and for damage or
distortion. If any damages or distortion are found,
replace the suspension arm with a new one.

Move suspension arm from side to side. There should

be no noticeable loose. Replace bushing if necessary.
Move suspension arm up and down.There should be no
noticeable loose. Replace bushing if necessary.

Upper Suspension Arm

Inspect the suspension arm and for damage or
distortion. If any damages or distortion are found,
replace the suspension arm with a new one.

Move suspension arm from side to side. There should

be no noticeable loose. Replace bushing if necessary.
Move suspension arm up and down.There should be no
noticeable loose. Replace bushing if necessary.

Check ball joint for damage, pitting, looseness and

roughness. If so ,replace it.
Checl ball joint bellows for cracks. Change if
necessary.

Stabilizer bar
Remove the stabilizer bar from the frame and the rear
swing arm. Check whether the damping rubber sleeve
of the stabilizer is powdered or cracked. If so, please
replace it with a new rubber sleeve.
Check the transverse stabilizer ball head for damage,
pitting, looseness, etc., and check the ball bellows for
cracks, damage, powdering, etc. If so, please replace it
with a new one

REASSEMBLY
Reassemble and remount the front suspension in the
reverse order of removal and disassembly. Pay
attention to the following points.
1.Install the washers and tighten the knuckle nuts
to the specified torque.
2.Replace the removed cotter pins with new
cotter pins.

8-4
 9. BRAKES SYSTEM

9. BRAKES SYSTEM

BRAKE FLUID REPLACMENT ···················· 9-2 BRAKE PADS REPLACMENT ······················ 9-3
BRAKE DISC ··········································· 9-3 BRAKE CALIPER ······································ 9-4
BRAKE LIGHT SWITCH ····························· 9-4 BRAKE HOSE ·········································· 9-5
HANDBRAKE ·········································· 9-6

This brake system is filled with an ethylene glycol-based DOT4 brake fluid. Do not use or mix different types
of fluid, such as silicone-based or petroleum-based brake fluids.
Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from
the last servicing or which has been stored for a long periods of time.
When storing brake fluid, seal the container completely and keep it away from children.
When replenishing brake fluid, take care not to get dust into fluid.
When washing brake components, use new brake fluid. Never use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the
brake disc with high quality brake cleaner or neutral detergent.
Brake fluid may cause damage to surfaces of plastic and rubber parts. Keep it far away from these parts.

9-1
 9. BRAKES SYSTEM

BRAKE FLUID REPLACMENT

Place the vehicle on a level surface.

Remove the master cylinder reservoir cap and

diaphragm.
Suck up the old brake fluid as much as possible.
Fill the reservoir with new brake fluid.

Remove the dust cap of air bleeder valve. Connect a

clear hose to the air bleeder valve and insert the other
end of the hose into a receptacle.
Loosen the air bleeder valve and pump the brake
pedal until the old brake fluid is completely out of the
brake system.

Close the air bleeder valve and squeeze and release

the brake pedal several times in rapid succession and
hold the pedal fully squeezed. Loosen the air bleeder
valve for about quarter of a turn so that the brake fluid
runs into the receptacle, this will remove the tension of
the brake pedal. Then close the bleeder valve, pump
and squeeze the pedal and open the valve. Repeat this
process until the fluid flowing into the receptacle
contains no air bubbles.

Tighten the air bleeder valve to 6N.m.

Disconnect the clear hose and install the dust cap of
air bleeder valve.

Fill the reservoir with new brake fluid to the upper

edge of the inspection window.
Install the master cylinder reservoir cap and
diaphragm.

CAUTION
While bleeding the brake system, replenish the
brake fluid in the reservoir as necessary. Make
sure that there is always some fluid visible in the
reservoir.

9-2
 9. BRAKES SYSTEM

BRAKE PADS REPLACMENT

Remove the wheel.

Remove the brake caliper mounting bolt and brake

pads mounting pins.
Remove the brake pads.
Make sure that pad spring is in position. Install the new
brake pads.
Install pad pins by pushing in the pads against pad
spring to align pad slots in the pads and caliper body.
Tighten the brake pad mounting pins to 18N.m.
Tighten the brake pad mounting pins to 80N.m.

CAUTION
Do not operate the brake pedal during or after
brake pad removal.
Replace the brake pads as a set, otherwise
braking performance will be adversely affected.
After replacing the brake pads, pump the brake
pedal a few times to check for proper brake
operation and then check the brake fluid level.

BRAKE DISC
Removal and disassembly

Remove the wheel.

Remove the caliper and hub.

Remove the brake disc.

Inspection

Inspect the brake disc for cracks or damage and measure the
thickness using the micrometer. If any damage are found or
the thickness is less than the service limit, replace the brake
disc with a new one.

Minimum thickness of front brake disc: 3.5mm.

Minimum thickness of rear brake disc: 3.0mm

Measure the warpage using the dial gauge. If the warpage exceeds the service limit, replace the brake disc with a
new one.
Maxmum warpage of brake disc:0.3mm.

9-3
 9. BRAKES SYSTEM

Reassembly and remounting

Reassemble snd remount the brake disc in the reverse order of removal and disassembly. Pay attention to the
following points:
Install the disc to the wheel hub with the punching letters on the disc showed up.
Make sure that the disc is clean and free of any greasy matter.
Apply THREAD LOCK to the brake disc bolts and tighten them to 26N.m.

BRAKE CALIPER
Removal
Loosen wheel nuts.
Raise vehicle and support it securely.
Remove appropriate wheel.
Remove the caliper bolts then the caliper. If the caliper is not being remove from the vehicle as during brake pad
replacement,simply hang the caliper with a piece of wire to take the weight off the brake hose.
If the caliper is being removed for replacement, drain brake system before removing the banjo fitting and its
sealing ring. Remove the caliper from the vehicle.
Catch spilled fluid with a rag. Attach the brake hose in a position to prevent the fluid from flowing out.

Disassembly
Remove brake pads.
Remove slide caliper support and pad spring.
Place rag over piston.
Place caliper body with piston down and apply small squirts of air pressure to the fluid inlet to remove piston.
Remove piston seal.
Clean piston grooves, caliper cylinder and piston with clean brake fluid.
Clean slide pins with brake cleaner and a rag.

Inspection
If boots are deteriorated or hard, replace with new ones.
Check caliper cylinder for scratches, rust or other damages. If so, replace caliper.
Check piston for scratches, rust or other damages. If so, replace caliper.

Assembly
Coat piston seal with clean brake fluid and install it into piston grooves in caliper.
Coat piston with clean brake fluid and install into cylinde with the closing toward caliper body.
Apply dielectric grease into sliding bores and install slide pins.
Install pad spring, caliper bracket and pads.

Installation
For installation,reverse the removal procedure, pay attention to the following details:
Use new sealing washers when installing banjo fitting retaining brake hose to caliper.
Install caliper in its orginal position.
Bleed the brake system
Check for leaks and make sure the brakes operate normally before driving.

BRAKE LIGHT SWITCH

The brake light switch is located on the brake master
cylinder. It can not be adjusted.

Inspection
Fist ensure brake light is good.
Check switch for dirt or corrosion. Make sure it is operating properly.
Depress brake pedal and check for brake light to turn on. Repeat with the brake pedal.

9-4
 9. BRAKES SYSTEM

Test

Disconnect switch connectors.

Check switch operation as follows.
SWITCH POSITION PIN RESISTANCE
Firmly pushed 1 2 0.2Ω max
Released Infinite
If switch is defective, replace with a new one. If switch
tests good, check wiring harness.

Remove
Disconnect switch connectors.
Drain brake system.
Unscrew brake light switch from master cylinder.
Catch spilled fluid with a rag.

Installation
For installation,reverse the removal procedure.
Bleed the brake system
Check for leaks and make sure the brakes operate normally before driving.

BRAKE HOSE
Inspection
Brake hose should be inspected frequently for leaks an damages.
Check if the hoses are crushed or damaged. Any deformation can restrict the proper flow of fluid and cause
braking problems.
Check hoses for cracking scrapes. This damage can cause hose failure under pressure.
When hoses are removed or disconnected, cleanliness must be observed. Clean all joints and connections before
disassembly. New hoses should be cleand with brake fluid before installation to remove any contamination.
Replace any defective parts.

Removal
Before removing any hoses, drain brake system.
Remove all necessary parts to reach the hoses.
Thoroughly clean the arer around the joints that will be disconnected.
Place a pan under the joint that will be disconnected.
Disconnect any retaining clips or brackets holding the hose and remove the defective parts.

Installation
Install the new hose.
Make sure the piece will not rub against any other part.
When there is a banjo fitting securing the hose to the caliper or to the master cylinder, always replace the sealing
washers with new ones.
Install any retaining clips or brackets.
Refill and bleed the brake system.
Check for leaks and make sure the brakes operate normally before driving.

9-5
 9. BRAKES SYSTEM

HANDBRAKE

Grip Brake

Check whether the handbrake assembly is worn or

damaged. If any defect is found, please replace it in time.

Brake cable

Check whether the handbrake wire is worn or damaged.

If any defect is found, please replace it in time.

Mechanical brake

Check whether the mechanical parking brake is worn

or damaged. If any defect is found, please replace it in time.

9-6
 10.CHASSIS

10. CHASSIS

EXHAUST SYSTEM ··································10-1 SILENCER INSPECTION·····························10-1

CARGO BODY ·········································10-2 SEAT ······················································10-2
WINDSHIELD ··········································10-3 CAR DOOR(FRONT) ··································10-3
CAR DOOR(REAR)····································10-4

EXHAUST SYSTEM

WARNING
Be careful not to operate when the engine is running or the silencer is at high temperature.

Disassemble /install procedures

1. Remove the clamp of the exhaust pipe of the
first cylinder and the exhaust pipe of the second
cylinder, and remove the clamp of the exhaust
pipe of the second cylinder and the silencer
2.Remove the connecting nut between the exhaust
pipe and the engine.
3. Remove the oxygen sensor from the exhaust pipe
and remove the exhaust pipe.
4. Disassemble the silencer and remove it from the frame.
5. Disassemble the muffler tail pipe parts and take out
the fire extinguishing net.
Note: Please refer to the above method when installing.

SILENCER INSPECTION
1.Check the leaks in exhaust pipe and the cracks in
heat insulating shield. 。
2.Check whether the rubber parts in silencer are
cracked or weathered, etc.
3.Clean the sundries and inspect any damage in the
fire retardant net.
If there is any problem, please replace it with a new one.

10-1
 10.CHASSIS
CARGO BODY

Check for the following conditions, if damaged,

please replace it with a new one in time
1. Whether the door panels of the cargo box are
damaged.
2. Whether there is any obvious damage or breakage
on the skin of the cargo box.
WARNING
Be careful not to operate when the engine is running or the
silencer is at high temperature
Check whether the nylon sleeve is worn seriously. If there is
cracked, please replace it in time
Check whether the cargo body handle spring is deformed after stretching. If it is deformed, please replace it in
time.
Check the cargo body handle limit rubber and replace it in time if cracked.
Check whether the rubber mount at the bottom of seat is cracked, if there is cracked need to replace it in time.
Cargo body air spring inspection
1、Whether the piston is moving smoothly during stretching and compressing, has balanced resistance, and its
pull rod upward。
2、A suddenly fracture in stretching or compressing.
3、Unable to stretch or have noise after compression.

If there is any problem, please replace it with a new one.

SEAT

Long-term exposure of the seat to sunlight can cause some wear on its components.

1.Check whether the following parts of the seat are cracked or severely worn, etc. if they are replaced, please
(1) Torsion spring I
(2) Torsion spring II
(3) Rubber holster
2. Check the seat leather for cracks, damage, etc., please replace it in time.
3. Check whether the safety belt can return to the retractor after stretching
if can not, please replace it with a new one in time.

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 10.CHASSIS
WINDSHIELD

After prolonged use, the debris flying in the air will

cause some damage to the windshield. If the
following conditions occur, please replace it immediately.

1. Unclear windshield affects driving.

2. The rubber of the windshield fixing buckle is worn
and cracked.

CAR DOOR (FRONT)

Disassembly procedures

1. Remove the connecting bolts of the half door and

half door hinge, and remove the connecting bolts
of the half door fixing plate and the frame
2. Remove the half-door switch,
3. Remove the half door lock

Check for the following conditions, if damaged,

please replace it with a new one in time
1. Is there any crack or distortion on the rotating
shaft of the half door hinge.
2. Whether the cable in the half-door switch is
broken, and whether the cable holster is powdered or cracked.
3. Whether the locking mechanism in the half door lock is damaged and the torsion spring is
damaged, etc.
4. Is there a crack in the half door and there is a gap in a large area of damage.

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 10.CHASSIS
CAR DOOR (REAR)

Disassembly procedures

1. Remove the connecting bolts of the half door and

half door hinge, and remove the connecting bolts
of the half door fixing plate and the frame
2. Remove the half-door switch,
3. Remove the half door lock

Check for the following conditions, if damaged,

please replace it with a new one in time
1. Is there any crack or distortion on the rotating
shaft of the half door hinge.
2. Whether the cable in the half-door switch is
broken, and whether the cable holster is powdered or cracked.
3. Whether the locking mechanism in the half door lock is damaged and the torsion spring is
damaged, etc.
4. Is there a crack in the half door and there is a gap in a large area of damage.

10-4
 11.ELECTRICAL SYSTEM

11. ELECTRICAL SYSTEM

POWER SUPPLY SYSTEM ··························11-1 STARTING SYSTEM ··································11-7

IGNITION SYSTEM ···································11-9 CHARGING SYSTEM ·······························11-11

Bulb will be very hot after turning on headlamp. Please do not touch it immediately after its off. In operation,
bulb needs to be cooled.

‹ In warning inspection of water temperature, fire or high temperature liquid may be needed. Keep it far
away from inflammable and do not to be burnt.

‹ The temperature will be very high in turning of headlamp. For replacement, grease dirt will be splashed to
glass in case of operation with bare hands or wearing dirty gloves. As a result, hot spots and glass
deformation may be caused with damage to bulb as well.

‹ Pay attention to the following in replacing bulb:

-- Do not replace bulb when it is on. Turn off ignition switch and replace it after cooling bulb.

-- In order to avoid splashing grease to glass, wear clean gloves in replacing bulb.

-- Use cloth with alcohol or banana water to clean glass to prevent any grease sticking to glass.

‹ Check battery to confirm whether it is normal.

‹ Regularly check switch and do not dismantle it from vehicle in inspection.

‹ Cables and wires of each part need to be arranged reasonably.

POWER SUPPLY SYSTEM

Removal and installation of battery

1、Open the hood
2、 Remove 3 plastic buttons on the top cover of the battery box;
3、Use appropriate tools to loosen the positive and negative
clamps of the battery connection post and remove the positive
and negative connection post from the battery connection post;
4、Remove the battery from the battery box

11-1
 11.ELECTRICAL SYSTEM
Precautions for Fuse Application
After determining the cause of the burn and troubleshooting, replace the broken fuse with a specified type of
fuse. If no troubleshooting is done before replacement, the fuse may be burned again.

Removal/installation of main fuse

1、Remove battery negative connection.
1、Remove the main fuse box cover.
2、Disassemble in the order specified in the table。
Installation sequence is opposite to disassembly sequence。

Remove/install fuse box

1、 Remove battery anode connection。
2、Remove self-tapping nail for fixing fuse box。
3、Installation sequence is opposite to disassembly sequence。

Inspection of ignition switches

1、Remove battery negative connection.
2、Open hood cover。
3、Disconnect ignition switch connector。
4、Check the conduction between the terminals of the
ignition switch with an ohmmeter and replace the
ignition switch if it does not meet the technical requirements
renewal

Inspection of backup power

1、Open hood cover
2、Disconnect the backup power connector.
3、Use a voltmeter to check the wire harness end 12 voltage.

exterior lighting system

Removal and Installation of Front Combined Headlamps
1、Remove the positive and negative connection of battery.
2、Open front hood。
3、Disassemble (1, bolt ;2, nut ;3, combined headlamp ;
4,、plug-in) in sequence as shown.

pay attention to：

1、 Halogen bulbs produce a lot of heat when used, if the surface of the bulb is dirty, heat will continue to
accumulate to shorten the service life of the bulb, when changing the bulb to hold the metal flange rather than
glass. The ohmmeter can be used to detect the resistance of the bulb, the resistance is infinite or 0 to replace
the bulb or lamp combination.

11-2
 11.ELECTRICAL SYSTEM

2、Front position lamp and front turn lamp are LED lamp band structure, can use ohmmeter to detect bulb
resistance, resistance infinity or 0 replacement lamp combination

Removal and installation of light control switches

1、Remove the positive and negative connection of battery。
2、Open hood cover。
3、Disconnect headlight switch connector。
4、Push the switch out of the back of the meter。
5、Check the conductivity between the ignition switch
Terminals with an ohmmeter and replace the switch
if it does not meet the technical requirements

Removal and installation of steering light control switches

1、Open hood cover。
2、Disconnect steering light or four-flash switch connector。
3、Push the switch out of the back of the meter。
4、Check the conductivity between the ignition switch
terminals with an ohmmeter and replace the headlamp
if it does not meet the technical requirements。

Removal and Installation of Top Lamps

1、Remove the positive and negative connection of battery。
2、Disconnect the positive power supply connected to the top lamp。
3、Disassemble (1, bolt ;2, top lamp) in the sequence shown in the diagram
4、The order of installation is contrary to the order of disassembly

Removal and Installation of Top Lamp Control Switch

1、Open hood cover。
2、 Disconnect headlamp switch connector。
3、Push the switch out of the back of the meter。
4、Check the conductivity between the ignition switch
terminals with an ohmmeter and replace the switch
if it does not meet the technical requirements。

11-3
 11.ELECTRICAL SYSTEM

Removal and installation of horn

1、 Disconnect horn plug。
2、Disassemble (1, bolt ;2, horn) in sequence shown in the diagram。
3、The order of installation is contrary to the order of disassembly。

Removal and installation of horn control switches

1、Open hood cover。
2、Disconnect horn switch。
3、Push the switch out of the back of the meter。
4、Check the conductivity between the ignition
switch terminals with an ohmmeter and replace
the switch if it does not meet the technical requirements。

Removal and Installation of Electric Top

1、Box raised。
1、Disconnect the electric ceiling。
2、Disassemble (1, open pin ;2, upper fixed pin ;3, open pin ;
4, lower fixed pin ;5, electric top) in sequence as shown.
3、The resistance value of electric top resistor can be
detected by using ohmmeter. The resistance is
infinite or the electric top can be replaced by 0

Removal and Installation of Electric Top Switch

1、Disconnect electric top switch plug-in。
2、Remove the electric top switch from the rear body guard。
3、Use ohmmeter to check the conduction between the
ignition switch terminals, if not meet the technical
requirements to replace the switch;

Removal and installation of instrumentation

1、 Open the hood cover。
2、Remove the nut of the fixed instrument
using the appropriate tool。
3、 Disconnect instrument plug。

11-4
 11.ELECTRICAL SYSTEM

Instrument Display Function Information

1、 A left steering light 12 V positive is effective; the left steering light flashes at the same frequency when the
vehicle turns on。
2、FFar light indicator light 12 V positive very effective light, after the far light turned on this indicator light at
the same time
3、A parking indicator light of 12 V is effectively on the negative pole. After the stop of the vehicle is pulled up,
the indicator lights up and the indicator lights out after the stop is released
4、Oil pressure switch alarm indicator lamp 12 negative effective light, after the engine operation oil pressure
alarm indicator lights out, engine operation when this indicator light is still on, indicating that the engine
lubrication system may not be normal;
5、 A right steering indicator light 12 V is very effective; the indicator lights flicker at the same frequency when
the vehicle turns on the left steering light
6、 A near-light indicator light of 12 V is very effective. When the near-light light is turned on, the indicator
lights up at the same time
7、A width indicator lamp of 12 V is effective. When the near-light is turned on, the indicator lights up at the same
time.
8、EPS the fault indicator light is effectively on the ground, the alarm indicator light EPS extinguished after the
engine is running, and the indicator light is still on when the engine is running, it means that the EPS system may
not be normal, can check whether the speed signal is normal, whether the controlled power input is normal, and
whether the input positive pole of the steering booster head is normal.
9、The fuel alarm indicator lamp, there are two coils in the fuel meter, respectively on the F and E side, the sensor
is a variable resistance controlled by the float height, the change of resistance value determines the strength of the
magnetic force line of the two coils, and also determines the display value of the oil level。
Turn off the ignition switch and disconnect the connector and use
the ohmic gear to measure the resistance
Lower: Blue/white :3-9Ω
Higher: blue/white :90Ω
If the resistance is not in the range of null and full value,
replace the fuel pump. If the fuel level sensor is good,

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 11.ELECTRICAL SYSTEM
please find the line or meter.
10、The water temperature alarm indicator lamp, the sensor of the water temperature meter is a kind of thermistor
type sensor, the signal comes from the coolant temperature sensor at the engine cylinder head;
11、The speedometer obtains the signal from the speed sensor on the gearbox and displays the number through the
change of pulse frequency.
12、 the tachometer works according to the magnetic principle. it receives the pulse signal generated when the
primary current is interrupted in the ignition coil and converts this signal to the displayable speed value. the faster
the engine speed, the more pulse times the ignition coil produces, the greater the rotational speed value displayed
on the table.
13、Engine fault indicator lamp, after engine operation fault alarm indicator lamp extinguished, engine operation
this indicator lamp is still on, engine operation may not be normal, can use the old, fault diagnostic instrument to
detect the fault code of the engine, fault code refers to the self-diagnosis system detected fault or fault.
open the hood upper cover and look for the harness connector
of the fault diagnosis tester next to the ECU.
Unplug the protector and connect the fault
diagnosis tester with special data line.
Open the fault diagnosis tester and read the fault code.

DTC System or Component DTC Description Related Calibration

Number
P0107 Manifold Absolute MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow
P0108 Pressure Sensor (MAP) MAP Circuit High Voltage KsDGDM_MAP_ShortHigh
P0112 Intake Air Temperature IAT Circuit Low Voltage KsDGDM_IAT_ShortLow
P0113 Sensor (IAT) IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh
Coolant/Oil Temperature Sensor
P0117 KsDGDM_CoolantShortLow
Circuit Low Voltage
Coolant/Oil Sensor Coolant/Oil Temperature Sensor
P0118 Circuit High Voltage or Open KsDGDM_CoolantShortHigh

P0122 Throttle Position Sensor TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow
P0123 (TPS TPS Circuit High Voltage KsDGDM_TPS_ShortHigh
P0131 Oxygen Sensor O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow
P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh
P0032 Oxygen Sensor Heater O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHig
h
P0031 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow
P0201 Fuel Injecto Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_Fault
P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_Fault
P0230 Fuel Pump Relay (FPR) FPR Coil Circuit Low Voltage or KsDGDM_FPP_CircuitShortLo
Open w
P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHi
gh
P0336 Crankshaft Position CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal
P0337 Sensor (CKP) CKP Sensor No Signal KsDGDM_CrankNoSignal
P0351 Cylinder 1 Ignition Coil Malfunction KsDGDM_EST_A_Fault
Ignition Coil
P0352 Cylinder 2 Ignition Coil Malfunction KsDGDM_EST_B_Fault
P0505 Idle Control System Idle Speed Control Error KsDGDM_IdleControl
P0562 System Voltage System Voltage Low KsDGDM_SysVoltLow

11-6
 11.ELECTRICAL SYSTEM
P0563 System Voltage High KsDGDM_SysVoltHigh
P0650 MIL MIL Circuit Malfunction KsDGDM_MIL_Circuit
P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low
Tachometer
P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High
P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow
Oxygen Sensor 2
P0138 O2S 2 Circuit High Voltage KsDGDM_O2_2_ShortHigh
P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHig
Oxygen Sensor Heater 2 h
P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow
P0500 Vehicle Speed Sensor VSS No Signal KsDGDM_VSS_NoSignal
P0850 Park Neutral Switch Diag Park Neutral Switch Error KsDGDM_ParkNeutralSwitch
P0445 CCP short to high KsDGDM_CCP_CircuitShortHi
gh
CCP
P0444 CCP short to low/open KsDGDM_CCP_CircuitShortL
ow

STARTING SYSTEM

Starter motor

11-7
 11.ELECTRICAL SYSTEM
Brush

Z Check the brush on the brush holder whether it is

worn abnormal, cracked or not smooth.

Worn, cracked, or not smooth: → Replace

Rectifier

Z Check the rectifier whether it is discolored,

abnormal wear or concave.

Abnormal wear or damage: → Replace

Z If the rectifier is discolored, grind it with sanding

paper, then wipe it with a clean fabric.

Z If there is concave, scrape off insulator B, so that

the distance with A is d.

d≥1.5mm

Armature coil

Z Test the connection between each wire and the

armature coil with the multimeter.

Z If they are not connected, replace the armature

shaft.

Oil seal

Z Check the oil seal lip for damage or leak.

Damage or leakage: →Replace the starter motor.

Starter relay
Z Inter-terminal voltage is 12V. Test the direct
connection of positive and negative poles with the
multimeter.

Z If the starter relay clicks and connected, the starter

relay is OK.
Z When there is no voltage of 12V, they are not
connected, the starter relay is OK.
Z Measure the coil resistance with the multimeter.
If the resistance exceeds the specified value, replace
the starter relay.
The multimeter is set to 1x10Ω.

Starter relay coil resistance: 3-5Ω

OTE: Do not apply battery voltage on the starter relay for more than 2 seconds. This will result in
overheating or damaging the relay coil.

11-8
 11.ELECTRICAL SYSTEM
Auxiliary starter relay

Z Apply 12V voltage between the positive and

negative terminals of

the starter relay. Test the connection between A and B

with the multimeter.

Z If the starter relay clicks and is connected, the

starter relay is OK.

Z When there is no voltage of 12V, they are not

connected, the starter relay is OK.

The multimeter is set to 1x10Ω.

Auxiliary starter relay coil resistance: 90-100Ω

IGNITION SYSTEM

Ignition coil
Primary peak voltage of ignition coil
Z Remove the spark plug cap as shown in the right
figure. Install the new spark plug to the cap. The
cylinder is connected to grounding.
Z Connect the multimeter and the peak voltage
adapter as follows:
+Probe: Green wire or grounding wire
-Probe: Black / yellow wire

11-9
 11.ELECTRICAL SYSTEM
NOTE:
Z Make sure the battery voltage ≥ 12V. The ignition coil wires are connected.
Z When using multimeter and the peak voltage adapter, please refer to the user manual.
Z Move the gear to the neutral position, turn on the ignition device.
Z Press the start button and crank the engine for a few seconds. Then measure the primary peak voltage of the
ignition coil;
Z Repeat the steps above for several times. Measure the maximal value of the primary peak voltage.
Set the multimeter at the AC voltage position.
Primary peak voltage of ignition coil: ≥150V

Note: Do not touch the test probes or spark plug, in case

of electric shock.
Z If the voltage is lower than the standard value,
check the ignition coil and coupling coil.
Resistance of ignition coil
Z Disconnect the ignition coil wires and spark plug
cap. Remove the ignition coil;
Z Measure the resistance of the primary and
secondary windings of the ignition coil with the
multimeter. If the resistance of two coils is close to
the specified value, the ignition coil is in good
condition.
Resistance of ignition coil
Primary winding: 0.1-1.5 Ω (terminal - ground)
Secondary coil: 12-22KΩ (terminal - spark plug cap)

Peak voltage of coupling coil

Z Check the peak voltage of the coupling coil with
following steps.
Z As shown in right figure, connect the multimeter
with the peak voltage adapter.
+Probe: Green wire
-Probe: Blue wire
Z Move the gear to the neutral position, turn on the
ignition device.
Z Press the start button and crank the engine for a
few seconds, and then measure the primary peak
voltage of the coupling coil;
Z Repeat the steps above for several times. Measure
the maximal value of the primary peak voltage.
Put the multimeter at AC voltage step.
eak voltage of coupling coil: ≥4V
Z If the voltage is lower than the standard value, replace coupling coil.
Resistance of coupling coil
The multimeter is put at 1x100Ω step.
Resistance of coupling coil: 120-130Ω
Z If the resistance is not within the specified value, replace the coupling coil.

11-10
 11.ELECTRICAL SYSTEM
CHARGING SYSTEM

Resistance of generator coil

Z Measure the resistance between three wires;
Z If the resistance is not within the specified value,
replace the stator coil.
Z Check the generator core whether it is insulated.
Install multimeter 1×10Ω.
Resistance of generator coil: 0.9-1.5Ω (color: yellow)
Insulation resistance ∞Ω (yellow - grounding wire)
No- load performance of the generator
Z Start the engine with the speed at 5000r/min.
Z Measure AC voltage three wires inside the
generator with the multimeter.
Z If the voltage drops below a specified value,
replace the generator.

Put the multimeter at AC step.

No- load performance of the generator:

﹥200V (AC) at 5000r/min

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 11.ELECTRICAL SYSTEM
Regulator / Rectifier
Z Measure the resistance between terminals with multimeter.

Z If the resistance is not within the range of specified values, replace the regulator / rectifier.

NOTE：If the probe is not connected and the multimeter reading is lower than 1.4V, replace the multimeter
battery.

Red
Black Yellow Yellow Yellow Green Red Black
Yellow 400-500
Yellow 400-500
Yellow 400-500
Green
Red 400-500 400-500 400-500 750-850
Black

11-12
 12. TROUBLESHOOTING

12. TROUBLESHOOTING

ELECTRICAL SYSTEM ·······························12-1 MAGNETO SYSTEM·································12-1

COUPLING UNIT ······································12-1 ENGINE GENERAL ···································12-2

ELECTRICAL SYSTEM

Symptom: NO SPARK OR POOR SPARK

1. Refer to ignition system.
Symptom: STARTER DOES NOT TURN
1. Refer to starting system.
Symptom: STARTER TURNS BUT DOES NOT CRANK THE ENGINE
1. Refer to starting system.
2. Check gear condition on electric starter.
 Worn and/or damaged starter gear. Replace electric starter and/or starter drive.
3. Check condition of starter pinion gear.
 Worn and/or damaged starter pinion and/or ring gear. Replace starter drive and/or drive
pulley fixed sheave.
4. Check splines on starter drive.
 Poor movement of pinion gear on splines. Clean and/or replace starter drive.
Symptom: STARTER TURNS BUT STARTER DRIVE DOES NOT MESH WITH RING GEAR
1. Refer to starting system.
Symptom: STARTER KEEPS RUNNING
1. Refer to starting system.

MAGNETO SYSTEM

Symptom: BATTERY NOT CHARGING OR CHARGING VOLTAGE INADQUATE

1. Check battery
 Battery shows less power. Reload battery.
2. Check magneto for damage and/or electrical failure.
 Radial position of rotor wrong due to broken woodruff key. Replace woodruff key.
 Coating on stator winding is damaged. Replace stator.
 Resistance value is out of specification (refer to technical specifications). Replace
magneto.
 Connector on magneto is damaged and/or has electrical failure. Repair and clean contacts
of connector.
3. Check voltage regulator/rectifier.
 Refer to charging system.
4. Check wiring harness for cracks or other damages.
harness shows electrical failure and/or other damages. Replace/repair wiring harness.

COUPLING UNIT

Symptom: 4 WHEEL DRIVE INDICATION FAILS

1. Check contact screw on gear housing right side for damage and/or wear.
 Shifting indicator switch pin is worn and/or damaged. Replace shifting indicator switch.
 Contact is corroded and/or contact screw for wiring harness got loose. Clean contact
surface and retighten contact screw with recommended torque.
 Wiring harness has broken cable. Replace wiring harness.
Symptom: 4 WHEEL DRIVE DOES NOT ENGAGE OR DISENGAGE

12-1
 12. TROUBLESHOOTING
1. Check actuator and/or actuator shifting fork for wear and/or damages.
 Check if selector works properly. If so, check actuator.
 If selector is out of specifications, check wires, connectors and/or replace selector.
 Actuator shifting fork is worn out and/or damaged. Replace shifting fork of actuator.
 Check function of actuator. Replace if actuator is not turning, refer to GEARBOX.
2. Check shifting sleeve splines and/or shifting fork for wear and/or damages.
 Check sleeve shows damaged splines. Replace shifting sleeve (refer to GEARBOX).
 Shifting fork is worn out and/or engagement pin is damaged. Replace shifting fork.
Symptom: ENGINE MAXIMUM RPM IS TOO HIGH AND VEHICLE TOP SPEED IS NOT REACHED.
1. Check drive/driven pulley area for contamination and/or water intrusion.
 CVT area is contaminated with water, dirt or oil. Clean CVT system and replace damaged
part(s).
2. Check drive/driven pulley spring tension.
 Drive pulley spring tension is too stiff. Replace spring.
 Driven pulley spring tension is too smooth and/or damaged. Replace spring.
Symptom: DRIVE PULLEY NOISE IN IDLE SPEED
1. Check slider shoes (drive pulley).
 Worn slider shoes (increased clearance between governor cup and drive pulley sliding
sheave). Replace all slider shoes at the same time (slider shoes kit).
2. Check driven pulley sliding mechanism (between driven pulley outer and inner sheave).
 Mechanism is stuck and/or damaged. Replace driven pulley assembly.
3. Check roller(s) and/or levers for wear (located on sliding sheave of drive pulley).
 Roller(s) on governor cup is (are) worn out and/or damaged. Replace governor cup
assembly.
 Lever(s) on drive pulley sliding sheave is (are) worn out and/or damaged. Replace all
levers at the same time (lever kit).
4. Check drive pulley screw for torque.
 Loose screw. Retighten screw with recommended torque.
5. Check one-way clutch condition on drive pulley sliding sheave.
 Bearing(s) do(es) not move freely. Replace damaged part(s) and lubricate inside of
one-way clutch.
 Spring sleeve(s) inside one-way clutch is (are) worn out. Replace both sleeves and springs
and lubricate inside of one-way clutch.
 Spring(s) inside one-way clutch is (are) worn out. Replace both pins and springs and
lubricate inside of one-way clutch.
Symptom: DRIVE PULLEY NOISE WHEN ACCELERATING/DECELERATING
1. Check if belt runs in dry condition.
 Drive pulley area is wet/contaminated due to water/dirt intrusion. Clean driven pulley area
and/or drain water out of CVT cover.
2. Check drive/driven pulley screw for torque.
 Loose screw on drive pulley. Retighten screw with recommended torque.
3. Check cam and driven pulley fixed sheave for wear.
 Cam and/or drive pulley fixed sheave out of wear limit and/or damaged. Replace
damaged part(s).
4. Check torque gear fixed in driven pulley sliding sheave for wear.
 Torque gear out of wear limit and/or damaged. Replace torque gear).
5. Check for foreign particles in CVT area (stones, dirt, etc.).
 Small particles damaged belt and/or pulley surface(s). clean system and replace damaged
parts.
Symptom: VIBRATIONS ORIGINATING FROM DRIVE PULLEY
1. Check tightening torque of drive pulley screw.
 Moving sliding sheave. Retighten screw.
2. Check fixed sheave bushings.
 Excessive gap between bushings and fixed sheave shaft, thus restraining sliding sheave
movements. Replace fixed sheave assembly.
3. Check if slider shoes are present and/or placed in correct position.
 Slider shoe(s) is (are) missing and/or damaged. Replace all slider shoes at the same time
(slider shoes kit).
Symptom: VIBRATIONS ORIGINATING FROM DRIVEN PULLEY
1. Check fixed and sliding sheave bushings on driven pulley.
 Excessive gap between bushings and CVT shaft, thus restraining sliding sheave
movements. Replace fixed and/or sliding sheave of driven pulley, polish CVT shaft area with fine
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emery cloth and wipe clean with a cloth.
Symptom: PULLEYS DO NOT DOWN/UP SHIFT PROPERLY.
1. Check drive pulley bushings (cleanliness, wear, etc.)
 Check items 1 and 2 of UNUSUAL ACCELERATION BEHAVIOR.
 Bushings stick to fixed sheave pulley shaft. Clean or replace.
 Spring seat sticks to sliding sheave pulley bushing. Clean system and/or replace sliding
sheave pulley.
 One-way clutch does not operate properly. Clean system and/or replace damaged part(s).
2. Check driven pulley spring tension.
 Driven pulley spring tension is too weak or broken. Replace.
 Driven pulley cam is worn or damaged. Replace.
Symptom: BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE
1. Check if CVT air intake and/or outlet is clogged.
 CVT area heats up due to contamination. Clean air intake and/or outlet from
contamination.
 Fans located on drive pulley is worn or damaged. Replace.
2. Check if pulley sheaves are clean.
 Oil on pulley surfaces. Clean pulley sheaves and replace belt.
 Water intrusion in CVT area. Find root cause and repair. Drain water and replace belt.
Symptom: BELT WORN EXCESSIVELY IN TOP WIDTH.
1. Check drive belt width.
 Considerable wear. Replace belt if narrower than specified (refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT) OR TECHNICAL SPECIFICATIONS)。
2. Check driver belt identification number.
 Wrong type of belt. Replace belt with an appropriate drive belt.
3. Check for localized belt wear caused by belt slippage.
 Localized wear. Replace belt.
Symptom: BELT DISINTEGRATION.
1. Check drive belt lifetime is exceeded..
 Clean CVT system and rebuild with a new drive belt.
2. Check drive belt identification number.
 Excessive belt speed. Using unspecified type of belt. Replace belt with proper type of
belt.
3. Check if pulley sheaves are clean.
 Oil on pulley surfaces. Clean pulley surfaces with fine emery cloth and wipe clean using
pulley flange cleaner and a cloth.
 Drive/driven pulley sheaves are damaged through stones inside CVT area. Clean pulley
surfaces with fine emery cloth, wipe clean with a cloth or replace drive/driven pulley sheaves and
belt.
Symptom: BACK BETWEEN COGS
1. Check drive belt condition.
 Considerable use, belt wearing out. Replace.
Brittle belt condition through aging. Replace belt.

ENGINE GENERAL

Symptom: ENGINE CRANKS BUT FAIL TO START

1. Check if spark plug connectors fit on spark plugs (refer to IGNITION SYSTEM).
2. Check spark plugs.
 Define spark plugs (no spark) or wrong spark plug gap. Readjust gap and clean spark
plugs or replace.
3. Check for fuel on spark plugs.
 Flooded engine (spark plugs wet when removed). Activate engine drowned mode and
crank engine with rags over the spark plug holes.
4. Check battery voltage.
 Battery is discharged and starter works not properly. Charge battery.
5. Check fuel level in fuel tank and fuel pressure. Ensure fuel pump was not disabled.
-- Low or no fuel pressure. Replace defective part(s).
6. Check fuel injectors.
 Plugged or faulty injector(s).Replace defective part(s).

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7. Check idle bypass valve.
 Stuck or defective..
8. Check encoder wheel.
 Bent tooth. Refer to MAGNETO SYSTEM.
9. Check engine compression.
 Insufficient engine compression. Replace defective part(s).
10. Check fault codes in DELPHI. system.
 Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to
COMPONENT INSPECTION AND ADJUSTMENT).
Symptom: ENGINE DOES NOT START
1. Electrical problem.
 Determine if the electrical system works correctly (fuse(s), battery, wiring harness, etc.).
refer to IGNITION SYSTEM.
2. Problem with fuel system (carburetor, fuel pump, hoses, etc.).
 Clean, inspect, repair or replace defective parts. Replace defective part(s).
3. Check engine compression.
 Insufficient engine compression. Replace defective parts.
 Valve seat worn and/or damaged. Repair by performing valve guide procedure (refer to
CYLINDER AND HEAD). Readjust valve clearance.
4. Internal engine problem.
 Overhaul engine to find defective parts. Refer to the appropriate section in ENGINE.
Symptom: ENGINE HARD TO START
1. Check idle bypass valve.
 Stuck or defective. Refer to ENGINE MANAGEMENT.
2. Check closed throttle and idle actuator with DELPHI.
 Wrong TPS zero setting/idle bypass valve reset. Refer to ENGINE MANAGEMENT.
3. Check engine compression.
 Wrong adjustment (likely too tight). Refer to ENGINE MANAGEMENT.
4. Check engine compression.
 Insufficient engine compression. Replace defective part(s) refer to LEAK TEST.
5. Verify spark plug condition.
 Defective, improperly set, worn out, fouled. Identify source of problem and correct.
Replace.
6. Check fuel level in fuel tank and fuel pressure.
 Low or no fuel pressure. Replace defective part(s) refer to FUEL TANK AND FUEL
PUMP.
7. Check CAPS (camshaft position sensor).
Defective sensor/wiring. Refer to ENGINE MANAGEMENT.

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