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Segway SNARLER ATV 2021 Series, Service Manual

The Segway SNARLER ATV 2021 Series is a powerful and versatile all-terrain vehicle designed for off-road adventures. To ensure optimal performance and maintenance, be sure to download the free Service Manual from 88.208.23.73:8080. This comprehensive manual will guide you through all aspects of the SNARLER ATV for a seamless riding experience.

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GENERAL INFORMATION

GENERAL INFORMATION

Standard fastener torque of the whole vehicle

NO.

NO.

Fastener

Fastener

Torque

Torque

Remark

Remark

N·m 

N·m 

kgf·m 

kgf·m 

ft·lb

ft·lb

11

bolt M6

bolt M6

8~12

8~12

0.8~1.2

0.8~1.2

69~103.6 in·lb

69~103.6 in·lb

22

bolt M8

bolt M8

30

30

～

～

40

40

3.0~4.0

22.1~29.5

22.1~29.5

33

bolt M10

bolt M10

40

40

～

～

50

50

4.0~5.0

4.0~5.0

29.5~36.9

29.5~36.9

44

bolt M12

bolt M12

50

50

～

～

60

60

5.0~6.0

5.0~6.0

36.9~44.3

36.9~44.3

Torque of special fasteners for vehicle

11

Nut M12×1.25

70

～

80

7.0~8.0

7.0~8.0

51.6~59

51.6~59

22

Nut M24×2

200

～

250

20~25

20~25

147.5~221.3

147.5~221.3

33

Bolt

30

～

37

3.0~3.7

3.0~3.7

22.1~27.3

22.1~27.3

44

Bolt  M10×1.25×20

Bolt  M10×1.25×20

40

40

～

～

50

50

4.0~5.0

4.0~5.0

29.5~36.9

29.5~36.9

55

Bolt  M10×1.25×40

Bolt  M10×1.25×40

40

40

～

～

50

50

4.0~5.0

4.0~5.0

29.5~36.9

29.5~36.9

66

Bolt  M12×1.25×65

Bolt  M12×1.25×65

50

50

～

～

60

60

5.0~6.0

5.0~6.0

36.9~44.3

36.9~44.3

77

Bolt  M8×16

Bolt  M8×16

35

35

～

～

45

45

3.5~4.5

3.5~4.5

25.8~33.2

25.8~33.2

88

Bolt  M10×1.25×20

Bolt  M10×1.25×20

40

40

～

～

50

50

4.0~8.0

4.0~8.0

29.5~36.9

29.5~36.9

99

Bolt  M10×1.25×120

Bolt  M10×1.25×120

40

40

～

～

50

50

4.0~5.0

4.0~5.0

29.5~36.9

29.5~36.9

10

10

Intermediate shaft support mounting 

Intermediate shaft support mounting 
bolt M12×1.25×25

bolt M12×1.25×25

50

50

～

～

60

60

5.0~6.0

5.0~6.0

36.9~44.3

36.9~44.3

11

11

Drive shaft mounting bolts GB5789 

Drive shaft mounting bolts GB5789 
M8×35

M8×35

35

35

～

～

45

45

3.5~4.5

3.5~4.5

25.8~33.2

25.8~33.2

12

12

Front suspension bolt M10×1.25×45

Front suspension bolt M10×1.25×45

40

40

～

～

50

50

4.0~5.0

4.0~5.0

29.5~36.9

29.5~36.9

13

13

Front suspension bolt M10×1.25×90

Front suspension bolt M10×1.25×90

40

40

～

～

50

50

4.0~5.0

4.0~5.0

29.5~36.9

29.5~36.9

14

14

Front suspension bolt M10×1.25×140

Front suspension bolt M10×1.25×140

40

40

～

～

50

50

4.0~5.0

4.0~5.0

29.5~36.9

29.5~36.9

15

15

Stabilizer bar ball pin GB/T 6183.2 M10×1.25

Stabilizer bar ball pin GB/T 6183.2 M10×1.25

40

40

～

～

50

50

4.0~5.0

4.0~5.0

29.5~36.9

29.5~36.9

16

16

Rear suspension bolt GB5789 

Rear suspension bolt GB5789 
M12×1.25

M12×1.25

50

50

～

～

60

60

5.0~6.0

5.0~6.0

36.9~44.3

36.9~44.3

17

17

Direction machine mounting bolt 

Direction machine mounting bolt 
M12×1.25×25

M12×1.25×25

50

50

～

～

60

60

5.0~6.0

5.0~6.0

36.9~44.3

36.9~44.3

18

18

Direction machine mounting bolt 

Direction machine mounting bolt 
M12×1.25×125

M12×1.25×125

50

50

～

～

60

60

5.0~6.0

5.0~6.0

36.9~44.3

36.9~44.3

19

19

Direction machine mounting nut 

Direction machine mounting nut 
M14×1.5

M14×1.5

100

100

～

～

120

120 10~12

10~12

73.8~88.5

73.8~88.5

20

20

Brake clamp body mounting bolt 

Brake clamp body mounting bolt 
M10×1.25×25

M10×1.25×25

  40

  40

～

～

50

50

  4.0~5.0

  4.0~5.0   29.5~36.9

  29.5~36.9

Summary of Contents for SNARLER ATV 2021 Series

Page 1: ...SERVICE MANUAL ATV SERIES PRODUCTS 20210804 V01...

Page 2: ...RONT AND REAR AXLE 4 1 4 1 FUEL SYSTEM 5 1 5 1 COOLING SYSTEM 6 1 6 1 INTAKE SYSTEM 7 1 7 1 DRIVE CHAIN SYSTEM 8 1 8 1 FRONT AND REAR SUSPENSION 9 1 9 1 WHEEL AND TIRE 10 1 10 1 BRAKE SYSTEM 11 1 11 1...

Page 3: ...ology Co Ltd and is prepared for qualified professional and technical personnel Attempts to repair and maintain the vehicle without proper training and without proper tools and equipment may injure th...

Page 4: ...REVISION INDEX REV RELEASE DATE CHANGES V01 20210709 Updated the Main Harness diagram Updated the Dashboard to new version Added brushed EPS topic Added di erential Rear Axle topic...

Page 5: ...er degree s Celcius centrifugal variable Transmission direct current farad s degree s Fahrenheit foot feet gram s Kilograms per square centimeter hour s liter s lb m mm min N Nm Pa HP PS psi r rpm TDC...

Page 6: ...WARNING WARNING indicates a potential hazard that may result in severe injury or death to the operator bystander or person s inspecting or servicing the vehicle CAUTION CAUTION CAUTION indicates a pot...

Page 7: ...1 1 GENERAL INFORMATION GENERAL INFORMATION Vehicle Identification Number 1 2 Technical parameters of vehicle 1 3 Unit conversion table 1 6 Torque 1 7 GENERAL INFORMATION...

Page 8: ...responding about the Segway Powersports vehicle QJLQH VHULDO FRGH UDPH LGHQWL FDWLRQ FRGH VEHICLE IDENTIFICATION CODE COMPOSITION 1 234567 8 9 10 AOSAAPX1 No Serial Number Meaning Digits No Serial Num...

Page 9: ...kg 9 Rear rack load 132 28 lb 60kg 10 Recommended Traction quality Pulled load quality 661 39 lb 300kg 771 62 lb 350kg Engine 11 Engine model 199MS 12 Engine type Four stroke Single cylinder Water coo...

Page 10: ...speed 36 Shift sequence L H N R P 37 Transmission gear ratio 0 648 2 976 38 Low 5 34 39 High 3 08 40 Reverse 4 40 Tire 41 Tire type All Terrain 42 Front tire speci cation 25 8 12 AT26 8 12 26 8 14 43...

Page 11: ...lectrical System 56 Ignition mode Electric ECU 57 Charge 450W 5500 rpm 58 Battery 12V 32Ah Light 2 status Light 2 status 59 Headlight LED 13 2W H4 55W 60W 60 Front turn light LED 2 64W 4 8W 61 Day lig...

Page 12: ...8 07 98 07 14 22 14 22 1 333 1 333 kPa kPa psi psi kPa kPa Power N N N N 0 1020 0 1020 0 2248 0 2248 kg kg lb lb kg kg kg kg 9 807 9 807 2 205 2 205 N N lb lb Volume L L L L L L L L L L L L mL mL mL m...

Page 13: ...4 16 18 16 18 1 6 1 8 1 6 1 8 11 8 13 3 11 8 13 3 7 Hexagon socket head stepped bolt 10 14 1 0 1 4 7 4 10 3 8 8 bolt M8 30 bolt M8 30 18 22 18 22 1 8 2 2 1 8 2 2 13 3 16 2 13 3 16 2 9 9 Connecting wat...

Page 14: ...0 8 1 2 69 103 6 in lb 69 103 6 in lb 28 28 bolt M6 35 bolt M6 35 8 12 8 12 0 8 1 2 0 8 1 2 69 103 6 in lb 69 103 6 in lb 29 29 bolt M6 40 bolt M6 40 8 12 8 12 0 8 1 2 0 8 1 2 69 103 6 in lb 69 103 6...

Page 15: ...rt mounting bolt M12 1 25 25 bolt M12 1 25 25 50 50 60 60 5 0 6 0 5 0 6 0 36 9 44 3 36 9 44 3 11 11 Drive shaft mounting bolts GB5789 Drive shaft mounting bolts GB5789 M8 35 M8 35 35 35 45 45 3 5 4 5...

Page 16: ...e oil cup 2 9 Check rear brake oil cup liquid level 2 10 Replace brake fluid 2 10 Pump out brake uid from brake system 2 10 Refill brake fluid 2 11 Discharge air in the brake system 2 12 Replace of fr...

Page 17: ...Engine Oil Level Check 2 19 Changing engine oil lter 2 20 Oli strainer clean 2 20 Oil lter change 2 21 Front Rear Axle Gear Oil 2 21 Wheels Tires Wheels Tires 2 22 Tire Inspection 2 22 Propeller Shaft...

Page 18: ...cted to severe use D Have an authorized dealer or other qualified person perform these services Perform all services at whichever maintenance interval is reached first Record maintenance and service i...

Page 19: ...rication 50 H 3 M 3 M 500 800 Lubricate all ttings pivots cables etc Throttle Body Intake Duct 50 H 6 M 500 800 500 800 Inspect duct for proper sealing air leaks Drive belt 50 H 6 M 500 800 Inspect ad...

Page 20: ...t clean replace worn parts D Spark plug 100 H 12 M 1000 1600 Inspect replace as needed D Clutches drive and driven 100 H 12 M 3700 6000 Inspect clean replace worn parts D Front wheel bearings 100 H 12...

Page 21: ...peed increases check the throttle lever free If the idle speed increases check the throttle lever free play and the cable routing play and the cable routing Stop the engine and check the throttle leve...

Page 22: ...fe driving conditions conditions C C B B A A Cleaning or replacing air lter A metal buckle B Air lter cover combination C filter element disassemble plastic parts before replacing it see body part cha...

Page 23: ...ke pads thickness is smaller than 1mm replace both brake pads together Inspection of front brake hose and connection Check brake hose and accessories if any aging crack and leakage If pipe is not prop...

Page 24: ...e new brake hose in position refer to annex and fasten oiling bolt Torque of brake hose oiling bolt 25N m 25N m 2 5kgf m 2 5kgf m 18 4ft lb 18 4ft lb Check uid level of front brake oil cup Put hand br...

Page 25: ...oil cup of hand brake upper pump assy C C oil cup cover of rear brake oil cup cover of rear brake D D oil cup of rear brake oil cup of rear brake E E bleeder valve bleeder valve disassemble oil cup co...

Page 26: ...ake hose re ll oil cup twice at least each time and screw up air nozzle clockwise and then rotate vacuum tank air valve to close it Torque of air outlet 12N m 1 2kgf m 1 2kgf m 8 8ft lb 8 8ft lb 2 Vac...

Page 27: ...zle clockwise and then rotate vacuum tank air valve to close it Torque of Air Outlet 7 9N m 7 9N m 0 8kgf m 0 8kgf m 94 8in lb 94 8in lb TIPS TIPS Check liquid level in the brake oil cup regularly Che...

Page 28: ...r brake bolt 40 50 N m 4 0 5 0kgf m 29 5 36 9ft lb WARNING WARNING When you replace brake discs you need to replace When you replace brake discs you need to replace inside and outside discs together i...

Page 29: ...ston please replace them Check first seal ring C and second seal ring D If any wearing damage deformation rot or swelling replace piston components to refresh seal ring If any fluid leakage is found i...

Page 30: ...iston If piston oil seal is changed dust seal cushion should be replaced too Besides the seal cushion should be replaced at intervals Replace dust seal and dust sleeve in the brake assembly piston A D...

Page 31: ...st parking wire handle till it is within parking handle free play speci cation Adjustment of free play of parking handle A A B B C C Check rear parking handle free play A Parking handle free play Chec...

Page 32: ...amage Keep the steam gun away more than 0 5 m 20 in from the radiator core A Hold the steam gun perpendicular to the core surface Run the steam gun following the core n direction Radiator Hose and Con...

Page 33: ...at spills on the frame engine or wheels Since coolant is harmful to the human body do not use for drinking Remove front rack see body part Remove front maintenance cover A Max level B Min level Add co...

Page 34: ...If the oil level is above the Upper Level then there is too much oil Engine operation with too little or too much oil will cause damage A Upper engraved line B Lower engraved line C Oil ller cap After...

Page 35: ...ge a new sealing washer onto the drain plug and reinstall the drain plug back C Torque specifications Oil drain plug 16 20 N m CAUTION CAUTION The hot oil may burn the skin Do not let the oil contact...

Page 36: ...lter Change a new O shape ring onto a new oil filter inspect and make sure the O shape ring is in good condition Remove the oil filter to be replaced by the tool counterclockwise Rotate clockwise to i...

Page 37: ...corresponding convex when the pattern block convex surface wear to the convex position you should change the tire otherwise due to insufficient strength the tire will burst midway internal damage requ...

Page 38: ...1 9 Oil Pressure Valve 3 1 10 Oil Pressure Valve 3 1 10 Oil Pressure Valve Removal 3 1 10 Oil Pressure Valve Removal 3 1 10 Oil Pressure Valve Installation 3 1 10 Oil Pressure Valve Installation 3 1...

Page 39: ...ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM 3 1 2 Exploded view...

Page 40: ...Needle Roller 4 15 8 18 Oil Pickup Pipe 19 Strainer Filter 20 Strainer Filter Spring 21 O Ring 82 3 1 22 Strainer Filter Cover 23 O Ring 13 8 2 5 24 Bolt M6 25 10 1 7 25 Engine Drain Plug M14 18 1 8 1...

Page 41: ...Grade Viscosity Capacity API SH or SJ SAE 10W 40 2 0 L 1 80 US qt when lter is not removed 2 2 L 2 01 US qt when lter is removed 2 4 L 2 33 US qt when engine is completely dry Oil Pressure Measurement...

Page 42: ...EM 3 1 5 Special tools and sealants Oil Pr Oil Pressure Gauge 10 kgf cm essure Gauge 10 kgf cm2 2 E01GZ0030001 Z0 Z0030001 030001 Oil Pressure Test Hose M10 Oil Pressure Test Hose M10 1 E01GZ0040001 0...

Page 43: ...Filter 7 Oil Nozzles 13 Transmission Countershaft Assembly 2 Oil Pump 8 Piston 14 Crankshaft 3 Oil Pressure Valve Unit 9 Camshaft IN 15 Starter One Way Gear 4 Oil Filter 10 Camshaft EX 16 Alternator...

Page 44: ...eral minutes for all the oil to drain back to the sump Unscrew the oil ller cap A wipe its dipstick B dry and tighten it into the ller opening Unscrew the oil ller cap and check the oil level The oil...

Page 45: ...in the Periodic Maintenance chapter to ll the oil lter Coarse Filter Removal Coarse Filter Removal Remove the Coarse Filter Cover The Coarse Filter A out of the crankcase Coarse Filter Cleaning Coars...

Page 46: ...110O O C 230 C 230O O F of oil temp F of oil temp If the oil pressure is much lower than the standard inspect the relief valve oil pump and or crankshaft bearing insert wear If the oil pressure is muc...

Page 47: ...valve to make sure that the valve A moves smoothly and that it returns to its original position by the force of the spring B NOTE NOTE The Oil Pressure Valve cannot be disassembled and it must be ins...

Page 48: ...Bolts A Oil Pump Cover E Shaft Oil Pump F Needle Roller 4 15 8 C Inner Rotor D Outer Rotor Oil Pump Installation Oil Pump Installation Apply engine oil Oil Pump Shaft Inner and Outer Rotors Install Ou...

Page 49: ...her 15 28 1 G Oil Pump Idler Gear H Hexagon Flange Boltm 10 1 25 25 A Flat Washer10 30 3 B Drive Gear D Flat Key C Oil Pump Gear Installation Oil Pump Gear Installation Apply engine oil Oil Pump Idler...

Page 50: ...tion Install 1 Replace the O ring D with new ones 2 2 Cooler Cooler C 3 Screw M6 16 B Torque Oil Pump Bolts B 10 N m 1kgf m 7ft lb 4 Spring band hose clamps A 5 Fill the engine coolant and oil Oil Fil...

Page 51: ...5 Crankshaft Runout 3 2 25 Crankshaft Main Bearing Journal Wear 3 2 25 Crankshaft Main Bearing Journal Wear 3 2 25 Transmission 3 2 26 Transmission 3 2 26 Transmission Removal 3 2 26 Transmission Remo...

Page 52: ...CRANKSHAFT TRANSMISSION CRANKSHAFT TRANSMISSION 3 2 2 Exploded view L L L L O O O O O O O O O O O O O O G G G G O O L L O O O O O O...

Page 53: ...CRANKSHAFT TRANSMISSION CRANKSHAFT TRANSMISSION 3 2 3 S S Left Left Right Right 4 4 S S 8 8 S S 6 6 S S S S S S 20 20 20 20 20 20 S S 20 20...

Page 54: ...ction Hole Plug 4 0 4 35 in lb L 14 Bearing 6304 O 15 Bearing 6203 O 16 Bearing 6006 O 17 Plate Bearing Retainer 18 Bolt M6 16 9 8 1 0 87 in lb L 19 Oil Seal 42 55 8 G 20 Bolt M6 40 9 8 1 0 87 in lb S...

Page 55: ...CRANKSHAFT TRANSMISSION CRANKSHAFT TRANSMISSION 3 2 5 Lh Lh L L L L L L O O O O O O O O O O O O G G G G R R G G G G O O O O O O L L L L L L L L L L Lh Lh...

Page 56: ...25 30 120 12 89 L 19 Spacer 12 5 32 5 20 O Ring 20 2 65 O 21 Transmission Shaft Flange 22 Oil Seal 44 60 7 G 23 Nut M55 1 5 6 LH 120 12 89 L Lh 24 Bearing 6205 25 Transmission Shaft 26 Bearing 6207 O...

Page 57: ...lt M6 40 14 1 4 10 L 54 Shift Fork Spring Seat 55 Shoulder Bolt 14 1 4 10 L 56 Detent Pawl 57 Detent Pawl Torsion Spring 58 Shift Fork 59 Shift Fork L 60 Shift Rail L O 61 Parking Brake Arm 62 Parking...

Page 58: ...ce Crankpin diameter Connecting rod big end inside diameter Connecting rod big end bearing insert thickness White Blue 0 13 0 48 mm 0 028 0 052 mm 39 992 40 000 mm 44 000 44 016 1 987 1 990 mm 1 984 1...

Page 59: ...CRANKSHAFT TRANSMISSION CRANKSHAFT TRANSMISSION 3 2 9 Item Standard Service Limit Transmission Transmission Shift fork ear thickness Shifter groove width 5 8 5 9 mm 6 0 6 1 mm 5 7 mm 6 2 mm...

Page 60: ...ANKSHAFT TRANSMISSION CRANKSHAFT TRANSMISSION 3 2 10 Special tools and sealants Outside Circlip Pliers Outside Circlip Pliers Bearing Driver Set Bearing Driver Set Sealant 5699 Sealant 5699 Sealant 56...

Page 61: ...r 5 Camshaft and Chain see Engine Top End chapter 6 Left Crankcase Bolts M6 A 7 Left Crankcase Bolts M8 B 8 Shiftshaft Cover Bolts M6 C 9 Parking Brake Spring Plug D Gasket Spring and Parking 10 Brake...

Page 62: ...B 2 Gear Sensor A 3 Right Crankcase Cover Bolts M6 30 C 4 Right Crankcase Cover D 5 Right Crankcase Cover Gasket E Remove 1 Circlip 25 1 2 A 2 Washer B 3 Gentrifugal oil air Separator C 4 Dowel Pin 6...

Page 63: ...RANKSHAFT TRANSMISSION 3 2 13 Remove 1 Wrap the teeth on the sprockets B by taping for protecting the bushing in the crankcase 2 Using the pry points A split the crankcase halves 3 Lift o the right cr...

Page 64: ...could result Apply a small amount of engine oil to the transmis sion gears bearings and shift fork Be sure the mating surfaces of the crankcase halves are clean and dry Press and insert the new ball...

Page 65: ...rque Chain Guide Bolts B 12 N m 1 2 kgf m 8 7 ft lb Apply a non permanent locking agent to the Bolts B Install Piston Injection Hole Plug G Flow Ori ce 1 F Tighten Torque Piston Injection Hole Plug G...

Page 66: ...Bearing 6006 2 Apply engine oil to the bearings Install the position plates D Apply a non permanent locking agent to the position plate mounting screws E Tighten Torque Position Plate Mounting Screws...

Page 67: ...ue Nut C 120 N m 12 kgf m 89 ft lb Apply a non permanent locking agent to the Nut C Install Grease the lip A of the oil seal 44 60 7 D and press the seal 1 0 mm H inwards from the end of the boss Inst...

Page 68: ...ent locking agent to the Nut B Install Grease the lip A of the oil seal 44 60 7 D and press the oil seal 2 2 mm H inwards from the end of the boss Install insert the O Ring 20 2 65 N to the Transmissi...

Page 69: ...305 Install Bearing Frame Plate A Screw M8 25 C Tighten Torque Screw M8 25 C 26 N m 2 7 kgf m 20 ft lb Apply a non permanent locking agent to the Screw C Install 1 Drive Bevel Gear Shaft Reduction Dri...

Page 70: ...ve Bevel Gear shaft Assembly A 2 Parking Brake Arm B Snap Ring 12 C Parking Brake Shaft D 3 Countershaft Assembly E Shift Rail L F Shift Rail H R G Shift Drum H 4 Transmission Main Shaft I 5 R Idle Ge...

Page 71: ...g A Crankshaft Rod B Crankshaft Case oil passages Main bearing bore E CAUTION CAUTION The Crankshaft and Balance Shaft Gear mark points D must be aligned Apply liquid gasket C to mating surface of the...

Page 72: ...ollowing the tightening sequence 1 5 M8 6 9 M6 Torque Bolts M6 Bolts M8 9 8 N m 1 0 kgf m 87 in lb 20 N m 2 0 kgf m 14 ft lb 1 2 L 70 mm 3 5 L 40 mm 6 9 L 65 mm Apply grease to the steel ball A Parkin...

Page 73: ...M6 40 F Shoulder Bolt J 14 N m 1 4 kgf m 10 ft lb 14 N m 1 4 kgf m 10 ft lb Apply a non permanent locking agent to the Bolts F and J Install N Shiftshaft Cover Gasket O Shiftshaft Cover P Oil Seal 15...

Page 74: ...ain bearing bore N Apply grease the lip of the oil seal L and M Install Put the O Ring 29 6 2 4 P into the Gear Sensor groove H Apply engine oil to the O Ring 29 6 2 4 P Install Right Crankcase Cover...

Page 75: ...ankshaft Runout Measure the crankshaft runout If the measurement exceeds the service limit replace the Crankshaft Standard TIR 0 04 mm 0 0016 in or less Service Limit TIR 0 10 mm 0 0039 in Crankshaft...

Page 76: ...ift lever see Shift Lever Removal Remove the Shiftshaft see Crankcase Disassembly Split the crankcase see Crankcase Disassembly Remove Drive Bevel Gear Component Bolts A Drive Bevel Gear Component B R...

Page 77: ...CRANKSHAFT TRANSMISSION CRANKSHAFT TRANSMISSION 3 2 27 Remove Main Shaft A Remove Countershaft Assembly B Shift Rail L C Shift Rail H R D Shift Drum E Component A A B B C C E E D D E E D D C C B B...

Page 78: ...allation Transmission Installation Install Insert the Parking Brake Arm Assembly in the crankcase until it is bottomed Install Drive Bevel Gear Assembly A Bolts M8 30 B Apply a non permanent locking a...

Page 79: ...r allow the transmission to jump out of gear when under power A 90 Shift Fork Gear and Shifter Groove Wear Shift Fork Gear and Shifter Groove Wear Measure the thickness of the shift fork ears B and me...

Page 80: ...n Transmission and Shift Mechanism Inspection Visually inspect Gears Dogs of Gear and Shifter If they are damaged or worn excessively replace them Install 1 Install the Countershaft Assembly Shift Rai...

Page 81: ...e gear 15 15 Circlip 25 1 2 Circlip 25 1 2 5 5 Spacer 28 36 5 1 Spacer 28 36 5 1 16 16 Gear H Gear H 6 6 Gear R Gear R 17 17 Bushing H Bushing H 7 7 Bushing R Bushing R 18 18 Gear P Gear P 8 8 Shifter...

Page 82: ...case with a torch This will warp the case Soak the case in oil and heat the oil Using a press and the bearing driver set A install the new ball bearing until it stops at the bottom of its housing Spe...

Page 83: ...f measuring inspect the bearing for abrasion color change or other damage Spin A the bearing by hand to check its condition If there is any doubt as to the condition of a needle bearing replace it Oil...

Page 84: ...ternator Stator Removal 3 3 8 Alternator Stator Removal 3 3 8 Alternator Stator Installation 3 3 9 Alternator Stator Installation 3 3 9 Alternator Inspection 3 3 10 Alternator Inspection 3 3 10 Stator...

Page 85: ...ENGINE ELECTRICAL SYSTEM ENGINE ELECTRICAL SYSTEM 3 3 2 O O O O O O L L L L L L 22 22 23 23 23 23 23 23 23 23 R R Exploded view...

Page 86: ...t M18 1 5 180 18 4 133 L 10 Alternator Rotor 11 Double Gear Shaft 12 One Way Clutch O 13 Spacer 12 18 12 14 Bolt M6 16 20 2 14 5 L 15 Spacer 12 20 1 16 Needle Roller Bearing K121616 O 17 Starting Driv...

Page 87: ...3 4 Item Standard Service Limit Charging System Charging System Alternator type Charging voltage Regulator recti er output voltage Alternator output voltage Stator coil resistance Three phase AC 14 15...

Page 88: ...ENGINE ELECTRICAL SYSTEM ENGINE ELECTRICAL SYSTEM 3 3 5 Flywheel Puller Assembly E01GZ0010001 Special tools Flywheel Holder E01GZ0050001...

Page 89: ...t A Bolts M6 30 12 B Bolts M6 55 2 C Alternator Cover Alternator Cover Installation Alternator Cover Installation Be sure all of the old gasket has been removed from the alternator cover and the left...

Page 90: ...Tool Flywheel Puller Special Tool Flywheel Puller E01GZ0010001 E01GZ0010001 Flywheel Holder Flywheel Holder E01GZ0050001 E01GZ0050001 Holding the Flywheel Holder Flywheel Holder B B turn the rotor pu...

Page 91: ...rotor Install the alternator rotor B while turning the starter clutch gear C Nut M18 1 5 D Tighten Torque Nut C 180 N m 18 4 kgf m 133 ft lb Apply a non permanent locking agent to the Nut C Special To...

Page 92: ...tip B 2 3 mm 0 08 0 12 in Tighten Torque Bolts M6 35 13 N m 1 3 kgf m 113 in lb Bolts M6 16 9 8 N m 1 0 kgf m 87in lb Install Crankshaft Sensor see Crankshaft Sensor Installation Fit the lead grommet...

Page 93: ...isconnect the alternator connector A Connect a hand tester as shown in the table Start the engine Run it at the rpm given in the table Note the voltage readings total 3 measurements Alternator Output...

Page 94: ...n open and must be replaced Much less resistance means the stator is shorted and must be replaced Using the highest resistance range of the hand tester measure the resistance between each of the black...

Page 95: ...d crankcase E where the starter motor is grounded If the O ring F shows wear or damage or if it is hardened replace it with a new one Apply a small amount of engine oil to the O ring Install Starter M...

Page 96: ...e Way Clutch Bolts A Tighten Torque Starter Motor Clutch Bolts 20 N m 2 kgf m 14 5 ft lb One Way One Way Clutch Inspection Clutch Inspection Remove Alternator Rotor see Alternator Rotor Removal Fit th...

Page 97: ...ect the Starter Gear If the gear does not operate correctly or if it makes noise disassemble it and examine each part visually Replace any worn or damaged parts Starter Gear Installation Starter Gear...

Page 98: ...aft Removal 3 4 8 Water Pump Shaft Removal 3 4 8 Mechanical Seal Replacement 3 4 8 Mechanical Seal Replacement 3 4 8 Water Pump Cover Installation 3 4 10 Water Pump Cover Installation 3 4 10 Thermosta...

Page 99: ...ENGINE COOLING SYSTEM ENGINE COOLING SYSTEM 3 4 2 Exploded view...

Page 100: ...in lb 4 Bolt M6 35 9 8 1 0 87 in lb 5 Hose 11 20 671 6 Clamp Hose 7 O Ring 33 2 62 8 Water Pump Gasket 9 Clamp Springband 10 Connector Tee 11 Hose 12 20 147 12 Adapter Water Pipe 13 Aluminum Washer 14...

Page 101: ...ter and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 31 3 0 L 3 17 US qt reserve tank full level including radiator...

Page 102: ...ENGINE COOLING SYSTEM ENGINE COOLING SYSTEM 3 4 5 Bearing Remover Head Bearing Remover Shaft Special tools Bearing Driver Set...

Page 103: ...Pump O ring A Install the Water Pump Gasket D to the sealing groove of the alternator cover Turn the notch B of the water pump shaft to align the convex square C side of the oil pump shaft Install th...

Page 104: ...ts A Water Pump Cover B Water Pump Cover Seal C Impeller Removal Impeller Removal Loosen the water pump impeller Bolt D counter clockwise Remove the Gasket E Remove the impeller F Water Pump Impeller...

Page 105: ...de of the Water Pump Body with the bearing driver set C Special Tool Bearing Driver Set CAUTION CAUTION If either the mechanical seal oil seal or the ball bearing is removed make sure to replace all o...

Page 106: ...hole Special Tool Bearing Driver Set From inside the Water Pump Body press and insert the ball bearing E until it is bottomed Special Tool Bearing Driver Set Install the Spacer F From inside the Wate...

Page 107: ...A and press the rubber seal B and sealing seat into the impeller by hand until the seat bottoms out install the Gasket C Tighten the water pump impeller by turning the bolt D clockwise Torque Water Pu...

Page 108: ...ts B Thermostat Housing Cover C Thermostat A Thermostat Installation Thermostat Installation Be sure to install the O ring D on the Thermostat Install Thermostat A Thermostat Housing Cover C Thermosta...

Page 109: ...hermometer B in a container of water with the heat sensitive portions C in almost the same depth NOTE NOTE Take care against burns from hot engine oil that will drain through the oil passage when the...

Page 110: ...Periodic Maintenance chapter Disconnect the Sensor lead Remove the Sensor B Coolant Temperature Sensor Installation Coolant Temperature Sensor Installation Apply silicone sealant to the threads of the...

Page 111: ...ction 3 5 13 Valve Cover Removal 3 5 14 Valve Cover Removal 3 5 14 Valve Cover Installation 3 5 14 Valve Cover Installation 3 5 14 Crank Position Sensor Removal 3 5 15 Crank Position Sensor Removal 3...

Page 112: ...ar 3 5 31 Piston Wear 3 5 31 Piston Cylinder Clearance 3 5 32 Piston Cylinder Clearance 3 5 32 Piston Ring Piston Ring Groove Wear 3 5 32 Piston Ring Piston Ring Groove Wear 3 5 32 Piston Ring Groove...

Page 113: ...ENGINE TOP END ENGINE TOP END 3 5 3 O O R R R R R R R R R R R R L L L L O O O O O O O O O O SS SS S S S S S S O O 8 8 O O O O O O O O O O G G Exploded view...

Page 114: ...inder Head Bolt 75 7 7 54 S 19 Bolt M8 25 20 2 0 14 20 Clamp 50 70 21 Air Intake Pipe 22 Bolt M6 12 9 8 1 0 87 in lb L R 23 Timing Driven Sprocket 24 Intake Camshaft Assembly O 25 Exhaust Camshaft Ass...

Page 115: ...d O ring L Apply a non permanent locking agent O Apply engine oil SS Apply silicone sealant S Follow the speci c tightening sequence R Replacement Part No Fastener Torque Remarks N m kgf m ft lb 49 Se...

Page 116: ...nce Cold Exhaust Intake Valve head thickness Exhaust Intake Valve stem bend Valve stem diameter Exhaust Intake Valve Stem Oil Clearance Exhaust Intake Valve Stem Overall Length Exhaust Intake Valve va...

Page 117: ...32 mm 0 0520 1 10 mm 0 0433 1 10 mm 0 0433 Camshafts Cam Lobe height Exhaust Intake Camshaft journal diameter All Camshaft Journal Bore diameter All Camshaft Oil Clearance Camshaft End Play Camshaft r...

Page 118: ...urface Warp Limit Cylinder Bore Standard Cylinder Out of Round Limit Cylinder Taper Limit Cylinder Piston Clearance 0 05 mm 0 002 98 992 99 000 mm 3 8973 3 8976 99 000 99 008 mm 3 8976 3 8980 0 025 mm...

Page 119: ...ENGINE TOP END ENGINE TOP END 3 5 9 Compression Gauge Valve Spring Compressor Assembly Valve Spring Compressor Adapter Compression Gauge Adapter M10 1 0 Special tools...

Page 120: ...ENGINE TOP END ENGINE TOP END 3 5 10 Spark Plug Valve Cover Throttle Body Camshaft...

Page 121: ...y Installation Throttle Body Installation Install Throttle Body Clamp 50 70 Air Intake Pipe Air Intake Pipe Removal Removal Remove Bolts M8 25 A Air Intake Pipe Removal B Air Intake Pipe Installation...

Page 122: ...Injector Press Plate C Fuel Injector Adapter D Fuel Injector E Fuel Injector Installation Installation Fuel Injector E Fuel Injector Adapter D Fuel Injector Press Plate C Fixed Plate B Fuel Injector B...

Page 123: ...e Such a shock to the part can damage it NOTE NOTE Remove the spark plug Stuff spark plug holes with shop towels to prevent anything from falling into the combustion chamber Spark Plug Installation Sp...

Page 124: ...A A A A B B D D Valve Cover Valve Cover Installation Valve Cover Installation Replace isolators B and valve cover seal C if oil leaks are evident Prepare valve cover sealing surfaces by cleaning thor...

Page 125: ...e crankshaft until the flywheel TDC mark B is aligned or centered in the Crankshaft Position Sensor CPS mounting hole to relieve most of the valve spring pressure The camshaft lobes should face out an...

Page 126: ...the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Tensioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the...

Page 127: ...retaining camshaft carrier carefully lift the camshaft carrier o the camshafts Lift the chain off the camshafts to allow each Camshaft to be removed NOTE NOTE Carefully remove camshafts from the cylin...

Page 128: ...sion Release unit Visually inspect the spring If damaged deformed or missing replace the spring Remove the spring and move the Weight Block back and forth If the Weight Block do not move smoothly repl...

Page 129: ...on the intake and exhaust camshafts Fix the hexagonal surface A of the Camshaft with tools and tighten the sprocket bolts Apply a non permanent locking agent to the bolts Torque Sprocket bolts 19 N m...

Page 130: ...damaged or if any part is worn past the service limit Standard Service Limit 22 954 22 975 mm 0 9036 0 9045 22 944 mm 0 9033 Temporarily install the camshaft carriers to measure the camshaft bore Torq...

Page 131: ...B and head gasket D Cylinder H Cylinder Head Inspection ead Inspection Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon CAUTION CAUTION Use care not to damage...

Page 132: ...emove them Remove the valve bucket F from the cylinder head Compress the valve spring by hand using valve spring compressor adapter G Push down on spring and remove split keepers H Slowly release valv...

Page 133: ...as possible to the cylinder head mating surface Move C the stem back and forth to measure valve valve guide clearance Repeat the measurement in a direction at a right angle to the rst If the reading...

Page 134: ...crometer in three places then rotate 90 and measure again take six measurements total Compare to speci cations Valve Guide I D 5 500 5 515 mm 0 2165 0 2171 Be sure to measure each guide and valve comb...

Page 135: ...ve seating surface A between the valve B and valve seat C Coat the valve seat with machinist s dye Push the valve into the guide Rotate the valve against the seat with a lapping tool Pull the valve ou...

Page 136: ...rea of the seat on the valve face apply a thin coating of Prussian Blue paste to the valve seat If using an interference angle 46 apply black permanent marker to the entire valve face A Insert valve i...

Page 137: ...5 C 60 D 1 0 1 1mm 0 0394 0 0433 Service Limit 1 4mm 0 055 A 30 B 45 C 60 E 1 5 1 6mm 0 0591 0 0630 Service Limit 1 9mm 0 075 Clean all lings from the area with hot soapy water Rinse and dry with comp...

Page 138: ...e times until the valve is fully seated and the seating surface is smooth Then repeat process for the other valve s Thoroughly clean cylinder head and valves CAUTION CAUTION Do not grind the seat too...

Page 139: ...ully spread the ring opening with your thumbs and then push up on the opposite side of the ring C to remove it Remove the 3 piece oil ring with your thumbs in the same manner Cylinder Removal Cylinder...

Page 140: ...g A so that the A1 mark B faces up Install the second ring C so that the A2 mark D faces up The piston ring openings must be positioned as shown in the gure The openings of the oil ring steel rails mu...

Page 141: ...the three locations total of six measurements shown in the gure If any of the cylinder inside diameter measurements exceeds the service limit replace the cylinder 10 mm 0 4 in A 60 mm 2 4 in B 20 mm...

Page 142: ...m 0 0007 0 0023 Second Ring 0 020 0 060 mm 0 0007 0 0023 Service Limit 0 12 mm 0 0047 If the piston ring groove clearance is greater than the service limit measure the ring thickness and groove width...

Page 143: ...Piston Ring End Gap Place the piston ring A inside the cylinder using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the...

Page 144: ...a non permanent locking agent to the bolts E Install Cylinder Head Assembly A Cylinder Head Bolts M11 1 25 150 B Bolts M6 90 C Tighten the cylinder head bolts M11 B following the tightening sequence a...

Page 145: ...u can reference the part number stamped on the end of the shafts and compare to the electronic parts catalog Lubricate all camshaft lobes and bearing journal surfaces with engine oil prior to installa...

Page 146: ...hain Tensioner Installation Camshaft Chain Tensioner Installation Push the stopper A to release the ratchet and push the push rod B into the tensioner body Install Replace the New Tensioner Gasket A T...

Page 147: ...easurement if clearance is out of speci cation Repeat the above steps until all four valves have been inspected Measurement Valve Clearance cold Exhaust 0 2 0 3mm 0 0080 0 0120 Inlet 0 1 0 2mm 0 0040...

Page 148: ...l the proper tappet Repeat the above steps until all necessary valves have been adjusted Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to speci cation Tighten Torque Bolts...

Page 149: ...appets Part Number F01A20007 001 002 003 004 005 006 007 008 009 010 3 digit number 480 482 484 486 488 490 492 494 496 498 Part Number F01A20007 011 012 013 014 015 016 017 018 019 020 3 digit number...

Page 150: ...asurement NOTE NOTE Use the battery which is fully charged Warm up the engine thoroughly and stop the engine Remove the spark plug see Electrical System chapter Attach the compression gauge and adapte...

Page 151: ...ged or missing compression release cam spring Replace the spring Compression release weights do not move smoothly Replace the compression release unit Cylinder compres sion is lower than usable range...

Page 152: ...0 Drive Belt Removal 3 6 10 Drive Belt Installation 3 6 10 Drive Belt Installation 3 6 10 Drive Belt Inspection 3 6 10 Drive Belt Inspection 3 6 10 Drive Pulley and Driven Pulley 3 6 11 Drive Pulley a...

Page 153: ...CVT SYSTEM CVT SYSTEM 3 6 2 L L G G G G R R Lh Lh R R R R Exploded view...

Page 154: ...lug Seal 8 Bolt M6 28 9 8 1 0 87 in lb L 9 CVT Cover Plug 10 Bolt M12 1 25 142 120 12 2 88 R Lh 11 Spacer 12 28 6 12 Bolt M10 1 25 80 80 8 2 59 R 13 Spacer 10 5 36 8 14 Drive Belt 15 Driven Pulley Spa...

Page 155: ...CVT SYSTEM CVT SYSTEM 3 6 4 R R R R G G R R L L Lh Lh M M G G G G G G...

Page 156: ...eight Shoes 14 Thrust Plate Shoes 15 Screw M4 8 6 0 61 53 L 16 Spring Washer 17 Spacer 18 Nut 100 10 2 74 Lh 19 Circlip 35 20 Bearing 61907 2RS R 21 Driven Fixed Sheave 22 Bushing 35 39 18 G 23 Circli...

Page 157: ...e Pulley Bushing 10 inside diameter Bushing 11 inside diameter Shoe side clearance Spring free length 55 005 55 095 mm 2 166 2 169 32 003 32 073 mm 1 260 1 263 0 15 0 30mm 0 0059 0 0118 81 5mm 3 2 55...

Page 158: ...T SYSTEM CVT SYSTEM 3 6 7 Circlip Pliers E01GZ0060001 Drive Pulley Puller Bolt E01GZ0000008 Drive Pulley Holder E01GZ0000012 Belt Separate Bolt E01GZ0000013 Spring Holder Set E01GZ0050001 Special tool...

Page 159: ...as shown Torque Converter Cover Bolts 9 8 N m 1 0kgf m 87 in lb WARNING WARNING Excessive imbalance or operating rpm could cause CVT pulley failure resulting in severe injury or death The pulleys of t...

Page 160: ...Inner Cover Seal C O Ring 30 3 D CVT Inner Cover Installation CVT Inner Cover Installation Replace CVT Cover Seal B CVT Inner Cover Seal E and CVT Inner Cover Seal C if water leaks are evident Prepar...

Page 161: ...nted information faces the same direction so the belt rotates in the same direction as originally installed When installing a new belt install it so the printed information A can be read from beside t...

Page 162: ...25 142 LH E Spacer 12 28 6 F Driven Pulley Bolt M10 1 25 80 D Spacer 10 5 36 8 C Remove the drive pulley A from the crankshaft by screwing the drive pulley puller bolt H clockwise while holding the d...

Page 163: ...hoes C Drive Movable Sheave D Drive Pulley Spring E Spring Seat F One Way Bearing Assembly G Dirve Fixed Sheave Assembly H Thrust Plate disassembly Screw M4 8 J Thrust Plate Shoes K One Way Bearing di...

Page 164: ...5 15 mm 2 171 Bushing 36 32 15 inside Diameter B Standard 32 003 32 073 mm 1 260 1 263 Service Limit 32 11 mm 1 264 Check the Surface wear of the Counterweight Shoes If the Counterweight Shoes D are d...

Page 165: ...e but not clockwise B the One Way Bearing is operating correctly If the One Way Bearing does not operate correctly or if it makes noise disassemble it and examine each part visually Replace any worn o...

Page 166: ...ll the One Way Bearing 1 Install the Cam Pin A and Cam Spring N together into the mounting hole of Drive Fixed Shaft 2 Turn down along the axis and counterclockwise to the end 3 Check the One Way Bear...

Page 167: ...e gap of the Thrust Plate A Install Screws M4 8 C Spring Washer D and Spacer E Tighten Torque Screws M4 8 6 N m 0 6kgf m 53in lb Apply a non permanent locking agent to the Screws C 7 Install the Thrus...

Page 168: ...assembly B Tighten the Bolt D and compress the spring with the spring holder E of the spring holder set Special Tool Spring Holder Set E01GZ0050001 Remove the circlip A with circlip pliers F Remove th...

Page 169: ...face B Straight Edge C If the sheave bushings D are damaged or worn replace the movable sheave or fixed sheave Bushing 35 39 18 inside Diameter D Standard 35 003 35 073 mm 1 378 1 381 Service Limit 35...

Page 170: ...ide Seat B Dirven Fixed Shaft C Driven Pulley Assembly Driven Pulley Assembly Clean off any grease or dirt on the movable and xed sheaves and dry them with a clean cloth Install 1 Assemble the Dirven...

Page 171: ...ial Tool Spring Holder Set E01GZ0050001 6 Put the Driven Pulley E onto the Dirven Fixed Shaft D of the Dirven Pulley Guide Seat Assembly 7 Tighten the Bolt G and compress the spring with the spring ho...

Page 172: ...sembly C CVT Driven Pulley Assembly D and Belt E and install them to taper B of the Crankshaft and spline of the Transmission Main Shaft Install Spacer 12 28 6 G CVT Drive Pulley Bolt M12 1 25 142 F S...

Page 173: ...sassembly 4 9 Front Di erential Gear Box Cover Disassembly 4 9 Bearing and Oil Seal 4 10 Ball or Needle Bearing Inspection 4 10 Oil Seal Inspection 4 11 Bevel Gear 4 12 Bevel Gear Inspection 4 12 Beve...

Page 174: ...gear oil 4 24 Add gear oil 4 24 Inspection of parts wear 4 25 Oil seal 37 55 7 4 25 Disassemble 4 25 Assemble 4 25 Oil seal 44 60 7 4 26 Disassemble 4 26 Assemble 4 26 Tooth gap adjustment 4 27 Disas...

Page 175: ...R KIT 4 UNIVERSAL JOINT COMBINATION 5 CONNECTION FORK B 6 UNIVERSAL JOINT 7 CONNECTION FORK A 8 LOCKED NUT M14 1 5 180 18 3 133 L 9 O RING 14 6 8 G 10 OIL SEAL 48 65 9 G 11 CIRCLIP 62 12 BEARING 6007...

Page 176: ...PLUG M18 1 5 18 1 83 13 21 FRONT Di erential GEAR BOX CASE 22 SLIDING SLEEVE 23 DIVIDE DEVICE CONNECTION 24 BEARING 16007 25 O RING 140 2 65 G 26 FRONT Di erential GEAR BOX COVER 27 AIR TAP 28 PIPE 6...

Page 177: ...0 32 US qt When there is no oil stains after internal cleaning 280 mL 0 3 US qt Only when changing gear oil 0 15 0 25 mm 0 06 0 10 in Rear gear box Rear gear box Type Refueling position Oil drain posi...

Page 178: ...4 6 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Special Tools Silicone Sealant Inside Circlip Plisers T sleeve 10mm Round nut M75 1 5 6 LH sleeve...

Page 179: ...O RING 16 4 2 5 Tool 8mm Allen wrench Rotate B counterclockwise and twist out let the waste oil flow out for 10 minutes then put A on the threaded end of B tighten it clockwise and wipe clean the spi...

Page 180: ...ace the universal joint with a new one Visually inspect the splines on the connection fork B D If they are badly worn chipped or loose replace the connection fork B D Also inspect the splines on the r...

Page 181: ...rive Bevel Gear F Bearing 6007 G Circlip 62 H Oil Seal 48 65 9 I Oil Seal 24 38 8 J Vehicle Speed Sensor K O Ring 19 4 2 4 L O Ring 16 4 2 5 M Plug M18 1 5 Front Di erential Gear Box Cover Disassembly...

Page 182: ...ement Spin the bearing by hand to check its condition If the bearing is noisy does not spin smoothly or has any rough spots it must be replaced Check the needle bearing A in the front Di erential gear...

Page 183: ...FERENTIAL FRONT AND REAR DIFFERENTIAL Oil Seal Inspection Inspect the oil seals A B Replace any if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or been otherw...

Page 184: ...the bevel gears as a set if either gear is damaged Bevel Gear Backlash related Parts Bevel Gear Bevel Gear A A F F E E C C H H G G A A B B D D A Drive Bevel Gear B Front Di erential Gear Box Case C S...

Page 185: ...4 13 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL...

Page 186: ...contact of the bevel gears First adjust backlash and then tooth contact by replacing shims A C A Shim s 83 71 T T 0 1 0 15 0 2 0 5 C Shim s 61 5 50 t t 0 1 0 15 0 2 0 5 B Di erential Gear Assy D Drive...

Page 187: ...l it is bottomed Install D Drive Bevel Gear E Ball Bearing 6007 F Circlip 62 Grease the lip of the Oil Seal 48 65 9 G and press the Seal 0 5mm inwards from the end of the boss Install A Connection For...

Page 188: ...g until it is bottomed Install the D Circlip into the mounting groove of the C needle bearing Front Di erential Gear Box Cover Assembly Install Grease the lip of the Oil Seal A and press the Seal 0 5m...

Page 189: ...Install C Fork D Rack E Cylindrical Pin 5 75 F Plug M8 10 Move the Rack to the bottom in the indicated direction G Install H O Ring 72 7 2 4 I Transfer Case Assembly Install J Bolt M8 20 K Clamp 12 75...

Page 190: ...ear Assy C Shim s 61 5 50 t t 0 1 0 15 0 2 0 5 D Shim s 83 71 T T 0 1 0 15 0 2 0 5 E O Ring 140 2 65 F Front Di erential Gear Box Cover Assembly G Bolts M8 28 Install the B Di erential Gear Assy and S...

Page 191: ...WD position Sliding Spline Sleeve D move to 4WD position and engages with the spline of the di erential gear E At this time the power output to the front wheels with di erential function C LOCK Positi...

Page 192: ...51 6 L 2 Hexagon ange boltsM10 1 0 30 70 6 8 51 6 L 3 Breathing joint 12 1 2 103 6 in lb L 4 Hexagon ange boltsM8 25 24 2 4 17 7 L 5 Screw plug assembly M14 18 1 8 13 3 6 Screw plug M14 18 1 8 13 G A...

Page 193: ...or 10 minutes Set A on the threaded end of B tighten it clockwise and wipe o the gear oil spilled around it P l e a s e d i s p o s e o f w a s t e g e a r o i l i n a n environmentally friendly way p...

Page 194: ...25 C Active bevel adjustment washer E Rear Di erential housing Disassembly Tools open end wrench 10mm Use an open end wrench to remove B from E by turning counterclockwise Push out A as a whole by 10...

Page 195: ...kgf m ft lb 1 Hexagon ange bolts M8 25 24 2 4 17 L 2 Breathing connector 12 1 2 9 L 3 Large Pan Head Hexagon Bolt M6 16 12 1 2 9 L 4 Hexagon ange bolts M10 1 25 30 70 6 8 49 L 5 Screw plug M14 18 1 8...

Page 196: ...ually cause damage to the gearbox Please replace the damaged O ring seal in time A O Ring B Screw plug assembly M14 C Screw plug M14 Drain gear oil Rotate B counterclockwise and unscrew it and let it...

Page 197: ...en its service life A Rear Di erential end cover B Oil seal 37 55 7 C Rear Di erential housing Disassemble Tool Flat blade screwdriver Destroy B from A remove and replace them Assemble Tool special to...

Page 198: ...ols special tooling for oil seal sleeve 15 Assemble Replace the old E with a new E with oil seal tooling and clean up the oil stains after the replacement is completed Tools special tooling for oil se...

Page 199: ...then take out B for a certain distance then take out C on both sides Tool Sleeve 10 Assemble Take the corresponding thickness of C according to the gear clearance value insert it between B and D then...

Page 200: ...will not work normally A Rear Di erential end cover B Solenoid valve assembly Disassemble Screw out B with a sleeve counterclockwise T Tool Sleeve 29 Assemble Rotate the new B clockwise into A by the...

Page 201: ...L SYSTEM 5 1 Exploded view of Fuel System 5 2 Fuel Tank 5 4 Disassembly 5 4 Assembly 5 4 Fuel Pump 5 5 Disassembly 5 5 Inspection 5 5 Assembly 5 5 Fuel Filter 5 6 Disassembly 5 6 Assembly 5 6 FUEL SYS...

Page 202: ...FUEL SYSTEM 5 2 Exploded view of Fuel System No Fastener Torque Remarks N m kgf m ft lb 1 Bolt M6 30 8 12 0 8 1 2 69 103 6 in lb 2 Install screw cap on oil pump 75 7 5 55...

Page 203: ...el tank Remove the body plastic and the seats See car body for details Remove the air lter Disconnect the battery cable Disconnect the fuel pump cable plug A and the high pressure oil pipe plug B Remo...

Page 204: ...ct the fuel tank opening effectively to avoid debris falling into the fuel tank thus damaging the fuel pump Inspection A cable plug B Position 1 C Position 2 D Pressure gauge Move the float lever to c...

Page 205: ...red value then replace the pump Assembly Con rm that the sealing ring is installed on the fuel tank Confirm the orientation of the fuel pump with the cable plug connector facing the left side of the f...

Page 206: ...t and fuel tank hood see body part for details Remove 3 air lter box connectors A Remove 2 bolts B and pull out the air lter box C from front to back Remove the clamp D with appropriate tools and take...

Page 207: ...Technical Parameter 6 5 Special Tool 6 7 Coolant 6 7 Coolant deterioration inspection 6 7 Coolant level check 6 7 Pressure test 6 8 Radiator removal 6 9 Radiator fan removal 6 10 Radiator fan installa...

Page 208: ...SYSTEM 6 2 Exploded view of Cooling System 1 2 No Fastener Torque Remarks N m kgf m ft lb 1 Radiator fan assembly bolt M6 8 12 0 8 1 2 69 103 6 in lb 2 Radiator mounting bolt M6 25 8 12 0 8 1 2 69 103...

Page 209: ...n this way the system controls the engine temperature within the narrow range of engine operation Even if the engine load changes the engine has the highest working e ciency The system is pressurized...

Page 210: ...1 Radiator 2 Water Pump 3 Radiator cover 4 Water storage tank 5 Switch of radiator fan 6 Cylinder Cylinder head 7 Radiator fan 8 Thermostat 1 2 3 4 5 6 6 7 8 Coolant Flow Black arrow hot coolant Whit...

Page 211: ...rust inhibitor chemicals Green Soft water 50 cooling water 50 3 4 L 3 6US qt Full level of the water storage tank including radiator and engine Radiator cover Pressure relief 93 123 kPa 0 95 1 25 kgf...

Page 212: ...COOLING SYSTEM 6 6 Special tools and sealants Silicone Sealant...

Page 213: ...the coolant level in the water storage tank keep the water tank vertical If the coolant level is lower than the MIN mark C remove the front inspection cover see the vehicle body chapter for details O...

Page 214: ...or coolant to prevent pressure leakage Slowly pressurize until the pressure rises to 123kPa 1 25kgf cm2 18psi During the pressure test do not exceed the design pressure of the system The maximum press...

Page 215: ...a flameout state Disassembly A Horn mounting bolt B Radiator over ow pipe clamp C Hose clamp for front section of radiator D Radiator mounting bolt M6 25 E Radiator Remove the front plastic part of t...

Page 216: ...or fan Remove the radiator rst see radiator removal Remove the radiator fan assembly bolts A Remove the fan assembly B Remove the radiator fan mounting nut C Remove the radiator fan D Radiator fan ins...

Page 217: ...ator cap If any one of them shows visible damage replace the cap A Bottom Valve Seal B Top Valve Seal C Valve Spring Install the cap A on a cooling system pressure tester B Wet the cap sealing surface...

Page 218: ...INTAKE EXHAUST SYSTEM Exploded view of Intake system 7 2 Disassemble Air Filter 7 3 Exploded view of Exhaust System 7 4 Mu er and exhaust pipe 7 5 Mu er disassembly 7 5 Exhaust pipe disassembly 7 6 In...

Page 219: ...stener Torque Remarks N m kgf m ft lb 1 Installment bolts for air lter M8 16 35 45 3 5 4 5 25 8 33 2 2 Type A worm drive hose hoop 80 3 Steel belt exible hose clamp 30 4 Type A worm drive hose hoop 70...

Page 220: ...ove the instrument cover assembly F G Instrument connector H Air lter air inlet screen I CVT intake strainer Unplug the instrument connector G Remove the CVT intake strainer I Air inlet screen for air...

Page 221: ...Remarks N m kgf m ft lb 1 Nut 30 40 3 0 4 0 22 1 29 5 2 Exhaust pipe connection bolt 30 40 3 0 4 0 22 1 29 5 3 Spring Fixed bolt M8 35 30 40 3 0 4 0 22 1 29 5 Seal cartridge Oxygen sensor 40 60 4 0 6...

Page 222: ...use as the exhaust components become very hot and can cause serious burns and injury Mu er disassembly Remove the exhaust pipe connection bolts A and spring B Remove the xed screw A Remove the mu er B...

Page 223: ...debris and other abnormalities inside the mu er Check the connection between exhaust pipe and engine cylinder head for leakage If so tighten the nut or replace the gasket Check whether there is leakag...

Page 224: ...DRIVE SYSTEM 8 1 DRIVE SYSTEM Exploded View of Drive System 8 2 Drive Axle Disassembly 8 3 Front Rear Drive Axle Disassembly 8 4 Front Rear Drive Axle Assembly 8 5...

Page 225: ...ploded view of Drive System A B 1 2 B B 2 2 No Fastener Torque Remarks N m kgf m ft lb 1 Hexagon Flange Bolts M8 35 35 45 3 5 4 5 25 8 33 2 2 Hexagon Socket Head Screw M10 1 25 25 A Apply Impermanent...

Page 226: ...y Remove the drive axle from the fixed end of the drive axle wheel end Remove the wheel and suspension components before the axle assembly see the wheels tires and suspension chapters for more details...

Page 227: ...rrow until it is taken out Take D the fear part of the front drive axle in the direction of the arrow until it is taken out A Hexagon socket head screw 8 pcs M10 1 25 25 B 10mm diameter spring washer...

Page 228: ...to the axle hole in the direction of the arrow shown in the picture until they reach the bottom and then install the upper and lower arms and wheel support and the wheel parts The installation of the...

Page 229: ...preloading adjustment 9 8 Measure free length of spring 9 9 Absorber damping adjustment 9 9 Compressure damping adjustment 9 9 Rebound damping adjustment 9 10 Absorber disassembly 9 10 Rear shock abso...

Page 230: ...FRONT REAR SUSPENSION 9 2 Exploded view of Front suspension...

Page 231: ...0 5 0 29 5 36 9 3 Front rocker arm mounting bolt M10 1 25 90 40 50 4 0 5 0 29 5 36 9 4 Rocker arm mounting bolt M10 1 25 85 40 50 4 0 5 0 29 5 36 9 5 Steering knuckle lower mounting bolt M10 1 25 40 4...

Page 232: ...FRONT REAR SUSPENSION 9 4 Exploded view of Rear suspension...

Page 233: ...on ange lock nuts M10 1 25 40 50 4 0 5 0 29 5 36 9 3 Rear wheel axle steady mounting bolt M10 1 25 100 40 50 4 0 5 0 29 5 36 9 4 Rear balance bar mounting boltM8 1 25 30 20 25 2 0 2 5 14 7 18 4 5 Rock...

Page 234: ...Gear 3 Gear 1 Gear 5 45mm 1 78in 35 55mm 1 38 2 17in Rear absorber Optional Preloading setting position of normal hydraulic damping absorber spring Preloading setting position of air damping absorber...

Page 235: ...FRONT REAR SUSPENSION 9 7 Dedicated Tools Internal circlip pliers Lifting jack Hook wrench Grease gun Slotted screwdriver Bearing drive kit Needle nose pliers...

Page 236: ...leeve of the hydraulic shock absorber A There are 5 adjustment positions the spring can be adjusted according to di erent terrain and loading conditions if you feel too soft and too hard it can be adj...

Page 237: ...action feels too soft or too hard set it to Position Spring Environment Load Terrain Speed STD Soft Hard Soft Hard Light Heavy Flat Bumpy Low High Absorber damping adjustment In order to adapt to vari...

Page 238: ...and install the bolts and nuts Install the lower end of the front shock absorber into the front rocker arm mounting base and install the bolts and nuts arm mounting base and install the bolts and nut...

Page 239: ...Refer to absorber removal Remove the valve cover A and release nitrogen Remove the valve As high pressure gas is dangerous do not point the valve to your face or body Inspection of adjustable air pre...

Page 240: ...ing bolt F Rocker arm assembly Remove the brake caliper mounting bolts and remove the caliper body Remove the brake hose retaining bolts A Remove the steering knuckle axle support assembly B Remove th...

Page 241: ...d lower kingpin assembly Rocker arm bu er sleeve Rocker liner Circlip Press out the upper kingpin assembly Press out the lower kingpin assembly Rocker arm assembly Tighten Rocker arm assembly mounting...

Page 242: ...ort and axle sleeve is reducing or after the vehicle runs every 1000km grease the straight type oil cup in the suspension system Including upper and lower rocker arm rear axle support and rear stabili...

Page 243: ...t hub bearing C Front knuckle D Rear axle mount Dedicated tool Circlip plier Bearing drive kit Disassembly of rear axle support assembly A Bu er sleeve B Hub bearing C Split ring D Axle support liner...

Page 244: ...stabilizer bar maintenance A Straight type oil cup When the vehicle runs 1000km it is necessary to add proper amount of grease into the buffer sleeve of stabilizer bar by the straight type oil cup A...

Page 245: ...tment 10 7 Wheels rims 10 8 Wheels disassembly 10 8 Wheels assembly 10 8 Wheel check 10 8 Wheel check 10 9 Tire 10 10 The tires have been removed 10 10 Tire installation 10 10 Tire check 10 11 Tire de...

Page 246: ...WHEELS AND TIRES 10 2 Exploded view of Wheels and Tires R W R 1 2 5 6 5 6 7 R R R R R W 1 2 3 3 4 3 7 4...

Page 247: ...eel nut M12 70 80 7 0 8 0 51 6 59 3 Cross tie rod end nut M10 50 60 5 0 6 0 36 9 44 3 4 Cross tie rod adjustment lock nut M12 50 60 5 0 6 0 36 9 44 3 5 Anti slip mounting bolt M8 35 45 3 5 4 5 25 8 33...

Page 248: ...e front rear Tire pressure in cold state front rear Maximum tire pressure In cold state Tread height of tire front rear 25 8 12 AT26 8 12 26 8 14 Tubeless Nylon 25 10 12 AT26 10 12 26 10 14Tubeless Ny...

Page 249: ...WHEELS AND TIRES 10 5 Special Tools Jack...

Page 250: ...The caster and camber angles of the kingpin are built in and di bit reqyure adjustment A rear B front toe value The distances A and B are measured at the height of the axle when the vehicle is parked...

Page 251: ...e same number of turns to achieve the designated toe If the front beam reaches the specified value the length D of each tie rod shall be 416 419mm 16 4 16 5 inches Adjust the length of the horizontal...

Page 252: ...valve A faces the outside of the vehicle Tighten the wheel nuts in a cross way Tightening bolt torque 70 80N m 5 0 6 0kgf m 51 6 59ft lb A 1 2 3 4 Wheel check Check whether there are depressions on bo...

Page 253: ...lve mouth assembly and throw away Replace the air valve every time you change the tire Do not reuse the air valve A Plastic cover B Spool C Stem seal D Stem E Seat Install new air valve on new rim Rem...

Page 254: ...s as they can spoil the tire Remove the tire from the rim using a suitable commercial tire changer Tires cannot be removed manually because they fit tightly to the rim Tire Assembly Check rim refer to...

Page 255: ...rface again and in ate it again Check whether there is air leak after the tire is in place correctly Apply soap solution around the tire tire rim and then check for air bubbles Bleed the tire to the s...

Page 256: ...and tire rims with oil or petroleum ingredients as they can spoil the tire Remove the tire from the rim using a suitable commercial tire changer Tires cannot be removed manually because they fit tigh...

Page 257: ...m Maximum tire in ation pressure can be xed to rim when cold Front and rear 250 kPa 2 5 KGF cm2 36 psi Do not in ate the tire above the maximum tire pressure Overin ated air can cause a tire to explod...

Page 258: ...solution to the tire rim and check whether there is air bubble Bleed the tire to the speci ed pressure Check the tire pressure with the barometer Segway o ers tire pressure gauges and user kits Tire...

Page 259: ...nstalling a brake disc see Braking chapter Tighten axle nut torque 250 N m 25 kgf m 184 ft lb Insert the new cotter A and bend it to the nut B When inserting the cotter if the slotted nut does not ali...

Page 260: ...11 7 Installation 11 7 Master Cylinder Disassembly 11 8 Caliper 11 9 Caliper Disassembly 11 9 Caliper Assembly 11 10 Piston and Cylinder Damage 11 11 Caliper Holder Shaft Wear Inspection 11 11 Brake P...

Page 261: ...Hose Inspection 11 14 Rear Brake Pedal 11 14 Brake Pedal Position Adjustment 11 14 Rear Parking cable 11 14 Parking cable removal 11 14 Parking cable installation 11 14 Rear brake pedal disassembly 1...

Page 262: ...8 8 0 90 78in lb 5 Distribution Valve Fastening Bolts 15 0 15 11in lb 6 Foot Brake Main Pump Bolts 45 4 5 33in lb 7 Oil Cup Bolts 8 8 0 90 78in lb 8 Oil Cup Screw 8 0 8 5 9in lb Exploded view of Brake...

Page 263: ...ss 1 mm 0 04 in 4 mm 0 16 in TIR 0 1 mm 0 004 in Rear Brake Lever Pedal and Cables Rear brake pedal position Working stroke of rear parking handle Working stroke of rear brake pedal 35 40 mm 1 38 1 57...

Page 264: ...BRAKE SYSTEM 11 5 Inside Circlip Pliers Special tool...

Page 265: ...parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 7 When handling the disc pads or disc be careful that no disc...

Page 266: ...der Clamping Bolt Torque 8 8N m 0 9kgf m 105 6in lb Install new at washers on each side of brake hose then tighten oil bolt Brake Hose Oil Bolt Torque 25N m 2 5kgf m 18 4ft lb If the Main Cylinder is...

Page 267: ...aning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be...

Page 268: ...se tting with new ones Tighten Caliper Mounting Bolts Brake Hose Banjo Bolt 25N m 2 5kgf m 18 4ft lb Check the uid level in the brake reservoir Bleed the brake line Check the brake for good braking po...

Page 269: ...caliper the piston may crush your hand or ngers If compressed air is not available do as follows with the brake hose connected to the caliper Prepare a container for brake uid Remove the pads and spr...

Page 270: ...see Brake Pad Installation Piston and Cylinder Damage Visually inspect the pistons A and cylinder surfaces Replace the caliper if the cylinder and piston are badly scored or rusty Caliper Holder Shaft...

Page 271: ...i rattle spring is in place Install 1 Install the brake pad in the upper and lower spring holder on the inner or outer side and fit the brake disc respectively 2 Rotate the brake caliper down so that...

Page 272: ...ion The disc must be installed with the marked side A facing toward the steering knuckle Apply a non permanent locking agent Disc Mounting Bolts Tighten Torque Disc Mounting Bolts 37N m 3 7kgf m 50 2f...

Page 273: ...ck the brake pedal free play Rear Brake Pedal A B Parking cable removal Taking the parking cable head out of the rotating arm in the rear brake Disassemble 2 piece of M8 nuts Loosen knurled locknut on...

Page 274: ...to remove the retainer ring B Remove the at gasket C Remove the brake pedal A assembly Remove D from the brake pedal Rear brake pedal installation Apply grease to the end of brake pedal shaft A Insta...

Page 275: ...2 1 STEERING SYSTEM Exploded View of Steering System 12 2 Steering System Technical Speci cation 12 4 Steering System Handlebar Disassembly 12 5 Steering System Handlebar Assembly 12 5 Steering Column...

Page 276: ...STEERING SYSTEM 12 2 Exploded View of Steering System 1 2 A A 3 4 5 5 5 6 3 B...

Page 277: ...crew M8 45 29 2 9 21 4 2 Hexagon Flange Bolts M8 16 35 3 6 25 8 3 Hexagon Flange Bolts M8 30 35 3 6 25 8 4 Hexagon Flange Bolts M10 1 25 20 45 4 6 33 2 5 Type 1 Hexagon Slotted Nut M10 45 4 6 33 2 6 T...

Page 278: ...is on the rod A Steering rod installation Install the smaller taper end of the rod toward the steering knuckle and the taper hole of the steering arm Make sure the length of the rod A is correct and...

Page 279: ...ture A Handlebar lower cover B Locking bolt C Locking bolt D Gap E Handlebar upper cover Place the lower handlebar bracket A on the steering rod with the holes aligned Place the handlebar in the cente...

Page 280: ...embly E Bolt M8 16 F Bolt M8 30 Remove two hexagon ange bolts M8 16 E Remove the ball block locking plate B and the ball block A Pull out the EPS steering rod assembly D Remove two hexagon flange bolt...

Page 281: ...installation 13 7 Air lter cover assembly removal 13 7 Disassembly of plastic parts of body 13 8 Front Lampshade 13 8 Front Upper Mudguard 13 8 Front Lower Mudguard 13 8 Front Strip 13 8 Front Panel 1...

Page 282: ...14 Disassembly 13 16 Exploded view of front and rear Di erential 13 20 Front Differential repairs 13 22 Disassembly 13 22 Installation 13 22 Front Differential repairs 13 23 Disassembly 13 23 Install...

Page 283: ...FRAME 13 3 No Fastener Torque Remarks N m kgf m ft lb 1 Hexagon Socket Large Pan Head Bolt M6 16 8 12 0 8 1 2 69 103 6 in lb 2 Cross Recessed Hexagon Screw ST4 8 16 8 12 0 8 1 2 69 103 6 in lb Explod...

Page 284: ...VEHICLE BODY AND FRAME 13 4 Exploded view of Body No Fastener Torque Remarks N m kgf m ft lb 1 Hexagon Socket Large Pan Head Bolt M6 16 8 12 0 8 1 2 69 103 6 in lb...

Page 285: ...DY AND FRAME 13 5 No Fastener Torque Remarks N m kgf m ft lb 1 Hexagon Flange BoltsM6X16 8 12 0 8 1 2 69 103 6 in lb 2 Hexagon Socket Large Pan Head Bolt M6 16 8 12 0 8 1 2 69 103 6 in lb Exploded vie...

Page 286: ...Cover Put the vehicle on at ground rst After removing the left and right armrest xing bolts A remove the rear armrest B Take out the 8 bolts of the rear shelf cover C and remove the rear shelf cover...

Page 287: ...ock hook behind the seat hook on the frame Air lter cover assembly removal Put the vehicle on flat ground and remove the seat cushion rst A Expansion screw assembly B Air lter cover assembly After rem...

Page 288: ...Take out the expansion screw A take out the screw B Remove the upper front fender The removal method of the upper front fender is the same on both sides Front Lower Mudguard Take out the bolt A Remove...

Page 289: ...nel Take out bolt A Remove the front panel Left and Right Guards Remove the cushion Take out bolt A Remove the left guard plate The removal method of the left and right guard plates is the same Left F...

Page 290: ...e left rear guard plate and left rear grille of the engine Remove the screw A to take out the left rear grille Right Rear Guard Plate and Right Rear Grille Remove the cushion Remove the right guard pl...

Page 291: ...the tail box cover lock A and open the tail box cover Pull out the tail box cover pin B Remove the tail box cover Left and Right Rear Tail Lamp Cover Take out expansion screw A Take out the left rear...

Page 292: ...elding components of the rear shelf Remove the seat cushion assembly Remove the backrest assembly Remove the left right rear side strip Remove the rear tail light panel and the tail box cover Remove r...

Page 293: ...d to the frame Remove the fuel tank cap Remove the left front mudguard The removal method of the right front fender is the same as the left and left front fender but the shift handle needs to be remov...

Page 294: ...9 5 2 Right foot guard bar combination mounting bolt M8X25 30 40 3 0 4 0 22 1 29 5 3 Right pedal bracket assembly mounting bolt M8X25 30 40 3 0 4 0 22 1 29 5 4 Combined mounting bolts for hanging on t...

Page 295: ...ting bolts M10X1 25 40 50 4 0 5 0 29 5 36 9 12 Hexagon socket head cap bolt M6x12 8 12 0 8 1 2 69 103 6 in lb 13 engine front mounting bolts M12X1 25X210 50 60 5 0 6 0 36 9 44 3 14 Mounting bolts M8X1...

Page 296: ...t pipe please protect the CVT air inlet to Avoid debris from falling into the engine thereby damaging the engine Use a flat screwdriver to remove the hoop C and remove the CVT outlet pipe After removi...

Page 297: ...remove the exhaust muffler mounting nut F and remove Exhaust mu er Exhaust mu er mounting nut torque 35 45N m 3 5 4 5kgf m 25 8 33 2ft lb Use a suitable tool to remove the shift rocker arm mounting bo...

Page 298: ...drive shaft from the engine when assembling use Thread glue to prevent the screws from loosening and falling o Use hose clamp pliers to remove the clamp K to remove the radiator outlet pipe And drain...

Page 299: ...ve right Foot support assembly Use a suitable tool to remove the bolt 4 so that the engine hanging assembly and The engine is disconnected Use a suitable tool to remove the bolt 5 remove the suspensio...

Page 300: ...29 5 36 9 2 Front Di erential mounting bracket combination mounting bolt M8 16 8 12 0 8 1 2 69 103 6 in lb 3 Mounting bolts on the front Di erential M10X1 25 40 50 4 0 5 0 29 5 36 9 4 Mounting bolts...

Page 301: ...ield mounting bolts M6x16 8 12 0 8 1 2 69 103 6 in lb 9 Weld drag bracket under mounting bolts M8 20 30 40 3 0 4 0 22 1 29 5 10 Weld drag bracket upper mounting bolts M8 30 40 3 0 4 0 22 1 29 5 11 Wel...

Page 302: ...move the 2 bolts B and disconnect the front drive shaft Into the connection with the front Di erential assembly Use a suitable tool to remove the nut piece 3 remove the bolt piece 2 and pull out the s...

Page 303: ...l heat shield Use a suitable tool to remove the nut 11 and pull out the bolt 9 Remove the bolt 13 with a suitable tool Remove the nut 10 with a suitable tool and pull out the bolt 12 Remove the weldin...

Page 304: ...ar shelf welding assembly mounting bolts M8X16 30 40 3 0 4 0 22 1 29 5 3 Left armrest assembly mounting bolt M8X16 30 40 3 0 4 0 22 1 29 5 Left armrest assembly mounting bolt M8X16 30 40 3 0 4 0 22 1...

Page 305: ...e the bolts 5 and 6 to make the rear plate and the frame welding components are disconnected Use a suitable tool to remove the bolt 4 and remove the left armrest assembly Remove the bolt 3 with a suit...

Page 306: ...g bolt M8X20 30 40 3 0 4 0 22 1 29 5 3 Front bumper welding assembly mounting bolt M8X20 30 40 3 0 4 0 22 1 29 5 4 Front bumper welding assembly mounting bolt M8X20 30 40 3 0 4 0 22 1 29 5 5 Front bum...

Page 307: ...wheel C is in line with the front The bumper welding assembly is disconnected Use a suitable tool to remove the split pin F pull out the pin shaft G and take out the hook E take out the cushion H and...

Page 308: ...rt yourself or others Use a suitable tool to remove the 4 bolts J and the spring washers and flat washers and remove the winch motor Remove bolt 1 with a suitable tool and remove the winch mounting pl...

Page 309: ...or 14 18 Function introduction 14 18 Working principle 14 18 Performance parameter 14 19 Electrical characteristic parameter 14 19 Troubleshooting 14 20 Electronic control unit ECU 14 21 Function intr...

Page 310: ...PS trouble removal 14 44 EPS fault code 14 45 EPS brush 14 46 Display 14 48 Dashboard 14 48 Dashboard Indicator light description 14 49 Instrument information display 14 51 Dashboard meter button func...

Page 311: ...1 5 16 8 10 0 8 1 0 70 8 88 4in lb 2 Cross hexagon screw st4 2 19 4 5 0 4 0 5 35 4 44 2in lb 3 Hexagon ange bolt M6 1 5 12 7 9 0 7 0 9 61 9 79 6in lb 4 Hexagon ange bolt M6 1 5 12 5 7 0 5 0 7 44 2 61...

Page 312: ...0 1 5 20 75 85 7 5 8 5 55 3 62 7 8 Hexagon ange bolt M8 1 25 20 22 28 2 2 2 8 16 2 20 7 9 Nut M6 7 9 0 7 0 9 61 9 79 6in lb 10 Nut M6 7 9 0 7 0 9 61 9 79 6in lb 11 Hexagon ange bolt M6 1 5 25 7 9 0 7...

Page 313: ...agon ange bolt M6 1 5 12 5 7 0 5 0 7 44 2 61 9in lb 17 Hexagon ange bolt M6 1 5 12 8 10 0 8 1 0 70 8 88 4in lb 18 Nut M6 7 9 0 7 0 9 61 9 79 6in lb 19 Nut M6 7 9 0 7 0 9 61 9 79 6in lb 20 Hexagon ange...

Page 314: ...V 3 000 r min rpm 0 33 0 49 Ignition System Spark plug Spark plug gap Spark plug cap resistance Ignition coil Primary winding resistance Secondary winding resistance 0 6 0 8 mm 3 12k 466 593m 8 2 10 5...

Page 315: ...4 7 Special tools When the multimeter is measuring voltage the meter pen should not be inserted into the current measuring hole When measuring resistance please be sure to disconnect the battery posit...

Page 316: ...ositive cable Take out the battery Turn o ignition switch Place the battery in place with the battery box and retainer First connect the battery positive cable then connect the negative cable Thin gre...

Page 317: ...the terminal voltage of the battery use a digital voltmeter When measuring the terminal voltage after charging the battery should stand still for more than 20 minutes Preventive measures 1 Colloidal b...

Page 318: ...em During charging keep the battery away from sparks and naked fire An explosive gas mixture that releases hydrogen and oxygen When using a battery charger connect the battery to the charger before tu...

Page 319: ...l voltage standard 12 6V or higher Remove the battery refer to the Removal of batteries section Recharge the battery in the following way The battery is sealed Do not open it Do not add water when cha...

Page 320: ...e Another Yellow wire 36 54 V If the output voltage is within the value in the table the alternator is operating normally and the regulator recti er has been damaged A much lower reading indicates tha...

Page 321: ...ELECTRICAL SYSTEM 14 13 1 Alternator 2 regulator recti er 3 Battery 4 Main Fuse 5 Ignition lock 6 Load Circuit diagram of charging system DYNAVOL T 1 2 3 4 5 6...

Page 322: ...ble below for the determination method of the voltage regulating rectifier resistance Output resistance characteristics unit Output Y1 Y2 Y3 Output Digital multimeter Diode gear Output Connect the red...

Page 323: ...ELECTRICAL SYSTEM 14 15 EFI system Schematic diagram of EFI system...

Page 324: ...er and seat cushion of the whole vehicle see A in the gure below C A B Working principle The NTC thermistor is encapsulated in the temperature sensor and its resistance value changes with the change o...

Page 325: ...0 303 0 326 110 0 1 0 1383 0 1451 B end resistances 50 0 2 176 280 80 0 2 63 4 81 4 110 0 2 24 6 30 6 Fault diagnosis When the cylinder temperature is greater than its credible upper limit or less tha...

Page 326: ...ic can di use through the ceramic itself It is this feature that converts the di erence in oxygen concentration between the inner and outer sides of the ceramic into a potential di erence thereby form...

Page 327: ...ent and the sensor connector Ambient temperature heating element break resistance 30 M Exhaust temperature 350 30 M Exhaust temperature 850 30 K Power supply voltage on plug Rated voltage 12 V Continu...

Page 328: ...re harness end pins are bent or deformed etc Check whether the resistance between pins B and D is normal Check whether the voltage between pin B and the main relay is normal Connect the connector and...

Page 329: ...ure is 23 5 If the system returns to normal operating voltage within 60 seconds ECU can still ensure normal operation System reverse voltage protection If UBR Pin8 is powered by the main relay the ECU...

Page 330: ...r ground 34 E3 K line diagnostic K line 11 H1 Intake air temperature sensor 35 D3 Neutral switch 12 G1 Throttle position sensor 36 C3 1 cylinder ignition diagnosis 13 F1 Engine temperature sensor 37 B...

Page 331: ...Working principle The ECU sends out electrical pulse signals to the injector coil to form a magnetic field force When the magnetic eld force rises enough to overcome the combined force of the return...

Page 332: ...self learning data is valid After the fault is removed the fault ag is reset Common fault codes are shown in the fault summary table Injector failure inspection Check the connectors are well connecte...

Page 333: ...nition coil installed on the engine see A in the gure below Working principle The ignition coil is composed of a primary winding a secondary winding an iron core and a shell When the battery voltage i...

Page 334: ...winding 8 27 9 4 10 53 k Primary current Charging time 3 9ms 7 4 8 0 8 6 A Secondary voltage Load 35pF 34 kV Ignition energy Zener voltage 1000V 40 mJ Fault diagnosis The ECU does not perform the fau...

Page 335: ...f 0 7 0 1 it will lead to unreliable ignition or failure to ignite Please adjust the gap or replace the spark plug in time Remove and install spark plugs Remove the ignition coil Use the spark plug sl...

Page 336: ...r outputs a sinusoidal voltage signal and the output signal see B on the left Coil resistance 23 950 20 Coil inductance 1000HZ 450 15 mH Fault diagnosis When the engine cannot be started the remaining...

Page 337: ...ance position which increases the output current in the circuit and vice versa reduces the output current in the circuit See A in the gure below The sensor is a normally open contact the working press...

Page 338: ...ps throttle position signal Ts intake air temperature signal The core of the intake air temperature sensor is the thermistor that responds quickly to temperature The intake air pressure sensor communi...

Page 339: ...resistance characteristics See the left picture Intake pressure sensor Change sensitivity 40 5mv kPa Output voltage characteristic See the left picture Three in one sensor performance characteristics...

Page 340: ...r axis The end of the screw rod is a plug so the plug can be retracted or extended to increase or decrease the cross sectional area of the bypass air inlet passage of the idle speed actuator until it...

Page 341: ...n circuits Common fault codes are shown in the fault summary table Three in one sensor fault inspection Check that the connector is well connected Check whether the wiring harness and injector pins ar...

Page 342: ...eration When the engine is running the instrument fault indicator is always on indicating that the system is faulty At present use a dedicated fault diagnosis instrument bottom left to read the corres...

Page 343: ...ake Air Temp Circ High Input 8 P0117 Engine Coolant Temp Circ Low Input 9 P0118 Engine Coolant Temp Circ High Input 10 P0122 Throttle Pos Sensor Circ Low Input 11 P0123 Throttle Pos Sensor Circ High I...

Page 344: ...0511 Idle Air Control Circuit Open 25 P0560 System Voltage Malfunction 26 P0562 System Voltage Low Voltage 27 P0563 System Voltage High Voltage 28 P0627 Fuel Pump A Control Circuit Open 29 P0628 Fuel...

Page 345: ...ystem circuit 1 Battery 2 Main Fuse 3 Lgnition lock 4 Fuse 5 Main relay 6 Low beam relay 7 High beam relay 8 Daytime running light relay 9 Daytime running light 10 High Low beam 11 Position lights 12...

Page 346: ...alogen headlights are damaged replace the bulbs of the same model If other light sources are damaged only replace the headlights Remove the 7 buckles on the rear guard of the headlight A Remove the fr...

Page 347: ...ht source of the halogen tail lamp is damaged the bulb of the same model can be replaced Remove the buckle on the rear guard of the headlight 4 A Remove the taillight guard B Remove the tail lamp bolt...

Page 348: ...replace the license plate bulb type W5W The license plate bulb number is W5W Place the license plate lamp at the installation position of the license plate lamp Tighten the license plate lamp bolt 1 B...

Page 349: ...installation rubber sleeve A from the installation bracket Remove the wiring harness connector Replace the asher B TEST If the turn signal does not flash or flashes abnormally on the whole vehicle the...

Page 350: ...e the power connector B and power connector C The interface of the plug B is de ned as follows G means green wire wire diameter 5 0 for grounding RW means red white wire wire diameter 5 0 12V The inte...

Page 351: ...ELECTRICAL SYSTEM 14 43 EPS system wiring schematic diagram 1 Battery 2 Fuse 50A 3 Fuse 30A 4 Fuse 5A 5 Fuse 5A 6 IG relay 7 Diode 8 Key switch 9 OBD 10 EPS...

Page 352: ...ay EPS will not work and the EPS fault light on the meter will not light up D C F E If the EPS fault light on the meter is on it means that the EPS is malfunctioning EPS fault light E and fault code F...

Page 353: ...otor o er no assistant power 1 No No E0010 on 11 overcurrent 1 No No E0011 on 12 Abnormal current 1 No No E0012 on 13 CAN communication abnormal 2 Set the vehicle speed to 30 cancel the positive and d...

Page 354: ...S controller A firstly remove the connector D connector E connector F connector G The method of disassembling the EPS motor B refers to the method of disassembling the steering assembly Only the elect...

Page 355: ...ne to OBD 7 Fault light to OBD 8 Vehicle speed from vehicle speed sensor 9 GND 10 12 11 0V 12 The main torque signal 13 The deputy torque signal 14 5V 15 motor 16 motor The EPS brushless and EPS brush...

Page 356: ...he user See the next page for display functions and instructions Using a high pressure water gun may damage the meter You should use your hands or hoses to clean the vehicle with neutral soap Do not u...

Page 357: ...t light tail light license plate light dashboard light are on This indicator not on when position light is on Check whether PIN31 has high level input if yes replace the meter if not check the relevan...

Page 358: ...e or broken Parking indicator The indicator will be on when the parking switch is applied The indicator not on when the parking switch is applied Check if PIN10 has low level input if so replace the m...

Page 359: ...wire harness if not solve it replace TBOX if still no replace dashboard 3 Power on remotely When using APP to power on remotely this icon lights up Power on remotely by APP this icon not lights up Che...

Page 360: ...th di erential 4 4 locking mode With di erential 9 Coolant temperature indicator Displays current coolant temperature H High temperature C Low temperature No coolant temperature display Check CNA H CA...

Page 361: ...referred mode of the rider was selected M Normal mode power normal H Comfort mode power light L Motion mode booster weight E P S model no display Check CNA H CAN L Wire harness Check EPS Check TBOX 16...

Page 362: ...button to save and exit To reset the total mileage In the power off state press and hold the A and B button at the same time then turn on the key to power on the interface CCC appears adjust by press...

Page 363: ...esistance value input 26 H gear Low voltage 9 Grounding Fuel level sensor grounding 27 L gear Low voltage 10 Parking signal Low voltage 28 2WD signal 11 N gear Low voltage 29 Left turning light High v...

Page 364: ...Power off the whole vehicle first and remove the front shelf assembly Pull out the connector A Remove the four bolts B A B T BOX B B T BOX fault code display area T0001 GPS module failure T0002 4G mo...

Page 365: ...attery power 11 OIL 12 OIL 13 CAN3 Reserve 14 CAN2 Engine CAN Failure phenomenon and failure reason NO Trouble Solution 1 Fault code T0001 Replace T BOX 2 Fault code T0002 Replace T BOX 3 Fault code T...

Page 366: ...tor turn the multimeter to the conduction position When the key is turned to the OFF position the two wires should not be able to conduct when the key is turned to the ON position the two wires should...

Page 367: ...isconnected and the key can be removed In the LOCK gear the front of the vehicle is in a locked state see vehicle body and frame and the key can be removed In the normal state the ON gear is in the fo...

Page 368: ...wer lock is in the ON position A Turn on high beam B Turn on lower beam C Turn o light D Turn on position light B Br Br L CLR FUNC W OFF B Br Gr L Gr R G B Br Gr B Sb O Br W L B W W Lg G Since the swi...

Page 369: ...turning light switch work normally When the switch is turned to the left steering position gray and orange can be connected while gray and light blue cannot be connected when the switch is turned to t...

Page 370: ...ress the start button to start the engine only when the ameout switch is in the unpressed state Check ignition key When the flameout switch bounces black white and white blue should be able to conduct...

Page 371: ...able to conduct E Emergency switch When the emergency switch is pressed the four front and rear turning lights ash at the same time when the emergency switch is pressed if a single turning light does...

Page 372: ...e handle When installing a new switch pay attention to snap the limit of the lower cover into the limit slot of the handle and then tighten the two xing bolts with a tool B Limit point Rotate the swit...

Page 373: ...green can be conducted After popping up the 2 4WD switch the switch is in the 2WD state the blue black and blue green can be conductive When the knob is shifted to the right after the four wheel drive...

Page 374: ...olt Remove the two blots Remove the switch from the handle When installing a new switch tighten the two xing bolts with a tool Rotate the switch around the handle tube after installation to con rm whe...

Page 375: ...ted plastic parts First remove the battery positive electrode A Remove the power cord of the winch B Remove the winch motor wire nut C Unplug the plug D Cut o the cable tie along the cable Be sure to...

Page 376: ...h motor wire J and winch relay G can be removed together After disassembling the bolt P and the wire rope R you can remove the strap Q hook O and rubber pad M Remove the bolt L and remove the guide wh...

Page 377: ...nd work after an interval of 30 seconds Continue to work in this way The wire rope diameter is 4 8 and the wire rope length is 14 5 The color of the insulation pad of the winch motor terminal and the...

Page 378: ...he clasp on the left and right sides of the fuse box cover to the outside Loosen the clasp and open the fuse box Do not use a fuse above the rated ampere value or replace it with anything else Please...

Page 379: ...S IG 5A R4 Main relay 12V 20A F8 Daytime running light 5A R5 2WD 4WD relay2 12V 20A F9 KEY 5A R6 ECU 4WD relay 12V 20A F10 EPS IG 5A R7 Lower beam relay 12V 20A F11 12V USB power output seat 15A R8 Hi...

Page 380: ...torque A Plug for dashboard black B Plug for dashboard gray C TBOX plug D Flasher plug E Buzzer plug F Right headlight plug G OBD plug H Left headlight plug I EPS plug J EPS plug K Brake switch plug...

Page 381: ...trigger B1 Right rear taillight plug B2 Left rear taillight plug B3 Trailer socket plug B4 License plate light plug B5 Fuel pump plug B6 Fan plug B7 Vehicle speed sensor electromagnet B8 Fuel mass pl...

Page 382: ...for the pin number of each plug in Harness plug in view direction The pin number of the plug in corresponds to the electrical schematic diagram A F M N O P Q R S Y Z T U V W X G H I J K L B C D E A1...

Page 383: ...ELECTRICAL SYSTEM 14 75 B10 B11 B12 B14 B15 B16...

Page 384: ...each plug in is shown in the gure below Lof wire cable A plug black for rear light switch B plug gray for LOF control modul C plug for trailer power socket D plug for rear fog light E plug for LOF tra...

Page 385: ...G Y G L G V G Br COLOUR Green Green Red Green Black Green White Green Yellow Green Blue Green Violet Green Brown CODE Y Y R Y B Y W Y G Y L Y Gr Y Br COLOUR Yellow Yellow Red Yellow Black Yellow Whit...

Page 386: ...ELECTRICAL SYSTEM 14 78 Wiring diagram...

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