Linhai T-Boss 550 Service Manual

SERVICE MANUAL
T-Boss 550
NOTICE
This manual was produced by the Linhai Group primarily for use by Linhai dealers
and their qualified mechanics. It is not possible to include all the knowledge of a
mechanic in one manual, so it is assumed that anyone who uses this book to perform
maintenance and repairs on Linhai vehicle has a basic understanding of the
mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone
without this knowledge are likely to render the vehicle unsafe and unfit for use.
Linhai Group is continually striving to improve all its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized
Linhai dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following
notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe

injury or death to the vehicle operator, passenger, a bystander, or
a person checking or repairing the vehicle.
CAUTION: A CAUTION indicates special precautions that must be taken to

avoid damage to the vehicle.
NOTE: A NOTE provides key information to make procedures easier or

clearer.
CONTENTS
CHAPTER1 ……………………………………………………….General Information
CHAPTER2 ………………………………………….……………………Maintenance
CHAPTER3…………………………………….……….….…………………….Engine
CHAPTER4…………………………………………..…………………………Chassis
CHAPTER5………………………………………………….……………….Final Drive
CHAPTER6………………………………………………………………………Brakes
CHAPTER7………………………………………………….….……………..Electrical
Never run an engine in an enclosed area. Carbon monoxide exhaust gas is
poisonous and can cause severe injury or death. Always start engines outdoors.
Gasoline is extremely flammable and explosive under certain conditions. Battery
electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Always keep alert and wear protection.
Exhaust system components are very hot during and after use of UTV. Never service
when the engine is warm or hot. Escaping steam from cooling system or hot oil from
the machine can cause severe burns. The engine must be cool before service.
Crate of the UTV and parts in the UTV maybe have sharp edge, always pay attention
and wear protection.
CHAPTER 1 GENERALINFORMATION T-Boss550 SERVICE MANUAL 20.0
CHAPTER 1 GENERAL INFORMATION
The parts of different types/ variants/ versions maybe un-interchangeable, even some parts
have almost same appearance. Always refer to Parts Manual of each UTV model for spare
parts information and service.
1.1 IMPORTANT INFORMATION
1.2 V.I.N AND ENG INE SERIAL NUMB ER
1.3 VEHICLE DIMENSIONS
CHAPTER 1 GENERAL PAGE. 1- 1

1.1 IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES

1. Remove all dirt, mud, dust and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. When disassembling the machine, always keep mated parts together. This includes gears,
cylinders, pistons and other parts that have been ”mated ”through normal wear. Mated part
must always be reused or replaced as an assembly.
4. During machine disassembly, clean all parts and place them in trays in the order of
disassembly. This will speed up assembly and allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
REPLACEMENT PARTS
Use only genuine parts for all replacements. Use recommended oil and grease for all
lubrication jobs. Other brands may be similar in function and appearance, but inferior in
quality.
GASKETS,OIL SEALS AND O-RINGS

1. Replace all gaskets seals and O-rings when overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal
lips.
LOCK WASHERS/PLATES AND COTTER PINS
Replace all lock washers/plates and cotter

pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has
been tightened to specification.
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the
manufacturer’s marks or numbers are
visible. When installing oil seals, apply a
light coating of lightweight lithium base
grease to the seal lips. Oil bearings liberally
when installing, if appropriate.
① oil seal
CAUTION:
Do not use compressed air to spin the
bearings dry. This will damage the bearing
surfaces.
① Bearing

CIRCLIPS
1. Check all circlips carefully before
reassembly. Always replace piston pin
clips after one use. Replace distorted
circlips. When installing a circlip ① ,
make sure that the sharp-edged corner
② is positioned opposite the thrust ③
it receives. See sectional view.
④Shaft
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on
the connector.
1. Disconnect:
Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector
two or three.
4. Pull the lead to check that it will not
come off.
5. If the terminal comes off, bend up the
pin ①and reinset the terminal into the
connector.
6. Connect:
 Connector
NOTE:
The two connectors ” click ” together.
7. Check for continuity with a tester.

NOTE:
 If there is no continuity, clean the
terminals.
 Be sure to perform the steps 1 to 7 listed
above when checking the wire harness.
 Use the tester on the connector as
shown.

Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and
can cause severe injury or death. Always start engines outdoors.
Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is
poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or
clothing. Always keep alert and wear protection..
Exhaust system components are very hot during and after use of UTV. Never service when
the engine is warm or hot. Escaping steam from cooling system or hot oil from the machine
can cause severe burns. The engine must be cool before service.
Crate of the UTV and parts in the UTV maybe have sharp edge, always pay attention and
wear protection.
CONVERSION TABLE
How to use the CONVERSION TABLE
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC MULIPLIER IMP
**mm x 0. 3937 = **in
**cm x 0.03937 = **in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
Torque m·kg 7.233 ft·lb
m·kg 86.794 In·lb
cm·kg 0.0723 ft·lb
0.8679
cm·kg In·lb
Weight kg 2.205 lb
g 0.03527 oz
Distance km/h 0.6214 mph
km 0.6214 mi
m 3.281 ft
m 1.094 yd
cm 0.3927 in
mm 0.03927 in
Volume/ cc(cm3) 0.03527 oz(IMP liq.)
3
Capacity cc(cm ) 0.06102 cu·in
lit(liter) 0.8799 qt (IMP liq.)
lit(liter) 0.2199 gal(IMP liq.)
Miscellaneous kg/mm 55.997 lb/in
kg/cm2 14.2234 psi(lb/in2 )
Centigrade 9/5(℃)+32 Fahrenheit(°F)

1.2 V.I.N AND ENGINE SERIAL NUMBER

The vehicle identification number ○ 1 is
stamped
into the rear right of the frame tube.
The engine serial number ② is stamped

into left side of engine crankcase.

1.3 VEHICLE DIMENSIONS

NOTES

CHAPTER 2 MAINTENANCE T-Boss550 SERVICE MANUAL 20.0
CHAPTER 2 MAINTENANCE
have almost same appearance. Always refer to Parts Manual of each UTV model for spare
2.1 PERIODIC MAI NTE NANCE
2.2 THROTTLE PEDAL INSPECTION
2.3 CHOKE ADJUS TMETN
2.4 FUEL SYSTEM
2.5 TOE ALIGNMENT
2.6 BRAKING SYSTEM INSPECTION
2.7 SUSPENSION SPRING RPELOAD ADJUSTMENT
2.8 W HEELS
2.9 TIRE PRESSURE
3.0 FRAME, NUTS , BOLTS, FASTENERS
CHAPTER 2 MAINTENANCE PAGE. 2- 1

2.1 PERIODIC MAINTENANCE

GENARAL
CAUTION
Mark on the following chart
DL ：Due to the nature of the adjustments marked with a DL on the following chart, it is
recommended that service be performed by an authorized dealer.
▲： Service/Inspect more frequently when operating in adverse conditions.
PERIODIC MAINTENANCE SCHEDULE

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
Inspection, adjustment and lubrication intervals of important components are explained in the
following chart on the following pages.
Maintenance intervals are based upon average riding conditions and an average vehicle
speed of approximately 16km/h (10 miles per hour). Vehicles subjected to severe use, such
as operation in wet or dusty areas, should be inspected and serviced more frequently.
Inspect, clean, lubricate, adjust or replace parts as necessary.
NOTE: Inspection may reveal the need for replacement parts. Always use genuine parts
available from your dealer.
Service and adjustments are critical. If you are not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
A = Adjust I = Inspect
C = Clean L = Lubricate
D = Drain R = Replace
T =Tighten to Correct Torque
Item Hours When Remarks

Service (Main) Brake System / Pre-ride I
Parking Brake / Pre-ride I
Tires / Pre-ride I
Wheels / Pre-ride I
Frame nuts, bolts fasteners / Pre-ride I
▲ Air Filter-Pre-Cleaner / Daily I C
Coolant/Level / Daily I
Coolant 150 Annually R
Coolant strength 25 3 months I Inspect strength seasonally
▲ Air Box Sediment Tube / Daily D

Headlamp Inspection / Daily apply dielectric grease to connector
when replaced
Tail lamp inspection / Daily apply dielectric grease to socket when
replaced
I C
▲ Air Filter-Main Element 2 Weekly
Replace if necessary
I
▲ Transmission Oil Level 10 Monthly
change annually
Battery Terminals 10 Monthly I C
DL Brake pad wear 10 Monthly I
10 Monthly C
▲ Gear case Oil
150 annually R
Engine Cylinder Head and I

25 3 months
Cylinder Base Fasteners (re-torque required at first service only)
General Lubrication L
▲ 25 3 months
all fittings, pivots, cables, etc.
Engine Oil-Level / Daily I
Engine Oil Change 30 3 months Break-in Service at 1 month. Change oil
more often in cold weather use.
▲ Oil Filter 50 6 months I C
▲ Engine breather hose 100 6 months I
Throttle Cable / Pre-ride I
DL Throttle Cable/Throttle pedal 50 6 months A L (Grease M) R if necessary
Shift linkage 50 6 months I A R if necessary
I
DL Transmission belt 50 6 months
R if necessary

▲ Steering 50 6 months I L T if necessary
I L
▲ Front Suspension 50 6 months
T if necessary
I
▲ Rear Suspension 50 6 months
T if necessary
I
Spark Plug 100 12 months
R if necessary
I
DL Ignition Timing 100 12 months
Adjust as needed
Check for leaks at tank, cap, lines, fuel
DL Fuel System 100 12 months valve, and filter. Replace lines every 2
years.
DL Fuel Filter 100 12 months R
Radiator 100 12 months I R
I
Cooling System hoses 50 6 months
R if necessary
C
Spark arrestor 10 monthly
R if necessary
I R
DL Clutches (drive and Driven) 25 3 months
R if necessary
Engine mounts 25 3 months I T
DL Valve clearance 100 12 months I A
Shift selector box

DL 200 24 months Change grease every two years
(R/N/ H/L)
Exhaust system 100 12 months I
DL Brake fluid Level / Pre-ride I
Brake fluid 200 24 months Change every two years
Idle Speed / As Required A
DL Toe adjustment / As Required Periodic inspection, adjust when parts

are replaced
Headlight Aim / As Required Adjust if necessary
▲ I, (for damage, wear, and play)

Ball joint (A arm- strut) 10 monthly
DL R. Replace if necessary
LUBRICANT AND FLUID

Item Lube Rec Method Frequency
SAE15W/40 Add to proper level on
 1. Engine Oil Check level daily
SG dipstick
As require;
Maintain level,Between
change every
2.Brake Fluid DOT 3 Only fill lines. See
two years or 200
“7.CONTROL”
hours
See “16.MAI- Change annually
3.Rear Gear case SAE
NTENANCE/ Rear or
oil GL-4 85W/90
Gear Case Lubrication” at 100 hours
See “16.MAI- Change annually
4.Front Gear case SAE
NTENANCE/ Front or
oil GL-4 85W/90
Gear Case Lubrication” at 100 hours
Lubricate the pivoting Every 3 months

 5.Steering system Grease
and sliding parts or 50 hours
 6.Tie rods Grease Grease Semi-annually
7.Shift Locate fittings

 Grease Semi-annually
Linkages and Grease
Inspect and replace

8.Front/Rear Wheel
 Inspect bearings if Semi-annually
bearings
necessary
Inspect, Locate fittings
 9.Ball joints Grease and Grease, or replace it Semi-annually
if necessary
10.Prop Shaft ＆
 Shaft Yoke, Spline Grease Locate fitting and Grease Semi-annually
Joint
Locate fitting on pivot
11. Front/Rear
shaft Every 3 months
 A-arm Grease
and grease with grease or 50 hours
pivot Shaft
gun
Grease, inspect
12.Throttle Monthly or 20
 Grease M and replace it if
Cable hours
necessary
13. Accelerator
Monthly or 20
 pedal and brake Grease Grease, inspect
hours
pedal
LUBRICATION RECOMMENDATIONS
NOTE:
1.More often under severe use, such as wet or dusty conditions.
2.Grease: Light weight lithium-soap grease.
3.Grease M：Molybdenum disulfide (MoS2 ) grease (water resistant).
4.When suspension action becomes stiff or after washing.
5.Hours are based on 10 mph(16Km/h) average.

2.2 THROTTLE PEDAL INSPECTION

THROTTLE FREEPLAY
If the throttle pedal has excessive play due to
cable
stretch or cable misadjustment, it will cause a
delay in throttle speed. Also, the throttle may
not open fully. If the throttle pedal has no play,
the throttle may be hard to control, and the idle
speed may be erratic. Check the throttle pedal
play periodically in accordance with the
Periodic Maintenance Chart and adjust the
play if necessary.
THROTTLE FREEPLAY INSPECTION

1. Apply the parking brake.
2. Put the gear shift lever in the N(Neutral) position.
3. Start the engine, and warm it up thoroughly.
4. Measure the distance the throttle pedal moves
before the engine begins to pick up speed. Free
play should be 1.5 – 3 mm.
Adjustment
1. Slide the boot off inline cable adjuster sleeve.
Loosen adjuster locknut.
2. Turn adjuster until 1.5 to 3 mm, freeplay is
achieved pedal. NOTE: While adjusting freeplay,
it is important you flip the throttle lever back and
forth.
3. Tighten locknut.
2.3 CHOKE ADJUSTMETN

If the choke knob does not stay out when pulled,
adjust the choke tension by tightening (clockwise)
the chock cable boot until the choke slider freely but
stays out when pulled.
If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing

2.4 FUEL SYSTEM
EFI
Always stop the engine and refuel

outdoors or in a well venltilated area.
Do not smoke or allow open flames or sparks in or near the area where refueling is
performed or where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get fuel in your eyes or if you swallow gasoline, see your doctor immediately.
If you spill fuel on your skin or clothing, immediately wash it off with soap and water and
change clothing.
Never start the engine or let it run in an enclosed area. Fuel powered engine exhaust
fumes are poisonous and can cause loss of consciousness and death in a short time.
Never drain the float bowl when the engine is hot. Severe burns may result.
FUEL LINES
1. Check fuel lines for signsof wear,
deterioration, damage or leakage.
Replace if necessary.
2. Be sure fuel lines are routed
properly and secured with cable
ties.
CAUTION:
Make sure lines are not kinked
orpinched.
Replace all fuel lines every two years.
VENT LINES AND ROLL OVER VALVE

1. Check fuel tank, oil tank, battery and
transmission vent lines for signs of wear,
deterioration, damage of leakage. Replace every
two years.
2. Be sure vent lines are routed properly and
secured with cable ties.
CAUTION: Make sure lines are not kinked or

pinched.
NOTE: Make sure the↑mark on the roll over valve is
upwards.
2.5 TOE ALIGNMENT

METHOD: STRAIGHTEDGE OR STRING
Be sure the steering wheel in a straight ahead position.
NOTE: String should just touch side surface of rear tire on
each side of the UTV.
Measure from string to rim at front and rear of rim.
Rear rim measurement (A) should be 1/8" to 1/4" (3 to 6
mm) more than front rim measurement (B).
Always pay attention to tie rods assembly, Both ends

must screw in same and enough threads length.
2.6 BRAKING SYSTEM INSPECTION

The following checks are recommended to keep the
braking system in good operating condition. Service life of
braking system components depends on operating
conditions. Inspect brakes in accordance with the
maintenance schedule and before each ride
Keep fluid level in the master cylinder reservoir to the
indicated level on reservoir.
Use DOT 3 brake fluid.
NOTE: Use new brake fluid or brake fluid from a sealed
container to avoid contamination to system.
Check brake system for fluid leaks.
Check brake for excessive travel or spongy feel.
Check friction pads for wear, damage and looseness.
Check surface condition of the disc.

BRAKE PAD INSPECTION

Pads should be changed when friction material is
worn to 3/64" (1mm).
HOSE/FITTING INSPECTION
Check braking system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
ADJUSTING THE BRAKE PEDAL

Check the brake pedal free play. Free play should be
8 – 12mm. Out of specification → Adjust.
1. Loosen the locknut
2. Turn brake rod in or out until the correct free play
is obtained.
Turning in: Free play is increased.
Turning out: Free play is decreased.
3. Tighten the locknut
ADJUSTING THE PARKING BRAKE

Although the parking brake has been adjusted at the
factory, the brake should be checked for proper
operation. The mechanical brake must be maintained to
be full functional.
1. With the engine off, apply the parking brake lever and
attempt to move the UTV.
2. If the rear wheels are locked, it is adjusted properly.
3. If the wheels are not locked, it must be adjusted.
To adjust (set up) the mechanical parking brake, use
the following procedure
Note: The adjusting on the caliper is for the wear out
of the pads.
1. With the engine off, loosen the adjustor on the
lever.
2. Loosen the jam nut of the adjuster on the caliper.
3. Turn the adjuster bolt CW (clockwise) by hand till
the pad touch the brake disc, turn the adjuster bolt
CCW (counterclockwise) by 1/4 to one turn for 10
to 20mm free play at the end of the parking lever.
4. Tighten the jam nuts securely against the
adjusters.
5. Make sure the rear wheels turns freely without

dragging.
6. Turn the adjustor (the one on the lever) and apply
the lever. While adjusting, it is important you
apply the lever back and forth for operation, free
play and the locking of the parking position.
7. Make sure the rear wheels turns freely without
dragging and parking brake works properly.
8. Field test for parking. It must be capable of holding
the laden UTV stationary on an 20% up and down
gradient.
A temporary adjusting can also be done to the brake
cable on the parking lever side by turn the adjuster
(nut) directly. But the adjust range is limited. Always do
the procedure 1 to 8 when necessary.
2.7 SUSPENSION SPRING RPELOAD ADJUSTMENT

Operator weight and vehicle loading affect suspen-
sion spring preload requirements. Adjust if necessary.
FRONT SUSPENSION
Compress and release front suspension. Damping
should be smooth throughout the range of travel.
Check all front suspension components for wear or
damage.
Inspect shock for leakage

Shock spring preload can be adjusted using the
shock spanner wrench.
REAR SUSPENSION
Compress and release rear suspension. Damping
should be smooth throughout the range of travel.
Check all rear suspension components for wear or
damage.
Inspect shock for leakage

Shock spring preload can be adjusted using the
shock spanner wrench.

Always adjust both shock absorber spring preload to

the same setting. Uneven adjustment can cause
poor handling and loss of stability.
Turn the adjuster ○ 1 to increase or decrease the
spring preload.
Standard position: 3
Minimum (Soft) position: 1
Maximum (Hard) position: 5
2.8 WHEELS
Inspect all wheels for runout of damage.
Check wheel nuts and ensure they are tight.
Do not over tighten the wheel nuts.
WHEEL REMOVAL
1. Stop the engine, place the transmission in gear and
lock the parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable
stand under the footrest frame.
4. Remove the wheel nuts and remove the wheel.
WHEEL INSTALLATION
1. With the transmission in gear and the parking Brake
locked, place the wheel in the correct Position on the
wheel hub. Be sure the valve stem is toward the
outside and rotation arrows on the tire point toward
rotation.
2. Attach the wheel nuts and finger tighten them.
Install as shown at left for front or rear wheels.
3. Lower the vehicle to the ground.
4. Securely tighten the wheel nuts to the proper
Torque listed in the table. On wheel nuts, Make
sure tapered end of nut goes into taper on wheel.
Wheel Nut Torque Specifications
Bolt Size Specification
Front M10X1.25 55Lbs.Ft 75Nm
Rear M10X1.25 55Lbs.Ft 75Nm
CAUTION: If wheels are improperly installed it could

affect Vehicle handling and tire wear.
2.9 TIRE PRESSURE

TIRE INSPECTION
CAUTION:
 Maintain proper tire pressure. Refer to the
warning tire pressure decal applied to the
Tire Pressure Inspection
vehicle.
 Improper tire inflation may affect UTV Front Rear
maneuverability.
 When replacing a tire always use original see detail on the see detail on the
equipment size and type and replace in pairs, mark of sidewall mark of sidewall
especially in 4X4 model.
 The use of non- standard size or type tires may affect
UTV handling and cause machine damage, especially
in 4X4 model.
TIRE TREAD DEPTH

Always replace tires when tread depth is worn to 1/8"
(3mm ) or less.
Operating an UTV with worn tires will increase the

possibility of the vehicle skidding easily with possible
loss of control.
Worn tires can cause an accident.
Always replace tires when the tread depth measures
1/8" (3mm ) or less.
3.0 FRAME , NUTS, BOLTS, FASTENERS

Periodically inspect the tightness of all fasteners in
accordance with the maintenance schedule. Check that
all cotter pins are in place. Refer to specific fastener
torques listed in each chapter.

NOTES

CHAPTER 3 ENGINE T-Boss550 SERVICE MANUAL20.0
CHAPTER 3 ENGINE
500 cc
3.1 Removal and Installation of Engine
3.2 Engine Overhaul Information
3.3 Checks & Adjustment
3.4 Engine Removal, Inspection & Installation
3.5 FUEL INJECTION SYSTEM
3.6 Cooling and Lubrication System
3.7 Troubleshooting
CHAPTER 3 ENGINE PAGE. 3- 1

3.1. Removal and Installation of Engine
Overhaul Info…..……………………………..3.1.1
Engine Removal and Installation…………...3.1.2
3.1.1 Overhaul info
Operation cautions
●Securely support the UTV with bracket when removing or installing engine.
Take care not to damage frame, engine body, bolts and cables.
●Wrap the frame to avoid any possible damage when removing or installing the engine.
●Following operation doesn’t require removal of engine from the vehicle:
—Fuel pump
—Throttle body, air filter
—Cylinder head cover, cylinder head, cylinder body, camshaft
—CVT system, CVT cover
—Right side cover, AC magneto, water pump
—Piston, piston ring, piston pin
●Following operation require removal of engine from vehicle:
—Crankshaft
—Gearbox
—Oil pump
●Tightening torque:
Engine front upper mounting bolt: 50～60N·m
Engine front rear mounting bolt: 50～60N·m
Nut, engine front rear mounting bracket 40～50N·m

●Engine Removal
Remove:
--Plastic
--Cushion Support Component
--Air Filter
--Throttle Body
--Clamp
--Water Inlet Hose
Remove cable shifter
Remove bolt
Remove shifting anchor plate
Remove connector of water temperature transducer
Remove clamp
Remove water outlet hose
Remove connectors of magneto, enriching device lead,

pickup, water temperature transducer, gear sensor as
illustrated on the right.

Remove spark plug cap from cylinder.
Remove protection sleeve of starter relay.
Remove Nut.
Disconnect positive wire of starter relay.
Remove Bolt.
Remove negative wire of starter relay.
Remove the Bolt and Nut of upper engine hanger.

Remove 2 Bolts and Nuts of lower engine hanger
Remove 4 Bolts of lower engine hanger.
Remove 4 Bolts of front steering kunckle connected

with the engine
Remove 4 Bolts of rear steering kunckle connected

with the engine

3.1.2 Engine Installation

Put engine onto the frame，install the two lower mounting bolts and nuts.
Then install the upper and lower engine hangers.
Tightening torque: Engine upper hanger bolt:50～60N•m

Engine lower hanger bolt:50～60N•m
Install:
--Water outlet and inlet hoses to engine with proper clamps.
--Positive and negative starting wires to engine.
--Connect all the connectors.
--Spark plug cap.
--Shifting anchor plate and cable shifter to engine.
--Air filter, throttle body and removed parts.

3.2．Engine Overhaul Information
Conversion Table ………………………………………………………………… ……… 3.2.1

General Precautions …………………………………………..………………… ………. 3.2.2
Fuel, Oil and Coolant ……………………………………………………………… …… 3.2.3
Brake-in Procedures …………………………………………………………………… …3.2.4
Engine Exterior and Engine No ………………………………………………………… 3.2.5
Engine Specification …………………………………………………………..……………3.2.6
Overhaul Data………………………………………………………………………………. 3.2.7
Tightening Torque Table………………………………………………………………….. 3.2.8
Tools …………………………………………………………… ………………………….. 3.2.9
Materials for Operation and Fixing ……………….…………………………………. …. 3.2.10
.
.

3.2.1 COVNERSION TABLE
Item Conversion
Press 1mmHg=133.322Pa=0.133322KPa
2
1kgf/cm =98.0665KPa 1KPa=1000Pa
Torque 1kgf.m=9.80665N.m
Volume 3
1ml=1cm =1cc
1l=1000 cm3
Force 1kgf=9.80665N
Warning/Caution/Note
Please read this manual and follow is instructions carefully. To emphasize special information, the symbol and
the words WARNING,CAUTION and NOTE have special meanings. Pay attention to the messages highlighted
by these signal words.
Warning:
Indicates a potential hazard that could result in injury or death.
Caution:
indicates a potential hazard that could be result in vehicle damage.
Note:
provides key information to make procedures easier or instruction clearer.
Please note, however, that the warnings and cautions contained in this manual can’t possibly cover all the
potential dangerous information to the servicing, or lack of the vehicle. Except WARNINGS and CAUTIONS
stated in this manual, mechanic should have a basic understanding of the mechanical ideas and the procedure
of machine repair. If mechanic can’t master all the troubleshooting operation, please consult with qualified
mechanic for advice.

3.2.2 GENERAL PRECAUTIONS
Warning ! Proper service and repair procedures are important for the safety of
operator and the safety and reliability of the vehicle.
When two or more persons work together, keep reminding each other for safety purpose.
When the engine indoors starts, make sure that the exhaust gas is forced outdoors.
If use hazardous or flammable material, please strictly operate according to manufacturer’s operation
manual. Operate in a well- ventilated place.
Never use gasoline as a cleaning solvent.
Do not touch the engine oil, radiator or muffler with bare hands to avoid scalding before it is cooled.
Check all the lines, and fittings related to the system for leakages, after repairing fuel, cooling, lubricating
or exhaust system .
Do not dispose used oil, coolant or defective parts optionally for environmental purpose.
CAUTION:
Use genuine LINHAI parts or their equivalent.

Place and store the disassembled parts separately in order for correct assemble.
Use special tools according to service manual.
Make sure that all parts used in reassembly are clean, lubricated them when specified.
Use the special lubricants, sealants and greases.
Pre-tighten the bolts, nuts and screws, then tighten according to the specified torque, from big to small and
from inner side to outer side.
Fix torque screw with torque wrench, clean grease or oil from the screw thread before fixing.
Check the parts after disassembling, clean the parts before measuring.
Check parts for tightness and proper operation, after assembling.
Replace the disassembled washers, o-rings, seals, locknuts, lockwashers, cotter pins, circlips with new
ones.
3.2.3 FUEL, OIL AND COOLANT

Fuel
Use unleaded gasoline with octane number over 87.
OIL
Use a premium quality 4-stroke motor oil to ensure
longer service life of your vehicle. Use only oils that
meet API service classifications SG and that
have a viscosity rating of SAE15W/40. If oil with a
rating of SAE 15W/40 is not available, select an
alternative according to the chart.
ENGINE COOLANT
Since antifreeze also has corrosion and rust-inhibiting properties, always use coolant containing antifreeze,
even if the atmospheric temperature does not go below the freezing point.
It is suggested that the freezing point of antifreeze should be 5℃ lower than the lowest ambient temperature
where the vehicle is used.
Recommended Coolant: -35℃ antifreeze, corrosion-resistant, high boiling point coolant
Warning! Coolant is poisonous. Never drink it. Store it properly.
Caution: DO NOT mix coolant with that of other engines.
3.2.4 BREAK-IN PROCEDURES

During manufacturing only the best possible material are used and all machined parts are finished to a very
high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to
maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. Refer to the following break-in engine speed recommendations.
For better performance and durability, a new engine requires a run-in time of 20 hours as under:
0~10 Hours:
Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour
of operation. Vary the speed of vehicle from time to time. Do not operate it at one set throttle position.
10~20 Hours
Avoid prolonged operation above 3/4 throttles. Rev the vehicle freely but do not use full throttle at any time.
Note: Keep the daily maintenance during the run-in time and eliminate the troubles, if any. After 20h run-in time,
do the maintenance according to the owner’s manual for normal operation of the UTV.

3.2.5 Engine Exterior and Engine No

3.2.6 Engine Specification

REF.
ITEM Type/SPECIFICATION
NO
Single Cylinder, 4-Storke, Liquid-cooled,
1 Type
4 Valve, SOHC
2 Bore and stroke 87.5mm×82.0mm
3 Displacement 493ml
4 Compression ratio 10.2: 1
5 Lowest continuous idle speed with load 1400r/min±100r/min
6 Starting type Electrical starting
Ignition /
EFI ECU Magneto ignition/BTDC10°1500r/min
Ignition Timing
Electrical Spark Plug/
7 DPR7EA-9 (NGK)/0.8mm-0.9mm
Spark Plug Gap
System
Magneto Permanent Magnet AC Type
Combustion Chamber Triangle Combustion Chamber
Combustion Air Filter Sponge Element Filter

8
System
Gasoline RQ-87
Valve
9 System Valve Type SOHC/Chain Drive
Lubrication Type Pressure & Splash
Oil Pump Trochoid
Lubrication Filter Type Full Flow Filter Screen
10
System
Oil Type SAE15W-40/SG
Cooling Type Closed Coolant Circulation
Cooling
11 Coolant Type —35℃ Rust-resistant antifreeze
System
Clutch type Wet, Auto-centrifugal
Operation Mode Automatic(CVT)+Parking and Gear Shifting
Gears 2 Forward Gears + 1 Reverse Gear
Shift Type/Sequence Hand Operation/L-H-N-R
Drive (CVT) Gear Ratio 2.88-0.70
System Final Ratio 1.333(24/18, bevel gear)
12 Transfer Secondary
1.952(41/21)
Ratio
Gear Ratio
Low Gear:2.25(36/16) High Gear :1.35(27/20)
Gears
Reverse Gear:1.471(25/17)
Total Low Gear:5.857, High Gear:3.514,Reverse Gear:3.828
13 Overall Dimension 610×568×519mm
14 Net Weight 70kg
15 Output type Front and rear shaft output
16 Rotational Direction of Engine Output Clockwise (from behind engine at forward gear)

3.2.7 Overhaul Data

Item Standard Service Limit Remark
Valve Head Diameter IN 30.6
-----------
EX 27.0
IN 0.05-0.10
Valve Clearance ------------
EX 0.010-0.037
Clearance Between Valve IN 0.010-0.037
------------
Guide and Valve Stem EX 0.030-0.057
Inner Diameter of Valve
IN & EX 5.000-5.012 -------------
Guide
IN 4.975-4.990 -------------
Outer Diameter of Valve Stem
EX 4.955-4.970 -------------
Valve Stem Play IN & EX ------------- 0.05
Length of Valve Stem End IN & EX 2.9-3.1 2.3
Valve Head Thickness IN & EX ------------- 0.5
Play of Valve Head Seal IN & EX ------------ 0.03
Width of Valve Seat Seal IN & EX 0.9-1.1 -------------
Valve Spring Free Length IN & EX 40 38.8
182-210N,(when
Valve Spring Tension IN & EX compressed to --------------
31.5mm)
IN 33.430-33.490 33.130
Cam Height
EX 33.500-33.560 33.200
Clearance Between Φ22 0.032-0.066 0.150
Camshaft Outer Diameter & Φ17.5 0.028-0.059
0.150
Hole
Φ22 21.959-21.980 ---------------
Camshaft Outer Diameter
Φ17.5 17.466-17.484 ---------------
Inner Diameter of Camshaft Φ22 22.012-22.025 ----------------
Hole Φ17.5 17.512-17.525 ----------------
Camshaft Play 0.10
Inner Diameter of Rocker Arm IN & EX 12.000-12.018 ----------------
Outer Diameter of Rocker
IN & EX 11.973-11.984 ----------------
Arm
Cylinder Head Distortion 0.03 0.05
Cylinder Head Cover
0.03 0.05
Distortion

Cylinder + Piston + Piston Ring + Connecting Rod

Cylinder Pressure 1000KPa ------------
Cylinder-Piston Clearance 0.030-0.051 0.15
Piston Skirt Diameter 87.460-87.480 87.380
(10mm form skirt end)
Inner Diameter of Cylinder 87.500-87.522 ------------
Cylinder Joint Face Distortion 0.015 0.05
Top R About 11.7 8.9
Piston Ring Free Gap Ring
2ND R About 12 9.5
Ring
Piston Ring Gap In Bore Top Ring 0.15-0.30 0.60
2ND Ring 0.15-0.30 0.60
Piston Ring Groove Top Ring 0.04-0.08 0.180
Clearance 2ND Ring 0.03-0.07 0.150
Top Ring 0.97-0.99 -------------
Piston Ring Thickness
2ND Ring 1.17-1.19 -------------
Top Ring 1.03-1.05 -------------
Piston Ring Groove Width 2ND Ring 1.22-1.24 -------------
Oil Ring 2.51-2.53
Inner Diameter of Piston Pin 23.002-23.008 23.030
Hole
Outer Diameter of Piston Pin 22.995-23.000 22.980
Inner Diameter of Connecting 23.006-23.014 23.040
Rod Small End
Clearance of Connecting Rod 0.10-0.55 1.0
Big End
Thickness of Connecting Rod 24.95-25.00
Big End
Crankshaft Play 0.03 0.08
Lubrication
Clearance between Inner 0.03mm-0.10mm 0.15mm
and Outer Rotors
Clearance between Outer 0.03mm-0.10mm 0.12mm
Rotor and Oil Pump Body
Oil Pressure 130Kpa-170Kpa ( 3000r/min) ---------
Oil Type SAE15W-40, API SG ---------
When changing 1900ml ----------
Oil Capacity When Replacing 2000ml ----------
Filter
Engine Repair 2200ml ---------

Clutch + Transfer

Clutch Plate Inner diameter 140.00-140.15 140.50
Clutch Engagement Speed 1800-2400r/min ---------
Clutch Lock Speed 3300-3900r/min ---------
Drive Belt Width 35.2 33.5
Free length of Secondary 168 160
Sheave Spring
Shift Fork to Groove
0.10-0.40 0.50
Clearance
Thickness of Left Shift Fork 5.8-5.9 ------------
Thickness of Right Shift Fork 5.8-5.9 ------------
Shift Fork Groove Width 6.0-6.2 ------------
Drive Output Gear Groove
6.0-6.2 ------------
Width
Cooling System

Thermostat Valve Opening
68-74℃ ----------
Temperature
Thermostat Valve Lift 4.5-6.5mm ( at 80℃) ----------
Radiator Cap Opening
110-140Kpa ----------
Pressure
Water
Resistance (Ω) ----------
Corresponding Relation Temperature (℃)
Between Water-temperature 50 154+16
Transducer’ resistance and 80 52+4
water-temperature 100 27+3
120 16+2
Functioning Temperature of OFF--ON 88 ℃ ------------
Thermoswitch ON--OFF 82℃ ------------
Coolant Type -35℃ antifreeze, corrosion-resistant, high
------------
boiling point coolant

Electrical System
Item Standard Remark

Spark Plug Type NGK;DPR7EA-9
Gap 0.8-0.9
Spark Character >8mm
Ignition coil Primary 0.1Ω-0.5Ω
Resistance
Secondary 12Ω-22Ω
Magneto Coil Pick-up 150Ω-300Ω
Resistance
Magneto Voltage (Without load) >100V(AC),5000r/min
Max. Magneto Output Power 300W, 5000r/min
Regulated Voltage 13.5V-15.0V, 5000r/min
Primary Peak Voltage of Ignition Coil >150W
Starter Relay Coil Resistance >120W
Starter Relay Coil Resistance 3Ω-5Ω
Auxiliary Starter Relay Coil Resistance 90-100Ω

3.2.8 Tightening Torques
Item Quantities Thread Size (mm) Tightening Torque Remark

(N.m)
Reverse Gear Sensor 1 M10×1.25 20
Spark Plug 1 M12×1.25 18
Water-temperature
1 M12×1.5 10 Apply Thread Locker
Sensor
Adjusting Nut,
4 M5 10
Valve Clearance
Nut, Primary Sheave 1 M20×1.5 115
Nut, Secondary
1 M20×1.5 115
Sheave
Ring Nut, Secondary
1 M30×1 100
Sheave
Nut, Front Drive Shaft 1 M14×1.5 97
Nut, Drive Bevel Gear 1 M22×1 145
Nut, Driven Bevel
1 M16×1.5 150
Gear
Fixing Nut, Clutch 1 M18×1.5 70 Counter Clockwise
Limit Nut, Drive Bevel
1 M60 110 Apply Thread Locker
Gear Bearing
Nut, Universal Joint Counter Clockwise,
1 M55 80
Yoke Apply Thread Locker
Bolt, Rocker Arm
2 M14×1.25 40
Shaft
Oil Drain Bolt 1 M12×1.5 30
Bolt, Overriding
6 M8 26 Apply Thread Locker
Clutch
Bolt, Magneto Stator 3 M6 10 Apply Thread Locker
Screw, CVT Plate 3 M6 10 Apply Thread Locker
Bolt, Oil Pipe 2 M14×1.5 40
Bolt, Oil Pump 3 M6 10
Bolt, Pressure
2 M6 10
Release Valve
Bolt, Drive Bevel
4 M8 32
Gear Cover
Bolt, Driven Bevel
4 M8 25
Gear Cover
Bolt, Gear Limit 1 M14×1.5 18
Bolt, Splined Spacer 1 M10×1.25 60

Tightening Torques
Item Quantiti Thread Size Tightening Torque Remark

es (mm) (N.m)
Bolt, Crankcase 14 M6 10
3 M8 25
Bolt, Driven Sector Gear 1 M6 12
Bolt, Oil Filter 1 M20×1.5 36
Bolt, Oil Starter Motor 2 M6 10
Bolt, Cylinder Head 4 M10 42
Bolt, Cylinder Head 2 M6 10
1 M8 25
Bolt, Cylinder (Upper &
4 M6 10
Lower)
Bolt, Cylinder Head
12 M6 10
Cover
Bolt, Chain Tensioner 2 M6 10
Bolt, Chain Tensioner 1 M8 20
Bolt, Fan Motor 3 M6 10
Bolt, Thermostat
2 M6 10
Housing
Bolt, Water Pump Cover 3 M6 10
Bolt, Water Pump 2 M6 10
Fixing Bolt, Timing Apply Thread Locker
2 M6 15
Chain
Other Bolts M5 4.5-6
M6 8-12
M8 18-25

3.2.9 Maintenance Tools

Measurement Tools
No. Description Specification Purpose
1 Vernier Caliper 0-150mm For measuring the length and thickness
2 Micrometer 0-25mm For measuring outer diameters of rocker arm, valve stem
and camshaft
3 Micrometer 25-50mm For measuring the max. lift of camshaft
4 Micrometer 75-100mm For measuring piston skirt
5 Cylinder Gauge For measuring cylinder bore diameter
6 Small Bore Gauge 10-34mm For measuring inner gauge of rocker arm, piston pin bore,
connecting rod small end bore
7 Dial Indicator 1/100 For measuring the play
8 Straightedge Gauge Plane measuring
9 Feeler Gauge Plane and valve clearance measuring
10 Fuel Level Gauge For measuring the carburetor fuel level
11 Thickness Gauge For measuring the clearance
12 Spring Balance For measuring the spring tension
13 Tachometer For measuring engine speed
14 Oil Pressure Gauge For measuring oil pressure
15 Compression Gauge & For measuring cylinder compression
Adapter
16 Radiator Cap Tester For measuring radiator cap opening pressure
17 Ohmmeter For measuring resistance and voltage
18 Ammeter For measuring current/switches
19 Thermometer For measuring liquid temperature
20 Timing Light For checking the ignition timing
21 Torque Wrench For measuring the tightening torque
General-purpose and Auxiliary Tools
22 Alcohol Burner Heating up
23 Magnetic Stand For micrometer
24 Slab Auxiliary tool for measuring
25 V-block For measuring the play
26 Tweezer For installation of valve cotter
27 Circlip Pliers For removal and installation of circlips
28 Long Nose Pliers For removal and installation of retainers
29 Impact Driver For removal of cross-headed bolts
30 (-) Driver
31 (+) Driver

Special Tools
No. Description Specifications Purpose

1 Spark Plug Wrench Removal and installation of spark plug
2 Clutch Holder For removing/installing clutch carrier nuts
3 Oil Filter Wrench Removal and installation of oil filter cartridge
4 Piston Pin Puller For removal of piston pin
5 Flywheel Puller For removal of magneto rotor
6 Crankcase Separating Tool For separation of left and right crankcase
7 Crankshaft Remover For removal of crankshaft from left crankcase
8 Crankshaft Installation Set For installing crankshaft to left crankshaft
9 Valve Spring Compressor For removal and installation of valve spring
10 Valve Seat Cutter For valve-seating
11 Ring Nut Wrench Removal/installation of CVT secondary sheave
12 Sheave Holder Removal/installation of CVT secondary sheave
13 Sheave Spring Compressor Removal/installation of CVT secondary sheave
14 Couple Gear/Middle Shaft
Removal/installation of the coupling gear nut
Tool
15 Bearing Driver Set For installation of bearing and oil seal
16 Bearing Removing Tool Set For removal of bearing
17 Oil Seal Removing Tool For removal of oil seal
18 Universal Joint Holder For removal/installation of the universal joint yoke nut

3.2.10Materials for Operation and Fixing
Materials for engine operation engine oil, grease and coolant. Fixing materials include sealant, thread locker,
etc.
Description Type Application Area Remark

10W-50 SN capacity
Cylinder bore 1900ml
Lubricating Crankcase (for changing oil)
Refer to Engine Lubrication 2000ml
Oil/Engine Oil
System (→14-14) (for replacing filet)
2200ml
(for engine repairing)
Molybdenum piston pin、valve stem、valve
lubrication oil oil seal、camshaft
Oil seal lip, O-ring and
#3 MoS2 Lithium Base sealing faces of other
Lubricating Grease
rubber seal materials,
Grease
bearings with seals, CVT
bearing and collar
-35℃ antifreeze, Cooling system、Water-seal Capacity according to
Coolant corrosion-resistant, high radiator and water hose
boiling point coolant system
Joint face of crankcase,
Joint Face Sealant crankcase and cylinder,
cylinder head and cover
Thread Locker Thread Parts

3.3. Checks & Adjustment
Periodic Maintenance table ……………………………………………………….3.3.1
Procedures of Maintenance and Adjustment…………….……………………..3.3.2
Valve Clearance…………………………………………………………... 3.3.2.1
Engine Idle Speed…………………………………………….…….…….. 3.3.2.2
Spark Plug……………………………………………………...…………. 3.3.2.3
Filter…………………………………………………………………………..3.3.2.4
Fuel Hose…………………………………………………………………….3.3.2.5
Drive Belt……………………………………………………...……………. 3.3.2.6
Inspection of Lubrication System………………………………………..…….. 3.3.3
Inspection of Cooling System………………………………………………….. 3.3.4
Inspection of Cylinder Pressure………………………………………..…………3.3.5
Inspection of Oil Pressure…………………………………………………...…. 3.3.6
Inspection of Clutch Engagement and Lock-up………………………..…….. 3.3.7

3.3.1 Periodic Maintenance Table

The table below lists the recommended intervals for all the required periodic maintenance work necessary to
keep the vehicle at its best performance and economy. Maintenance intervals are expressed in terms of
kilometer, miles and hours, whichever occurs first.
Note: More frequent maintenance may be required on vehicles that are used in severe conditions.
Interval Km Initial 750 Every 1600 Every 3200 Remark
Miles Initial 450 Every 900 Every2000
Item Hours Initial 20 Every 50 Every 100
Valve Clearance IN: 0.05~0.10
I -- I
EX:0.15~0.20
Idle Speed I I I 1400±100r/Min
Spark Plug -- -- I No carbon deposit
Replace every 6000Km Gap: 0.8~0.9mm
Air Filter Element R R R Replace every 1500Km
Fuel Hose -- -- I Replace every 4 years
Clutch -- -- I
Drive Belt -- I R
Engine Oil R -- R
Oil Filter R -- R
Coolant Level I I I
Water Hose & Pipes I I I
Coolant Replace every 2 years
I=Inpection and adjust, or replace if necessary
R=Replace
C=Clean

3.3.2 Procedures of Maintenance & Adjustment
This section describes the maintenance procedures for

each item mentioned in the Periodic Maintenance Chart.
3.3.2.1 VALVE CLEARANCE
Inspect initially at 20-hour break-in and every 40 hours

or every 1000km thereafter. Inspect the clearance after
removing cylinder head.
Excessive valve clearance results in valve noise and

insufficient valve clearance results in valve damage and
reduced power.
Check the valve clearance at the period indicated above
and adjust the valve clearance to specification, if
necessary.
Remove cover ①
Remove inspection cap ②on left crankcase.
Remove 2 valve adjusting cover ③
Turn the crankshaft until the line④ of T.D.C. on rotor is
aligned with mark⑤ of inspection hole on left
crankcase.
Insert feeler gauge to check the clearance between
the valve stem end and the adjust bolt on the rocker
arm.
Valve Clearance (When cold)

IN: 0.05-0.10mm EX: 0.15-0.20mm
Note:
The valve clearance must be adjusted when the
engine is cold.
Adjust the valve clearance when the piston is at the
Top Dead Center (T.D.C.) on the compression stroke.
If the clearance is incorrect, bring it into the specified range

using the special tool.
Loosen valve adjust bolt and nut, insert a feeler gauge

between the valve stem end and valve adjusting bolt,
tighten valve adjust bolt, make sure it slightly contacts the
feeler gauge, tighten bolt and nut.

Take out the feeler gauge, measure the clearance.

If the clearance is incorrect, repeat the above steps until
the proper clearance is obtained.
Locknut: 10 N•m
Caution:
Securely tighten the locknut after completing
adjustment
Install:
2 valve adjusting cover;
Inspection cap;
Recoil starter;
Cover plate;
Apply a small quantity of THREAD LOCKER to recoil
starter fixing bolts.
Tools:
Valve adjuster
Feeler gauge
Material:
Thread Locker
3.3.2.2 ENGINE IDLE SPEED

Inspect initially at 20 hours run-in and every 40
hours or 1000km thereafter.
Start the engine and warm it up for several minutes,

measure engine speed with a tachometer. Set the
engine idle speed between 1300~1500 r/min by turning
the throttle stop screw of carburetor.
Engine idle speed: 1400r/min±100r/min
Note:
Make this adjustment when the engine is hot
Tool: Tachometer
3.3.2.3 SPARK PLUG

Inspect initially at 20 hours run-in and every 80 hours or
2000km thereafter. Replace every 6000km.
Remove the spark plug with a special tool
Specification: DER7EA-9(NGK)
If the electrode is extremely worn or burnt, or spark plug

has a broken insulator, damaged thread, etc, replace the
spark plug with a new one.
In case of carbon deposit, clean with a proper tool.

SPARK PLUG GAP
Measure the spark plug gap with a feeler gauge.
Out of specification: → Adjust
Spark plug gap: 0.8-0.9mm
Caution:
Check the thread size and reach when replacing the
spark plug. If the reach is too short, carbon will be
deposited on the screw portion of the spark plug hole and
engine damage may result.
Installation:
Caution:
To avoid damaging the cylinder head threads; first,
tighten the spark plug with fingers, and then tighten it to
the specified torque using the spark plug wrench.
Tightening Torque: 18 N•m

Tool: Spark Plug Wrench, Feeler Gauge
3.3.2.4 Air Filter

Inspect every 40 hours or 1000 km, clean it if
necessary.
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. Check and
clean the air filter as following:
Remove fixing clamp① and top cover②
Note:
Be careful not to drop the o-ring into the air filter box that
is attached to the air filter top cover.
Loosen screw③, remove filter element④, separate
support⑤, filter element⑥ and filter element seat⑦.
Fill a wash pan of a proper size with a
non-flammable cleaning solvent A. Immerse the
filter element in cleaning solvent and wash it.
Press the filter element between the palms of both
hands to remove the excess solvent. Do not twist or
wring the element or it will tear.
Immerse the element in engine oil B, and then
squeeze out the excess oil leaving the element
slightly wet.

A--Non-flammable cleaning solvent

B—Engine oil SAE#30 or SAE10W/40.
Warning:
Never use with gasoline or low flash point solvents to
clean the filter element
Inspect the filter element for tears. torn element must be

replaced.
Note:
If driving under dusty conditions, clean the air filter element
more frequently. The surest way to accelerate engine wear
is to operate the engine without the element or with torn
element. Make sure that the air filter element is in good
condition at all times.
Remove the drain plug⑧ of air box to drain out any
water.
3.3.2.5 Fuel Hose

Inspect every 80 hours or 2000 km, replace every 4
years.
Inspect the fuel hose for damage and fuel leakage. If any
damages are found, replace the fuel hose with a new
one.
3.3.2.6 Drive Belt

Removal:
Remove CVT cover
Hold the primary sheave and loosen primary sheave nut.
Remove primary sliding sheave 1;

Hold the secondary sheave and loosen
secondary sheave nut. Remove secondary sheave
together with drive belt.
Remove drive belt from secondary sheave

Inspection:
Inspect drive belt for wear and damage. If any cracks or

damages are found, replace drive belt with a new one.
Inspect drive belt for width, if width is out of service limit,

replace drive belt with a new one.
Service Limit: 33.5mm
Tool: Vernier Caliper
Installation
Reverse the removal procedure for installation. Pay
attention to the following:
Insert drive belt, as low as possible, between secondary
sliding sheave and primary fixed sheave.
Hold secondary sheave and tighten the nut
to the specified torque.
Nut, Secondary Sheave: 115 N•m
Install primary sheave and nut. Hold the primary sheave

and tighten the nut to the specified torque.
Nut, Primary Sheave:115N•m
Turn primary sheave, until the drive belt is properly

seated and both the primary and secondary sheaves
rotate together smoothly and without slipping.
Caution:
Fit the drive belt with the arrow on the drive belt
points toward normal turning direction.
The drive belt contact surface of the driven face
should be thoroughly cleaned.
Install CVT cover

3.3.3Inspection of Lubrication System
Replace engine oil and oil filter initially at 20

hours or 200km and every 80 hours or 2000km
thereafter.
Check Engine Oil Level

Keep the engine in a plan position.
Remove oil dip rod 1
Clean oil dip rod, insert oil dip rod but do not tighten
it.
Take out oil dip rod and check if oil is between upper
and lower limit.
If the engine oil is insufficient, fill more oil until the
sufficient oil is obtained.
Engine Oil: SAE10W-50SN
Note:
Keep the engine in a plan position
Do not tighten oil dip rod when measuring oil
level
Replacing Engine Oil

Remove oil dip rod 2, drain bolt 2
and washer 3.
Drain out the engine oil while the engine is still
warm.
Clean oil dip rod, drain bolt and washer with solvent.
Install washer and drain bolt.
Drain Bolt: 30 N•m
Fill engine oil. ( about 1900ml)

Install oil dip rod, start the engine and allow it to run
for several minutes at idling speed.
Turn off the engine and wait for about 3 minutes,
and then check the oil level on the dipstick.
Caution:
The engine oil should be changed when the engine is
warm. If the oil filter should be replaced, replace engine
oil at the same time.
Replacing Oil Filter
Remove relative parts ( see Replacing Engine Oil)

Remove oil filter① with the special tool
Install washer and drain bolt
Install new oil filter with the special tool
Fill engine oil (about 2000ml) and check (see
Replacing Engine Oil)
Tool: Oil Filter Wrench
Engine Oil Capacity

When replacing oil: 1.9L
When replacing oil filer: 2.0 L
Engine overhaul:2.2 L

3.3.4 Inspection of Cooling System
Check initially at 40 hours or 1000km, replace

coolant every 2 years.
Check radiator, reservoir tank and water hoses.
Leakage or Damage: → Replace
Check coolant level by observing the upper and the
lower limit on the reservoir tank.
If the level is below lower limit, fill coolant until the level
reaches the upper limit.
Replacing Coolant
Remove radiator cap① and reservoir tank cap②.
Place a pan below water pump, and drain coolant by
removing drain plug③ and water hose④.
Drain coolant from reservoir tank.
Warning !
Do not open radiator cap when engine is hot,
you may be injured by escaping hot liquid or
vapor.
Engine coolant is harmful. If coolant splashes in
your eyes or clothes, thoroughly wash it away
with water and consult a doctor. If coolant is
swallowed, induce vomiting and get immediate
medical attention.
Keep coolant away from reach of children
Clean radiator with fresh water, if necessary.
Connect water hose④ and tighten drain bolt③
securely.
Fill the specified coolant into the radiator.
Loosen bleed bolt⑤ on water pump, when coolant
flow from bleed bolt, tighten the bolt. Install radiator
cap ①securely after filling coolant.
Start the engine and keep it running for several
minutes. After warm up and cooling down the
engine, open radiator cap and check coolant. Fill the
specified coolant until the level is between the upper
and lower lines on the reservoir tank.
Caution:
Repeat the above procedures several times and make
sure the radiator is filled with coolant and air is
discharged.

Fill coolant into the reservoir tank till between upper and
lower limit.
Install reservoir tank cap.
Warning: Never mix with other brand
Inspection of Radiator Hose
Perform inspection every 40 hours
Check radiator hose and clamp.

Leakage or Damage: →Replace
3.3.5 Inspection of cylinder pressure

Check cylinder pressure is necessary.
Cylinder Pressure: 1000kpa
A lower cylinder pressure may be caused by:

Excessive wear of cylinder;
Wear of piston or piston ring;
Piston ring jam in groove;
Poor closure of valve seat;
Damaged cylinder gasket or other defects
Note: When cylinder pressure too low, check the above

items.
Testing Cylinder Pressure
Note: Before testing of cylinder pressure, make sure that
cylinder head bolts are tightened to the specified torque
and valve clearance has been properly adjusted.
Warm up the engine before testing;

Make sure battery is fully charged;
Remove spark plug 1;
Install cylinder pressure gauge 2 in spark plug
hole and tighten nut;
Keep throttle full open;
Press start button crank the engine a few
seconds. Record the maximum reading of
cylinder pressure.
Tools: Cylinder Pressure Gauge
Adaptor

3.3.6 Inspection of Oil Pressure

Oil Pressure: 130～170kpa at 3000r/min
Lower or higher oil pressure may be caused by:
Ⅰ Oil pressure is too low
Clogged oil filter;
Leakage from oil passage;
Damaged O-ring;
Oil pump failure;
Combination of above items;
Ⅱ Oil pressure is too high

Oil viscosity is too high;
Clogged oil passage;
Combination of above items;
Testing Oil Pressure
Install hose① and hose②;
Connect tachometer③with ignition coil
Install oil pressure gauge④ and joint seat to main oil
gallery.
Warm up engine as per following:
Summer: 10 minutes at 2000r/min
Winter: 20 minutes at 2000r/min
After warming up, increase engine speed to 3000r/min,

and record readings of oil pressure gauge.
Tools：Oil pressure gauge

Tachometer

3.3.7 Inspection of Clutch Engagement and Lock-up

Engine is equipped with a centrifugal type
automatic clutch.
Before checking the initial engagement and clutch
lock-up two inspection checks must be performed to
thoroughly check the operation of the drive train.
I Initial Engagement Inspection
Connect tachometer to ignition coil
Start engine
Shift gear lever to “High” position
Slowly increase throttle and note down the engine
speed (r/min) when the vehicle starts to move
forward.
Engagement speed:1800r/min～2400r/min
If the engagement speed is out of the above range,
check the following:
Clutch shoes
Clutch shoe wheel
Primary and secondary sheave
Refer to Chapter 12 for inspection of clutch
II Clutch Lock-up Inspection
Connect the tachometer to ignition coil;
Start the engine;
Shift gear lever to “High” position;
Apply front and rear brakes as firmly as possible;
Fully open the throttle for a brief period and note the
maximum engine speed obtained during the test
cycle.
Lock-up Speed: 3300r/min～3900r/min
Warning:
Do not apply full power for more than 5 seconds or
damage to clutch or engine may occur.
If the lock-up speed is out of the above range, check the
following:
Clutch shoes
Clutch wheel
Primary and secondary sheave
Refer to Chapter 12 for inspection of clutch
Tool: Tachometer

Ⅰ
3.4. Engine Removal, Inspection & Installation
Engine Removal
Δ Preparation before engine removal
Prepare a proper tray used for load of components
Prepare necessary removal and assembly tools
Drain up engine oil
Drain up coolant
△ Engine Periphery
Water Hose/Pipe
Remove water hose clamp① and②;

Remove water hose③
Remove screw④ and water hose⑤
Left Side Cover

Remove 4 bolts (M6X12) of left side cover
Remove left side cover
Inspection Plug
Remove inspection plug⑥ with screwdriver
Δ Engine Front Side

Spark Plug
Remove spark plug⑦ with special wrench

Tool: Spark Plug Wrench
Turn crankshaft, align T.D.C. line A on magneto rotor

with mark B of left crankcase

Cylinder Head Cover

Remove valve adjusting cover
Remove12 bolts of cylinder head cover
Remove cylinder head cover
Timing Chain Tensioner
Remove screw plug①, insert a flat screwdriver into

slot of timing chain tensioner adjuster , turn it
clockwise to lock tensioner spring;
Remove tensioner fix bolt
Remove tensioner and gasket
Camshaft
Loosen timing sprocket bolt;
Remove timing sprocket bolt and lock;

Remove C-ring①
Remove timing sprocket from camshaft, remove
camshaft
Note: Take care not to drop spacer, bolt, bolt lock

and C-ring into crankcase.
Remove tensioner plate
Cylinder Head
Remove cylinder head bolt
Remove cylinder head bolts diagonally;
Remove cylinder head
Note: Take care not to drop dowel pin into

crankcase
Cylinder
Remove dowel pin and cylinder head gasket
Remove timing chain guide①

Remove cylinder bolt

Remove cylinder
Note：Take care not to drop dowel pin

into crankcase
Remove dowel pin and cylinder gasket
Note：When performing above removal process,

be sure to hook up timing chain to
prevent it from falling into crankcase
Piston
Remove piston pin circlip① with long nosed pliers
Note: Put a clean rag under piston so as not to

drop piston pin circlip into crankcase
Remove piston pin②and piston③
Notes:
When installing piston, make sure its
identification conforms to that of cylinder;
When removing piston pin, clean off burrs of
piston pin hole and groove. If it’s difficult to
remove the piston, DO NOT hammer, use a
special remover④
Tool: Piston Pin Remover
Δ Engine Left Side
Starting Motor
Remove 2 bolts of starting motor
Remove starting motor

Oil Filter
Remove oil filter with special tools
Tool: Oil filter Remover
Sector Gear
Remove bolt of sector gear housing cover
Remove wire clip and sector gear housing cover
Remove dowel pin and gasket

Remove drive sector gear 1
Remove bolt 2 of driven sector gear
Remove washer3 and driven sector 4

Water Pump
Screw out bolt of water pump
Remove water pump
Remove left crankcase cover 1.
Remove nut.
Install special tool to rotor thread;

Remove rotor and woodruff key
Tool: Rotor Remover

Starting Motor Gear

Remove driven gear ① and needle bearing
Remove spacer ②
·Remove dual gear and shaft ③

·Remove idle gear and shaft ④
Oil Pump Sprocket and Chain
Remove drive sprocket nut ⑤

Remove C-ring ⑥
Remove oil pump drive and driven sprockets and
chain

Δ Engine Right Side
CVT Cover
Remove bolt of CVT cover
Remove CVT cover
Remove gasket and dowel pin
CVT(Continuously Variable Transmission)
Remove primary sheave nut

Remove primary sliding sheave
Remove secondary sheave nut

Remove secondary sheave
Remove drive belt
Remove primary fixed sheave ①
Remove bolt for air guide plate.
Remove air guide plate

CVT Case
Remove bolt 1 of CVT case
Remove bolt 2 of CVT case
Remove outer clutch face and CVT case
Remove dowel pin, front and rear gasket
Clutch
Remove one-way clutch
Remove clutch shoe fixing nut
Remove clutch shoe.
Note: The clutch shoe nut has left-hand threads.
Timing Chain
Remove timing chain

Engine Center
Gear position bolt
Remove gear position bolt 1

Remove spring and steel ball
Right Crankcase
Remove left crankcase bolts
Remove right crankcase bolts
Separate right crankcase with special tool
Caution
The Crankcase separator plate
should be parallel with the end face
of crankcase
Crankshaft should remain in the left
crankcase half.
Driven Bevel Gear, Front Output Shaft

Remove bevel gear cover bolt
Remove driven bevel gear ②
Remove front output shaft nut ③

Remove Oil seal①, Bearing limit nut②

Remove Bearing③, Front Output Shaft ④
Shift Cam, Fork/Shaft

Remove Shift Cam⑤, Fork /Shaft⑥
Drive Bevel Gear

Remove left crankcase from driven bevel gear
Drive Shaft, Drive Shaft
Remove drive shaft⑦ and driven shaft⑧
Balancer Shaft
Remove balancer shaft

Crankshaft
Separate crankshaft from left crankcase with special

tool
Tool: Crankshaft Separator
Oil bump, Relief Valve
Remove oil bump and relief valve

Engine Components Inspection
Cylinder Head Cover
Disassembly
Caution: Each removed part should be identified to its
location, and the pars should be laid out in groups
designated as “Exhaust”, “Intake”, so that each will be
restored to the original location during assembly.
Remove rocker arm shaft bolts A
Remove rocker arm shaft by using M6 bolts B
Cylinder Head Cover Distortion
Clean off sealant from the fitting surface of cylinder head

cover, place cylinder head cover on a surface plate and
measure distortion with a thickness gauge.
Cylinder head Cover Distortion

Limit: 0.05mm
Tool: Thickness Gauge
Distortion out of range: → Replace
Note: Cylinder head cover and cylinder head should be

replaced together.
Rocker Arm Shaft
Measure out diameter of rocker arm shaft with a

micrometer.
Rocker Arm Shaft O.D.: (IN, EX)
Limit: 11.973~11.984mm
Tool: Micrometer (0~25mm)

Rocker Arm
When checking the rocker arm, check the inner

diameter of the valve rocker arm and wear of the
camshaft contact surface.
Rocker Arm I.D. : .000~12.018mm
Tool: Dial Calipers
Assembly
Note: Intake rocker arm shaft A has oil holes.
Apply engine oil to rocker arms and shafts;

Install rocker arms and tighten rocker arm shaft to
the specified torque:
Rocker Arm Shaft Bolt: 28N•m
Cylinder Had
Disassembly
Remove intake pipe
Remove water temperature sensor ①and

thermostat cover ②

Remove thermostat
Compress the valve spring and remove valve cotter

with tweezers.
Tools: Valve Spring Compressor

Tweezers
Remove valve spring upper seat and valve spring
Remove valve from the other side.
Remove valve stem seal ring and valve lower seat.

Cylinder Head Distortion
Clean off carbon deposit from combustion chamber;

Check the gasket surface of the cylinder head for
distortion with a straightedge and thickness gauge. Take
clearance readings from several places. If any clearance
reading is out of the service limit, replace with a new
cylinder head.
Cylinder Head Distortion Service Limit: 0.05mm

Valve Seat Width

Coat the valve seat with color uniformly. Fit the
valve and tap the coated seat with the valve face in
a rotating manner. To get a clear impression of the
seating contact, use a valve lapper to hold the valve
head.
The ring-like dye impression on the valve face
should be continuous, without any break. The width
of the dye ring, which is the visualized seat width,
should be within the following range:
Valve Seat Width: 0.9-1.1mm

Tool: Valve Lapper
Valve Stem and Valve Guide
Lift the valve about 10mm from valve seat. Check

the valve stem deflection in the directions of X and Y
perpendicular to each other, with a dial gauge. If the
deflection measured is out of the limit, replace either
the valve or the valve guide. (If the valve stem is
worn to the limit and the clearance is found to be in
excess of the limit, replace the valve. If the valve
stem is within the limit, replace the valve guide.
Double check the clearance after replacing the
valve stem or the guide).
Valve Stem Deflection (IN & EX): 0.35mm

Tool: Micrometer
Magnetic Stand

Valve Stem O.D

Measure valve stem O.D with a micrometer
Service Limit
IN: 4.975-4.990mm
EX: 4.955-4.970mm
Tool: Micrometer (0-25mm)
Valve Stem Run-out

Support valve stem with V block as illustrated on the
right. Check the run-out with a dial gauge.
Tool: Magnetism Stand
Dial Gauge (1/100)
V block
Valve Head Radial Run-out

Measure the valve head radial run-out as illustrated
on the right.
Valve head Radial Run-out out of range: →Replace
Tool: Dial Gauge (1/100)
Magnetic Stand
V Block
Valve Face Wear

Check each valve face for wear or damage.
Replace valve with a new one if it is found to have
abnormal wear. Measure valve head thickness T.
Valve head thickness T out of range: → Replace
Valve Stem End

Check valve stem end for pitting or wear. In case of
any pitting or wear, resurface the valve stem end. If
the length T is less than service limit, replace valve
with a new one.
Valve Stem End Length

Valve Spring
Valve Spring keeps valve and valve seat tight.

Weakened spring results in reduced engine power
output and chattering noise from valve mechanism.
Measure the spring free length.

Spring free length out of range: →Replace
Tool: Vernier Caliper.
Measure the force to compress the spring to the

specified length.
Valve spring tension out of range: → Replace
Service Limit: (IN/EX)
182N-210N/31.5mm
Tool: Spring Scale.
Measure valve spring incline.

Spring incline out of range:→ Replace
Valve Spring Incline Limit: 2.5º/1.7mm
Assembly of Cylinder Head

Install each valve spring seat;
Apply moly oil to valve stem seal and fit into
position.
Material: Moly oil
Note: Do not reuse the valve stem seal.
Insert the valves, with stems coated with moly oil all
around.
Note: When inserting the valve, be careful not to

damage the lip of the stem seal.

Install valve spring with small-pitch end “b” facing

cylinder head. Big-pitch end “a” is marked.
Put on the valve spring retainer. Use the valve

spring compressor to press down the spring. Fit the
two cotter halves to the stem end and release
compressor to allow the cotter ① to wedge in
between seat and stem. Make sure that the rounded
lip② of the cotter fits into the groove③ in the stem
end.
Tool: Valve Spring Compressor

Tweezers
NOTE: Knock the valve end with rubber

hammer. Make sure valve cotter is
fit into groove.
Check the sealing effectiveness of cylinder head.

Dip clean solution into valve IN/EX ① and check
for any leakage of valve seat ② after a few
minutes.

Install thermostat
Install thermostat cover
Install water temperature sensor, apply thread

locker to the thread part, tighten it to the
specified torque.
Water temperature sensor

Tightening torque: 10 N·m
Install intake pipe, apply lubricant to 0-ring.
Camshaft
Check camshaft for wear and run-out of cams and

journals if the engines produces abnormal noise or
vibration or lacks power output. Any of these symptoms
could be caused by wear of camshaft.
Note: Do not try to disassemble the camshaft/automatic

decompression assembly. It is not serviceable.

Automatic Decompression
Move the automatic decompression weight with
hand and check if it is operating smoothly. If it is
not working smoothly, replace with a new
camshaft/automatic decompression assembly.
Cam Wear
Worn cams can often cause mistimed valve
operation resulting in reduced power output. The limit of
cam wear is specified for both IN and EX cams in terms
of cam height “a”. Measure with a micrometer the cam
height.
Cam height out of range: →Replace
Cam height service limit:
IN: 33.130mm
EX: 33.200mm
Tool: micrometer (25-50mm)
Camshaft Journal Wear

Check whether each journal is worn to the limit by
measuring camshaft journal oil clearance with the
camshaft installed.
Camshaft journal oil clearance
Service limit: 0.15mm
Check according to the following steps:
Clean off materials from cylinder head and cover;
Install camshaft with plastic gauge;
Install cylinder head cover and tighten bolts evenly
and diagonally to the specified torque:
Remove cylinder head cover, read the width of the
compressed plastic gauge with envelop scale. The
reading should be taken from the widest part.
Tool: Plastid Gauge
Note: Do not turn the camshaft with plastic gauge in

place.
If the camshaft journal oil clearance exceeds the limit,

measure the outer diameter of camshaft;
Replace either cylinder head set or the camshaft if the

clearance is not correct.

Camshaft Journal O.D.
Measure camshaft journal O.D. with a micrometer.

If the O.D. is out of range, replace camshaft with a
new one.
Camshaft journal O.D. service limit:
Sprocket end: 22.959 mm—21.980mm

Other end: 17.466mm—17.484mm
Tool: micrometer (0-25mm)
Camshaft Run-out
Measure the run-out with a micrometer. Replace
camshaft is the run-out is out of range.
Service limit: 0.10mm
Timing Sprocket and Chain
Check timing sprocket and chain for wear or

damage.
Replace with new parts if abnormal wear or damage
is found.
Tensioner and Chain Guide
Check contact surface of tensioner and chain guide

for wear and damage.
Replace with news parts if abnormal wear or

damage is found.

Chain Tensioner
Inspection
Check tensioner for any damage or poor function.
Damage, poor function: →Replace
Insert screw driver into the slotted end of adjusting

screw, turn it clockwise to loosen the tension and
release the screwdriver.
Check the push rod movement. If the push rod is
stuck or there is a failure with spring mechanism,
replace the chain tensioner with a new one.
Cylinder
Cylinder Distortion
Check the gasket face of cylinder for distortion with
a straightedge and thickness gauge and take
clearance readings at 7 points as illustrated. If the
largest reading at any of the 7 points of the
straightedge is out of the range, replace the
cylinder.
Cylinder Distortion Service Limit: 0.05mm
Tool: Straightedge
Thickness Gauge
Cylinder Bore
Check cylinder wall for scratches, nicks or other
damage. Replace with a new one if any.
Measure cylinder bore diameter at three points of
upper, middle and lower.
Standard Cylinder Bore: 87.500-87.522mm

Tool: Cylinder Gauge Set

Piston
Piston Diameter
Use a micrometer to measure the diameter at the
point 10mm above the piston end, as illustrated on
the right. If the measurement is less that the limit,
replace the piston
Standard: 87.460-87.480mm
Limit: 87.380mm
Tool: Micrometer (75-100mm)
Calculate the piston to cylinder clearance according

to the above measurement.
If the clearance is more than 0.15mm, replace the
cylinder or piston, or both.
Piston Ring to Groove Clearance

Use a thickness gauge to measure the side
clearance of topt ring and 2nd ring.
If the clearance exceeds the limit, replace both
piston and piston rings.
Service Limit:
Top ring: 0.18mm
2nd ring: 0.15mm
Standard width of piston ring groove

Top ring: 1.03-1.05mm
2nd ring: 1.22-1.24mm
Oil ring: 2.51-2.53mm
Standard thickness of piston ring

Top ring: 0.970-0.990mm
2nd ring: 1.170-1.190mm
Tools: Thickness gauge

Micrometer (0-25mm)

Piston Ring Free End Gap and End Gap

Before installing piston rings, use vernier caliper to
measure the free end gap of each ring, and then fit
ring into the cylinder.
Use thickness gauge to measure each ring end gap,
if any ring has an excess end gap, replace the
piston ring.
Piston ring free end gap limit:

Top ring: 8.9mm
2nd ring: 9.5mm
Piston ring end gap limit:

Top Ring: 0.60mm
2nd ring: 0.60mm
Tool: Vernier caliper

Thickness gauge
Piston Pin and Pin Bore

Use a bore gauge to measure the inner diameter of
piston pin bore.
Use micrometer to measure outer diameter of piston
pin.
If out of limit, replace both piston and piston pin.
Piston pin bore limit: 23.030mm
Use micrometer to measure piston pin outer

diameter at three points
Piston pin outer diameter limit: 22.980mm

Tools: Bore gauge (18-35mm)
Micrometer (0-25mm)

Connecting Rod/Crankshaft
Connecting rod small end I.D.
Use a dial gauge to measure the I.D. of connecting
rod small end. If the measurement exceeds the limit,
replace the connecting rod.
Connecting rod small end I.D. : 23.040mm

Tool: Dial Gauge (18-35mm)
Connecting Rod Deflection

Check the movement of the small end of the rod and
inspect the wear of the small end. This method is
also applicable to check and inspection of big end.
Connecting Rod Deflection: 3.0mm

Tools: Dial Gauge
Magnetic stand
V-block
Connecting Rod Big End Side Clearance

Push the big end to one side, and use thickness
gauge to measure the other side clearance.
If out of limit, replace with a new crankshaft.
Connecting Rod big end side clearance: 1.0mm

Crankshaft Run-out
Support crankshaft with “V” blocks as illustrated. Put
the dial gauge, slowly turn the crankshaft and
measure run-out with a dial gauge.
If the run-out exceeds the limit, correct or replace
the crankshaft.
Run out limit: 0.08mm

Tools: dial gauge
Magnetic stand
V-block

Clutch
Clutch Shoes
Check clutch for chipping, scrape, uneven wear or
heat discoloration. At the same time check depth of
the grooves of clutch shoes. If any of the clutch
shoes has no groove, replace the clutch.
Note: clutch should be replaced as a set.
Clutch Wheel
Check the inner clutch wheel ① for scratches, scuffs or
blue discoloration or uneven wear. If any damage is
found, replace the clutch wheel with a new one.
Check oil seal lip for wear or damage.
Wear or Damage: →Replace
Use special tool to remove oil seal
Tool: Oil seal remover
Use special tool to assemble oil seal
Tool: Oil seal installer set
Check the turning of bearing.
Abnormal damage: →Replace
Assembly
Apply lubricant grease to oil seal when assembling.

Primary and Secondary Sheave

Primary Sliding Sheave
Disassembly
Remove spacer
Remove Cam ①and Roller②
Roller
Check each roller and sliding face for wear and
damage.
Wear and damage: →Replace
Note: rollers should be replaced as a set.
Oil Seal
Check oil seal lip for wear and damage.
Wear and damage: →Replace
Remove the oil seal

Primary Sliding Sheave and Fixed Sheave

Check the drive face for any abnormal conditions
such as damage or stepped wearing.
Damage or wearing: → Replace
Install oil seal with special tool.

Tool: Bearing install set
Assembly
Reverse the removal procedure of primary sliding and
fixed sheave for installation.
Pay attention to the following:
Apply grease to inner bore and oil seal lip.
Note:
Wipe off any excessive grease thoroughly.
Take care not to attach any lubricant grease
to contact surface of drive belt.
Material: Lubricant grease
Position 8 rollers ①on the primary sliding sheave

Install 4 dampers ② to cam ③
Install cam to primary sliding sheave.
Notes:
When inserting the spacer, press down the cam
so that the rollers will not come out of position.

Install spacer
Secondary Sheave
Disassembly
Use special tool and holder to hold the secondary
sheave. Remove secondary sheave nut with special
tool.
Caution:
Do not remove the ring nut before attaching the
clutch spring compressor.
Tool: Nut Wrench

Sheave Holder
Attach special tool to the secondary sliding sheave

and compress it by turning in the tool handle.
Note:
Make sure that spring end A is inserted into slot
B of the tool handle.
Remove ring nut.

Tool: Secondary sliding sheave spring compressor
Note:
Since a high spring force applies to the
secondary sliding sheave, take special care that
the secondary sliding sheave will not come off
abruptly.
Slowly loosen tool handle and remove the special

tool.

Remove spring ①
Remove spring seat ②.
Remove guide pin and spacer.
Remove secondary sliding sheave ③
O-ring and Oil Seal
Check the O-ring and oil seal for wear and damage.
Wear and Damage: → Replace
Remove Oil Seal

Install oil seal with special tool.

Tool: Bearing install set
Secondary Sheave Spring

Use vernier caliper to check the spring free length. If
the length is shorter than the service limit, replace
with a new one.
Secondary Sliding and Fixed Sheave

Check drive face for any abnormal condition such
as stepped wear or damage.
Wear or damage: → Replace
Assembly
Install a new O-ring
Apply lubricant grease to O-ring, oil seal lip and
guide pin groove.
Material: lubricant grease

Install guide pin and spacer ①
Note: To avoid damage to the oil seal lip during

assembly, slide the lip with a 0.1mm steel sheet
as guide.
Install spring seat. Align hole A with hole B.
Install spring and spring plate. Insert spring end into

the hole.
Compress spring with special tool.

Align the secondary sheave end with spring plate
hole.
Tool: Secondary sheave spring compressor
Tighten ring nut temporarily.

Remove the special tool from secondary sheave.

Tighten the ring nut with special tool to the specified

torque.
Ring Nut Tightening Torque: 100N·m

Tool: Ring nut wrench
Sheave Holder
Drive belt
Check belt for any greasy substance.

Check contact surface of belt for any cracks and
damage.
Check belt width with vernier caliper.
Damage, width out of range: →Replace
Belt width service limit: 33.5mm

Tool: vernier caliper
Caution:
If belt surface is stained with grease or oil, degrease the
belt thoroughly.

Transmission
No. Description Qty No. Description Qty.

1 MAIN SHAFT. GEARSHIFT 1 10 DRIVEN GEAR, HIGH RANGE 1
2 SHIFT CAM 1 11 DRIVEN GEAR, LOW RANGE 1
3 RIGHT CRANKCASE 1 12 SPRING, SHIFT FORK 1
4 LEFT CRANKCASE 1 13 RIGHT SHIFT FORK 1
5 DRIVEN SECTOR GEAR 1 14 GUIDE BAR 1
6 SPROCKET, REVERSE GEAR 1 15 DRIVEN SHAFT 1
7 CHAIN, REVERSE GEAR 1 16 SPRING, SHIFT FORK 1
8 DRIVEN OUTPUT GEAR 1 17 LEFT SHIFT FORK 1
9 DRIVE SECTOR GEAR 1 18 SHIFT FORK ASSEMBLY 1

Inspection
Check main shaft gear and sprocket surface for any
damage or over wear.
Damage or over wear: → Replace
Check reverse gear chain for any damage or over

wear.
Disassemble driven shaft as illustrated.
Check each gear surface for any damage or over

wear.
Check bearing and collar for any wear or damage..

Check the shift fork clearance with a thickness

gauge in the groove of its gear.
Clearance exceeds the limit: → Replace
Shift fork to Groove clearance

Standard clearance :0.10-0.30mm
Service Limit :0. 50mm
Measure shift fork groove width with vernier caliper
Standard shift fork groove width: 6.05-6.15mm
Measure shift fork thickness with vernier calipers;
Standard fork thickness: 5.08-5.90mm
Check shift fork ① and ② for damage or bend
Damage, bend: → Replace
Install shift fork to guide bar and move left and right.
In case of any unsmooth moving, replace with a new
one.

Put the guide bar on a flat plate and roll it. In case of
any bend, replace with a new one.
NOTE:DON NOT attempt to correct a bent guide bar.
Check shift fork spring for breakage, damage

Broken or damaged: → Replace
Check shift cam groove for scratches, damage.

Scratch or damage: → Replace
Assembly
Reverse the removal procedure for assembly. Pay

attention to the following:
Use new retainers. Pay attention to the direction of

the retainers. Fit to the side where the thrust is as
illustrated.
Coat the gears and shafts with engine oil before

assembly.
Note:
Do not reuse the retainers
Do not expand of the gap end of new retainers too
wide when assembling.
Make sure that all the retainers are properly fitted.

When assembling the guide bar, take care not to

assemble the two shift forks and springs in the
opposite direction.
1. Guide bar 2. Retainer

3. Left shift fork 4. Shift fork Spring (small)
5. Right shift fork 6. shift fork spring (big)
7. Spring seat
OIL PUMP
Disassembly oil pump as illustrated:
1. Oil pump housing 2.Dowel pin
3.Oil pump shaft 4.Straight pin
5.Inner rotor, oil pump 6.Outer rotor, oil pump
7. Oil pump cover
Check oil pump housing and cover for cracks and

damage.
Crack or damage: → Replace
Measure top clearance “a” between inner and outer

rotors and side clearance “b” between outer rotor
and oil pump housing. If the clearance exceeds the
limit, replace with new one.
Top Clearance:0. 03-0.10mm

Service Limit: 0. 15mm
Side clearance: 0. 03-0.10mm


Oil strainer
Check oil strainer ① and O-ring ② for damage
Damaged oil strainer: → Replace
Clean the surface of oil strainer with engine oil
Relief Valve
Check the valve body ① 、valve ② and spring ③O
ring④ for damage or wear.
Damage or wear: → Replace
Drive Bevel Gear

Use a clean rag to protect the drive bevel gear shaft,
clamp it to the pliers.
1. Drive bevel gear cover 5. Adjust washer

Loosen drive bevel gear nut 3, remove the drive 2. Output driven gear 6. Drive bevel
bevel gear 4 and adjust washer 5 gear shaft
3. Drive bevel gear nut 7. Bearing press
Check the drive bevel gear 4 and output driven gear 4. Drive bevel gear 8. Bearing
2 for rust, scratch, wear or damage. Replace if any.
Check if the bearing 8 turns smoothly, replace with a

new bearing if necessary.
Adjust Washer 5 if any of right crankcase, drive

bevel gear 4, or drive bevel gear cover 1 is replaced.
Refer to bevel gear adjustment for details.
Apply engine oil to bearing 8 when assembling and

tighten nut 3 to the specified torque.
Drive bevel gear nut

Tightening torque: 145N•m

Front Output Shaft

Check bearing 7 for smooth turning and abnormal
wear. Check oil seal 5 for damage.
Apply lubrication oil to bearing 7 and oil seal 5 lip

before assembly.
Apply thread locker to bearing limit nut 6 (left thread)

and tighten to the specified torque.
Bearing limit nut Tightening torque: 80N•m
Tighten Nut 1 to the specified torque

Front output shaft nut tightening torque: 97N•m
Driven Bevel Gear

Remove nut 19, washer 18, coupler 17 and oil seal 16.
Protect end thread of driven bevel gear with proper

device ②. Fix bevel gear cover 14 and press out
driven bevel gear.
Place a clean rag ① under bevel gear cover.
Remove bearing limit nut 10 with special tool ② and
remove bearing.
Check driven bevel gear 8 surface for scratches,

wear. Scratch or wear: → Replace
Check free turning of bearing 9 and 11. Replace

with a new one if any abnormal is found.
Use new oil seal 16 and O-ring 12 when

assembling.
Adjust washer 13 if any of right crankcase, driven

bevel gear 8 or driven bevel gear cover 14 is
replaced. Refer to bevel gear adjustment for
details.
Apply lubrication oil to bearing 9 and 11 and oil seal

16, O-ring. Apply thread locker to nut 10 and tighten
Tightening torque :110N•m
Tool: driven bevel gear nut wrench
Driven bevel gear nut tightening torque:150N•m
Bevel Gear Washer Adjustment
Adjust washer ① and ② when replacing crankcase

and/or bevel gear and/or bevel gear cover,

Bevel Gear
Note: Proper bevel gear engagement depends

on that the gear backlash and tooth contact are
within the proper range.
Bevel Gear Backlash

Install drive and driven gears to the
crankcase. Wrap a (--) screwdriver ③with a
rag ② and insert it into the speed sensor
hole ① of left crankcase to fix the drive
bevel gear.
Install special tool ③ and micrometer ④.

Tool: Bevel gear side clearance dial gauge
Micrometer
a=46mm
Turn the driven bevel gear in each direction

and measure the backlash.
NOTE: Measure four points in the mutual

vertical direction
If the backlash is not within the
specification, adjust the thickness of the
driven bevel gear adjust washer. Re-check
the backlash until the backlash is correct.
Bevel Gear Backlash: 0.1-0.2mm
Adjustment
Measured Backlash Washer Thickness

Adjustment
＜0.1mm Decrease washer thickness
0.1~0.2m Correct
＞0.2mm Increase washer thickness

Tooth Contact
After adjusting the backlash, check the tooth contact
according to the following procedures:
Remove drive and driven bevel gear shafts from

crankcase;
Clean and degrease every tooh of drive and driven

bevel gear;
Coat the driven bevel gear with machinist’s layout

dye or paste;
Install drive and driven bevel gear;
Rotate the driven bevel gear several turns in both

directions;
Remove drive and driven bevel gear shafts and

check the coated teeth of the drive bevel gear;
Refer to the illustration on the right for tooth contact

pattern ①, ② and ③
① Incorrect (contact at tooth top)
② Correct
③ Incorrect (contact at tooth bottom)
If tooth contact is correct (Contact ②), continue the

next procedure.
If tooth contact is not correct (② and ③), adjust the
thickness of the washer of drive bevel gear. Repeat
above steps to check tooth contact until it is correct.
Adjustment
Tooth Contact Washer Adjustment

Contact at tooth top ① Increase Thickness
Contact at tooth Decrease Thickness
bottom ③
Note:
After adjusting the tooth contact, the backlash must
be checked again;
If the backlash is adjusted but tooth contact is still
out of specification, replace the drive and driven
bevel gears;
Both tooth contact and backlash should be within
the required specification.

Balancer Shaft
Remove the parts as illustrated on the right. Check
each part for abnormal wear or damage.
① Balancer shaft gear
② Woodruff key
③ Balancer shaft
④ Balancer shaft sprocket
⑤ Washer
⑥ Bolt
Magneto Rotor
Remove starter clutch nut;

Check starter clutch roller and holder for abnormal

wear or damage.
Install the starter clutch in the correct direction.
Note:
When install the starter clutch to the magneto rotor,
make sure side “A” is in the right direction.
Face arrow mark “B” to the engine side;

Apply engine oil to starter clutch.
Apply thread locker to bolt and tighten to the

specified torque:
Tightening torque of starter clutch bolt: 30N•m

Material: Thread Locker
Install the starter driven gear
Make that the starter driven gear turns in the

opposite direction of the arrow mark “B”. The gear
cannot turn in the direction of the arrow.
Check starter driven gear bearing. In case of

anything unusual, replace the bearing.
Remove starter driven gear bearing with special tool
Install starter driven gear bearing with special tool.
Tool: Bearing Installer/Remover

Electric Starter Gear

Check the gear surface for scrap or damage.
Scrape or Damage: → Replace
LEFT CRANKCASE COVER（MODEL2）
Check magneto stator coil 2, pickup coil 3 for

damage,
burn or short circuit, if any , replace with new one;
LEFT SIDE COVER
Disassembly
1— Left side cover

2— End cap

CVT Cover
Remove screw 5, oil seal limitator 4. Remove oil
seal 3 with special tool;
Check bearing 2 for free turning. In case of any

abnormal, remove with special tool and replace with
a new bearing;
Apply lubrication oil to outer ring of bearing and

install bearing with special tool. Check bearing for
smooth turning.
Apply grease to bearing inner side;
Apply grease to oil seal lip and install oil seal with
special tool.
Note: Use a new oil seal.
Install oil seal limitator and tighten screw after

applying thread locker.
Tool: Bearing Remover

Oil Seal Remover
Bearing Installer
CVT Case
Check bearing 5 for smooth turning. In case of any

abnormal, remove screw 3 and bearing retainer 4
and replace with a new bearing.
Check oil seal 7. In case of any damage, replace it;
Apply grease to oil seal lip and install with special

tool.
Apply lubrication oil to bearing 5 and install with

special tool; Check bearing for smooth turning. The
seal side of bearing 5 should face bearing retainer
4.
Install bearing retainer 4 and screw 3.
Install oil seal 1 into clutch housing 2 with special

tool.
Tool: Oil Seal Installer
Bearing Installer

Crankcase
1.Right Crankcase 11.Gear Sensor 21.Bearing

2.Bearing 12.Bolt 22.Bearing
3.Seal 13.Left Crankcase 23.Oil Dip Rod
4.Bearing 14.Oil Pipe 1 24.O-ring
5.Bearing 15.Oil Pipe 2 25.Bolt
6.Bearing 16.Link Bolt 26.Speed Sensor
7.Oil Seal 17.Washer 27.O-ring
8.Washer,Reverse Gear Sensor 18.Bearing 28.Washer
9.Reverse Gear Sensor 19.Bearing 29.Oil Drainage Bolt
10.O-ring 20.Bearing

Clean and grease the bearings, turn the inner race

of bearing and check the play, noise and smooth
turning. In case of any abnormal, remove bearing
with special tool and replace;
Check all the oil seals for over wear or damage. In
case of any over wear or damage, remove with
special tool and replace with a new oil seal;
Remove gear sensor (11) and check for continuity
with reverse gear sensor (9) with a multimeter.
Remove link bolt and oil pipe (14)(15) and check oil pipe
for crack or clog. Replace with a new one if any;
Remove oil drainage bolt (29) and clean it.
Note: Check bearing for smooth turning after installation.

Install new O-ring and apply grease;
Install gear sensor;
Install reverse gear sensor (9) and tighten to the
specified torque.
Reverse gear sensor tightening torque: 20N•m

Install speed sensor (26)
Install oil pipe and tighten the link bolt to the

specified torque;
Link bolt tightening torque: 40N•m
Install washer (28) and oil drainage bolt (29) and
tighten to the specified torque;
Drain bolt tightening torque: 30N•m
Tool: Bearing Remover
Bearing Installer
Multimeter
III Engine Assembly

Reverse the engine removal procedure for installation.
Caution:
Clean all the parts before assembly;
Make sure that the parts are in good condition
without any damage;
Apply engine oil to the moving parts before
assembly;
Apply grease to oil seal lip and O-ring
Caution:
Make sure that drive belt, primary and secondary
sheaves are not stained with grease.
Engine Center
Oil Pump and Relief Valve
Install oil pump and relief valve to left crankcase, as
illustrated on the right. Tighten to the specified
torque:
Oil pump bolt: 10N•m
Relief valve bolt: 10N•m
Connecting Rod
Install connecting rod to left crankcase with special

tool;
Note:
Do not hammer the conrod into crankcase with
plastic mallet;
Use special tool to avoid affect of conrod precision
Tool: Conrod Installer
Balancer Shaft
Install balancer shaft
Caution: Balancer shaft driven gear should be aligned to

the mark as illustrated.
Main Shaft, Counter Shaft
Install main shaft and counter shaft.

Shift Cam, Shift For
Install shift can① and shift fork②
Check each part for smooth turning
Install low range driven gear to counter shaft③
Spray adequate engine oil to each part.
Drive Bevel Gear
Install drive bevel gear and tighten to the specified

torque.
Drive bevel gear tightening torque: 32N. m

Material: Thread Locker
Right Crankcase
Driven Bevel Gear
Install driven bevel gear and tighten to the specified

torque.
Driven bevel gear tightening torque: 25N. m
Check bevel gear backlash
Front Output Shaft
Install front output shaft to right crankcase

Apply sealant ①to the mating face of right

crankcase.
Note: Apply sealant evenly in an uninterrupted thin line.
Install 5 dowel pins②
Assemble crankcase and tap slightly with a rubber

hammer so that the crankcase is properly fitted.
Install bolt and tighten to the specified torque.
Crankcase bolt tightening torque: M6: 10N•m

M8: 25N•m
Note: Crankcase bolts should be tightened diagonally in

several steps.
Place the steel ball and install gear positioning bolt

and tighten the bolt to the specified torque.
Gear positioning bolt tightening torque: 40N•m
Engine Right
Timing Chain
Put on timing chain (2)
Clutch
Install clutch (1) and nut (2). Tighten the nut to the
specified torque (left thread).
Clutch nut tightening torque: 80N•m

Install new o-ring⑥ in spacer⑧
Install spacer onto the clutch housing shaft, then

install into CVT case
Note: align oil nick on spacer with oil hole on the shaft
CVT Case
Install dowel pin ④, gasket ② and gasket⑤ to the

right crankcase. Install CVT case assembly to right
crankcase.
Install bolt ⑿ and nut③
Note:
Tighten bolt/nut diagonally
Use a new gasket
Install air guide plate⑩ and screw⑾
Primary Sheave, Secondary Sheave, Drive Belt
Install primary fixed sheave ①as illustrated on the

right;
Install drive belt between secondary sliding/fixed

sheave and tap with a plastic hammer to keep the
belt as low as possible.
Note:
Install the drive belt with the arrow on the belt turn in
the clockwise direction
Drive belt contact surface should be free from any

stains.

Install secondary sheave;
Install primary sliding sheave
Tighten primary sheave nut to the specified torque;
Primary sheave nut tightening torque: 115 N·m
Tighten secondary sheave nut to the specified torque;
Secondary sheave tightening torque: 115 N·m
Note:
Turn the primary fixed sheave until the belt is seated in
and both primary and secondary sheaves move together
smoothly without slip.
CVT Case Cover
Install the new gasket and dowel pins.

Install CVT case cover bolts and tighten diagonally

in several steps.
Engine Left
Oil Pump Sprocket and Chain
Install oil pump drive sprocket;
Install oil pump driven sprocket;
Install oil pump drive chain;
Install oil pump sprocket bolt;
Install sprocket retainer with a long nose pliers
Tool: Long Nose Pliers
Dual Gear, Idle Gear
Install dual gear shaft① and dual gear ②
Install dual gear shaft③, dual gear ④and bush⑤
Starting Driven Gear
Install starting driven gear bush⑥

Install starting driven gear;
Magneto Rotor
Install Magneto Rotor (1)

Install Nut (2)
Nut tightening torque: 160N•m
Install left crankcase cover (1)
Install end cap (2)

Water Pump
Install water pump;
Install water pump fixing bolts;
Note: Before tightening the bolts, be sure to insert oil

pump shaft into groove of water pump shaft.
Sector Gear
Install the parts as illustrated on the right.
1- sector gear cover and gasket

2-dowel pin
3-drive sector gear
4-driven sector gear
5-driven sector gear bolt
Note: When the shift cam is in the neutral position, the

mark of drive sector gear should be between the two
marks of the driven sector gear.
Driven sector gear tightening torque: 14N•m

Oil Filter
Install oil filter bolt and tighten to the specified

torque;
Oil filter bolt tightening torque: 36 N·m
Apply engine oil to O-ring;
Install oil filter, turn it by hand until the filter gasket

contacts the mating surface. Tighten the bolts to the
specified torque.
Tool: Oil Filter Wrench
Starting Motor
Apply engine oil to new O-ring;
Install starting motor;
Install bolt and tighten to the specified torque
Tightening torque: 10N·m
Engine Top Side
Piston
Install the piston rings in the order of oil ring, ②ring
and ①ring.;
The first member to go into the oil ring groove is

spacer①, after placing the spacer, fit the two side
rails②.
Warning: when installing the spacer①, do not overlap its

two ends in the groove.
Install the second ring A and first ring B
Note: 1st ring and 2nd ring differ in shape

1st and 2nd rings have letter “R” marked on the side.
Be sure to bring the marked side to the top when
fitting them to the piston.
Position the gaps of the three rings as illustrated on

the right. Before installing the piston into the cylinder,
check that the gaps are so located.
Apply a light coat of moly oil to the piston pin;
Install piston pin into holes of piston and conrod

small end.
Note: When installing the piston, the “IN” mark on piston

top is located to the intake side.
Place a clean rag beneath piston and install piston

pin circlip ①
Note: while rotating crankshaft, pull the cam chain

upward, or the chain will be caught between sprocket
and crankcase.
Install the dowel pins and the new cylinder gasket;
Note: Use a new cylinder gasket to prevent oil leakage

Cylinder
Apply engine oil to piston skirt and cylinder wall;
Hold each piston ring with proper position, insert

piston into the cylinder;
Tighten the cylinder base bolts temporarily;
Note: When installing the cylinder and cylinder head,

pull the cam chain upward, or the chain will be caught
between sprocket and crankcase.
Install chain guide①;
Fit the dowel pin and new cylinder cover gasket;
Note: Use a new cylinder cover gasket to prevent oil

leakage
Cylinder Head
Install the cylinder cover, tighten the cylinder head

bolts diagonally to the specified torque.
Cylinder head bolt tightening torque: Initial: 25 N·m

Final: 40 N·m
Tighten the cylinder head nuts to the specified

torque;
Cylinder head nuts tightening torque:

M6: 10 N·m
M8: Initial 10 N·m
Final 25 N·m
Tighten the cylinder top nuts and cylinder base to

the specified torque;

Install chain tensioner;
Camshaft
Align mark “A” on magneto rotor with mark “B” on

crankcase;
Note: while rotating crankshaft, pull the cam chain

upward, or the chain will be caught between
sprocket and crankcase.
Align the mark “A” on the camshaft so that they are

parallel with the mating surface of the cylinder head.
Note: Do not rotate the magneto rotor while doing this.

when the sprocket is not positioned correctly, turn
the sprocket;
Engage the chain on the sprocket with the locating

pin “B” as illustrated on the right;
Recheck if the position of mark “A” and “C” is correct.

If not, reassemble until it is correct.

Install crankshaft C-ring ①
Install lock washer so that it covers the locating pin;
Apply thread locker to the bolts before installing, and

tighten them to the specified torque;
Sprocket bolt tightening torque: 15 N·m
Bend up the lock washer to lock the bolts.
Cylinder Head Cover
Clean the mating surface of cylinder head and

cylinder head cover;
Install dowel pin to the cylinder head
Apply sealant to the mating surface of the cylinder

head cover;
Install cylinder head cover bolts, tighten diagonally

Cylinder head cover bolt tightening torque: 10 N·m
Note: When tightening the cylinder head cover bolts,

the piston must be at top dead center on the
compression stroke.

Gasket Sealant Applying Place
Chain Tensioner
Insert (--) screwdriver into slotted end of chain

tension adjuster, turn it clockwise to lock the
tensioner spring;
Install the chain tensioner and the new washer (1);
Install the bolt (2), tighten it to the specified torque;
Chain tensioner bolt tightening torque: 10 N·m
After chain tensioner is installed, turn the (--)

screwdriver counter clockwise. The tensioner rod
will be advanced under spring force and push
tensioner against chain.

Install the new gasket (3);
Install chain tensioner screw, tighten it to the

specifiedTorque
Chain tensioner screw tightening torque: 8 N·m
Valve Adjuster Cover
Use new rubber gasket and apply grease;
Install Valve Inspection Cap
Install valve inspection cap bolt;
Spark Plug
Install spark plug with special tool and tighten to the

specified torque;
Note: To avoid damage to the cylinder head thread,

screw in the spark plug with hand first, then
tighten it to the specified torque with spark plug
wrench.
Spark plug tightening torque: 18N•m

Tool: Spark Plug Wrench
Engine Periphery
Left Side Cover
Install left side cover
Install the bolts
Valve Inspection Cap
Install valve inspection cap

Water Pipe and Hose
Install water hose (5)
Install bolt (4)
Install water hose (3)
Install clamp (1) and (2)

3.5. FUEL INJECTION SYSTEM
3.5.1 ECU
3.5.1.1 Description & Working Principle
3.5.1.2 Appearance
3.5.1.3 Handling – Don’ts & Do’s
3.5.1.4 Installation requirements
3.5.1.5 Power Requirements
3.5.1.6 Temperature Requirements
3.5.1.7 Maintenance service and Repair
3.5.2 INJECTOR
3.5.2.1 Appearance
3.5.2.2 Temperature Requirements :
3.5.2.3 Fuel Contamination
3.5.2.4 Injector Installation
3.5.2.5 Replacement Techniques
3.5.2.6 Interchange ability
3.5.2.7 Cleaning Procedure
3.5.3 Throttle Body Assembly
3.5.3.1 Description and Working Principle
3.5.3.2 Appearance
3.5.3.3 Throttle Body Removal
3.5.3.5 Throttle Body Installation
3.5.4 Engine Coolant Temperature Sensor
3.5.4.2 Appearance
3.5.4.3 Installation Requirements
3.5.4.4 Sample Cleaning
3.5.5 Intake AirPressure and Temperature Sensor(MAP&MAT)
3.5.5.2 Appearance
3.5.5.3 Operating Environment
3.5.6 Oxygen Sensor
3.5.6.2 Appearance
3.5.6.3 Technical Parameters
3.5.6.4 Fuel Quality Requirements
3.5.7 Ignition Coil
3.5.7.2 Appearance
3.5.7.4 DOs a nd DONTs

3.5.8 Fuel Pump Module

3.5.8.2 Appearance
3.5.8.3 Operating Conditions
3.5.8.4 Service Procedure
3.5.8.5 Fuel Module Removal:
3.5.8.6 Fuel Module Installation:
3.5.8.7 Fuel Pressure Relief Procedure:
3.5.8.8 Fuel Leakage Check Procedure:
3.5.9 Motor Scanner ( for MT05 EMS)

3.5.9.1 Precautions
3.5.9.2 Configurations
3.5.9.3 Preparations Connection
3.5.9.4 Functions
3.5.9.5 MT05 ECU Malf Code

3.5.1 ECU
3.5.1.1 Description & Working Principle
The ECU continuously monitors the operating conditions of the engine through the system
sensors. It also provides the necessary computation, adaptability, and output control in order to
minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all
operating conditions. The ECU also provides diagnosis when system malfunctions occur.
3.5.1.2 Appearance
The MT05 ECU has a polyester header, with an aluminum base plate. The ECU is shown
below.
3.5.1.3 Handling –Don’ts & Do’s
ACTION REASON
DO NOT: Place the ECU close to the exhaust pipe High temperature might reduce the life of the ECU
or Engine when removed. and also can damage the ECU.
DO NOT: Place the ECU close to or pour water, oil

ECU is susceptible to water and liquids
or any other liquids.
DO NOT: Allow mud or other debris to accumulate Having mud or debris accumulated on the ECU
on the surface of the ECU. casing reduces its heat dissipation efficiency.
DO NOT: Apply any voltage relative to any point to Drastically affects the performance of the ECU and
the ECU. may lead to ECU damage.
DO NOT: Clean ECU with any solvent or any

Can damage the housing of the ECU.
corrosive liquid.
DO: Take extreme care that water droplets or ECU connectors can get short and may lead to ECU
excess moisture should not fall on ECU connectors. damage.
DO: Clean the ECU with a moist cloth and keep it

Prevents ECU damage.
dry.

The ECU shall be mounted using M6 machined screws with a torque of 8 Nm ±10%. The
mounting surface should also be flat to avoid subjecting the base plate to unnecessary force and
warping the PCB.

3.5.1.5 Power Requirements

● Operating Range: All planned functions are executed in this range. Battery and/or Ignition
voltage: 9.0 to 16V DC. However, when the battery voltage is lower than 13.6 volts, the engine’s
start speed may be low. Then, you should charger the battery with the charge.
● Reverse Voltage: The controller will survive with no permanent damage: Battery and/or
Ignition voltage < -13V DC for 1 minute. But the fuse will fuse.
3.5.1.6 Operating Temperature

The controller shall operate in the ambient temperature from -20 ℃ to +85 ℃.
3.5.1.7 Maintenance service and Repair

ECU is a non-serviceable part. Once there are problems, it’s important to first determine if the
problem is caused by software/calibration. If it is caused by software/calibration, please reflash
the ECU by professional tools. In the event of ECU hardware failure or malfunction (during
warranty period only) the ECU should be sent back to the vehicle manufacturer giving complete
details of the ECU Part No, Serial number, Vehicle Model & Make, manufacturing Date, Total
kms run on the vehicle, Location of use, Vehicle No, Date of return.
3.5.2 INJECTOR
3.5.2.1 Appearance
The figure below shows the standard M3.5 Fuel Injector appearance.
3.5.2.2 Temperature Requirements :

Typical injector temperature environments are defined below. The injector will not experience
any loss of the ability to comply with the flow tolerance requirements after exposure to the follow-
-ing temperature environments. Also, they will not experience unacceptable external leakage,any
type of physical degradation, or loss of service life during or after being exposed to these ambient
conditions.
● Normal Operating Temperature Range: - 30℃ to 125℃
● Extreme Operating Temperature Range (some performance degradation): - 40℃ to 150℃
3.5.2.3 Fuel Contamination
The injector fuel inlet filter protects the fuel injector from initial build fuel contamination as well
as from fuel system assembly contamination. Filtration is extremely important because particle
contaminants can cause an injector to stick open, flow shift or tip leak.
The injector inlet filter is not a serviceable component and is designed only to trap potential
built-in contamination between the chassis fuel filter and injector.
Please replace the fuel filter regularly according to the usage. The filter is located above the
tank.
3.5.2.4 Injector Installation

Follow these guidelines to prevent damage to the injector and its electrical interface during
the replacement or re-installation process.
● Lubrication: Apply a light coating of lubricant to the lower injector seal ring. ISO 10 light
mineral oil or equivalent is recommended.
● The preferred technique is to apply the lubricant to the sockets the injectors are being
installed into, rather than directly to the seal ring itself. This will help minimize the possibility of
injector contamination.
● Avoid applying lubricant over the director plate holes – this may restrict injector flow. Do not
dip the injector tip in lubricant.
● The injectors come from the factory with the seal rings attached. The re-use of seal rings is
not preferred when replacing an injector. If an injector is to be re-used, and no new seal rings are
available, take care to inspect each seal ring for signs of damage. Even minor defects in the seal
ring can lead to leakage. Take extra care in installing seal ring over flange of injector inlet.
● Carefully installing the harness connector will prevent terminal damage. Listen for a positive
audible click from the connector retention device — this ensures that it is fully engaged.
● Avoid unnecessarily disconnecting/reconnecting the harness connector.
● Wires routed in a manner that can allow them to become pinched between components can
result in a short circuit and a stuck open injector.
● For injectors that require orientation for spray pattern, do not rotate the injector in the fuel rail
assembly to install the injector electrical connector. This may dislodge the retaining clip, and
result in improper spray orientation.
The table is a list of lubricant oils that were tested and approved for O-ring lubrication. These
lubricants have shown to have no effect on injector performance (plugging, sticking).

3.5.2.5 Replacement Techniques

The following procedure outlines standard the Injector removal and replacement.
Warning: The injector and all associated hardware may be extremely hot.
● Shut off ignition.
● Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is
made to start the engine.
● Disconnect the electrical connector from the injector wiring harness.
● Relieve fuel pressure
● Remove the retaining clip from the fuel injector.
● Remove the fuel line connection from the injector
● Carefully clean debris from the interface surfaces. Do not damage seal mating surfaces.
● Remove the injector from the manifold.
● Apply a light coating of a lubricant to both the upper and lower injector seal ring of the
replacement injector.
● Install the new injector into the manifold. Check that the injector is installed in the original
orientation to maintain proper spray targeting, and that the retaining clip is properly seated on the
injector and the fuel line.
● Install the retaining clip after connecting the fuel line.
● Tighten the injector mounting to the desired torque as mentioned in the manufacturer manual.
● Tighten the fuel line.
● Re-install the injector electrical connector
● Check for fuel leaks with the key “on” and the engine “off”.
● Start engine and verify proper operation.
3.5.2.6 Interchange ability

The injector should be replaced in service only with an equivalent injector of the same part
number. On occasion, a new part number may supersede part numbers. Consult the appropriate
vehicle service manual and part number guide for the latest replacement injector part number
information.

● Electrically disable the fuel pump by removing the fuel pump connection.
● Relieve the fuel pressure in the system and disconnect the fuel connection at the injector.
Plug the fuel feed line.

● Injector cleaner with the specific ratio of the cleaner and gasoline to be mixed in the Injector
cleaning tank.
● Connect the injector-cleaning tank to injector in the vehicle.
● Pressurize the injector-cleaning tank to system pressure.
● Start and idle the engine for 15- 20 minutes.
● Disconnect the injector-cleaning tank from the system and install the fuel pump connections.
Connect the fuel feed line to injector.
● Start and idle the vehicle for an additional 2 minutes to ensure the residual injector cleaner is
flushed from system.
3.5.3 Throttle Body Assembly

The Throttle Body Assembly is an interactive system comprised of the following subsystems:
the main casting body, bearing system, shaft and valve system, return spring system, cable
interface system, throttle position sensing system, and the bypass air control system. The
subsystems interact and support each other to provide all the functional requirements, which are
mentioned below:
● Control intake air flow
● Control idle air flow
● Sense throttle position - Provide position feedback to Engine Controller
● Provide reactionary force to the throttle
3.5.3.2 Appearance
3.5.3.3 Throttle Body Removal

● Disconnect negative terminal of the battery
● Disconnect electric lead wire of throttle position sensor coupler, stepper motor coupler and
MAP/MAT sensor coupler ( if this sensor is mounted on the throttle body)
● Disconnect accelerator cable from throttle body
● Remove air cleaner outlet hose and throttle body outlet hose


If there is cover on the bottom, it may be removed and cleaned using carburetor cleaner (3M
make recommended). Once the throttle body cover is removed, spray the throttle-body cleaner
inside the shipping air passage, and use the brushes to gently dislodge the dirt, gum and varnish
that are present. Do not let the bye pass holes be blocked by dirt or foreign particles.
3.5.3.4 Throttle Body Installation

Reverse the procedure for installation noting the following:
● Adjust accelerator cable play.
● Check to ensure that all removed parts are back in place.
● Reinstall any necessary part which have not been reinstalled.
3.5.4 Engine Coolant Temperature Sensor

This sensor is used in water cooled engines. It provides a resistance that varies as a function
of temperature within prescribed tolerance limits. The sensor has a negative temperature
coefficient of resistance.
3.5.4.2 Appearance
3.5.4.3 Installation Requirements

Dynamic Torque Requirement: The sensor shall be hand into the application and then driven
by a driver with a maximum no load speed of 400 rpm or installed to the desired torque by a hand
torque wrench (5/8” hex). The recommended installation torque is:
● Minimum: 20 N·m
● Maximum: 25 N·m
● Static Torque Requirement: The torque required to remove the sensor from the mating hole
shall be within 200% of the installation torque mentioned above.
When necessary the samples may be cleaned in isopropyl alcohol for one minute with mating
connectors in place and then air-dried.
3.5.5 Intake AirPressure and Temperature Sensor(MAP&MAT)

This sensor has two functions. The first is the intake manifold air temperature, it provides a
resistance that varies as a function of temperature within prescribed tolerance limits. The second
is the intake manifold air pressure; it provides a voltage varies as the intake air pressure. This
sensor is installed on the Throttle Body Assembly.
3.5.5.2 Appearance
3.5.5.3 Operating Environment

This device is intended for use in inlet manifold for sensing air temperature and pressure
which shall withstand such an under hood environment.
● Pressure Range: 20~102kPa
● Temperature Range: -40~105°C
● Relative Humidity: 0 to 100% RH.
● Typical Voltage: The sensor circuit operates with a DC voltage reference of 5 ± 0.1 VDC.

When necessary the samples may be cleaned in isopropyl alcohol or gasoline for one minute
with mating connectors in place and then air-dried.
3.5.6 Oxygen Sensor

This sensor is a device for monitoring the residual oxygen in the exhaust of an internal
combustion engine. It is the feedback element for engine closed loop control.
3.5.6.2 Appearance
3.5.6.3 Technical Parameters

● A/F ratio rich threshold: ＞750 mVDC
● A/F ratio lean threshold: ＜120 mVDC
(These parameters as above are measured basing on 450°C (engine dyno), typically on 70%
duty at 10Hz and under 13.5V)
● Heater part resistance: 9.6±1.5Ω (This parameter is measured basing on 21°C)
● Operating temperature range: 260-850 °C

3.5.6.4 Fuel Quality Requirements

● Pb≤0.005g/L
● P≤0.0002g/L
● S≤0.04% (weight proportion)x
● MMT≤0.0085g/L
● Si≤4ppm
3.5.7 Ignition Coil

This coil provides energy to the spark plug in the combustion chamber. The coil itself doesn’t
have a driver. The high voltage tower of the coil is connected to the spark plug using a high
voltage cable assembly.
3.5.7.2 Appearance

● The vehicle frame provides the mounting surface and mounting holes.
● Mount coil close to the spark plug and keep the plug wire length very short (less than 6 “).
● Mount coil away from any pick coil device. Especially, a VR type Crank / Cam sensor. Keep a
Min distance of 150 mm (around 6”) between coil and any VR sensor device.
● Never route the coil C- wire with the same bundle as the Crank sensor wires. There is around
200 V peak potential between C- wire and engine ground. This voltage potential could cause a
noise on sensor cables.
3.5.7.4 DOs and DONTs
ACTION REASON
DO NOT: Install the low voltage connectors with the This might cause an unwanted secondary firing,
power applied. possibly leading to personal injury.
It is possible to damage a secondary lead in such a
DO NOT: Use a screw driver to asset in removing manner that creates an electrical path to outside the
secondary boots from the secondary tower. Use system permitting improper system operation
tools designed for secondary removal. misfire, or even possible personal injury if arcing
occurs.
DO NOT: Use parts that have been dropped or

Damaged components can lead to premature failure.
display physical damage.
DO NOT: Scratch or apply any non approved This can jeopardize the seal integrity of the mating
material to the surface of the high voltage tower surfaces which in turn can create a secondary high
which mates with the high voltage secondary leads. voltage leak path.
DO NOT: Strike any part of the ignition system with a This can lead to physical damage which can cause a
tool or other object. system malfunction or failure.
Insulating type sprays can create a high resistance
DO NOT: Permit paint or other sprayed materials to
or open connection. And, a conductive type spray
be sprayed onto the electrical connectors.
can create an electrical short condition.
These leads are not designed to support the weight
DO NOT: Support the ignition system by the wiring of the ignition system. It can create a poor electrical
harness or plug wire. connection Or become disconnected allowing the
system to fall and be subjected to physical damage
This creates an electrical path to outside the system
DO NOT: Pierce or probe the secondary leads. permitting improper system operation, misfire, or
even possible personal injury if arcing occurs.
If a technician or mechanic comes in contact with the
high voltage generated during operation, personal
DO NOT: Operate without the spark plug attached. injury may occur. Or, if the engine is operated under
this condition, unburned fuel may fill the converter
area creating a potential hazard.
This prevents electrical cross talking between
DO NOT: Share ignition component wiring with other
components which can lead to component
components, Dedicated wiring is required.
malfunction.
DO NOT: Apply voltage to the ignition system other This can cause reduced performance or an electrical
than vehicle system voltage for testing purposes. malfunction of the ignition system
DO NOT: Use high impact tools to apply the spark
plug boot to the ignition secondary towers. Damage to the coil tower, secondary boot, or mating
Installation of the high voltage secondary leads by connection surfaces might occur.
hand is preferred.
In the event the low voltage connection has been
DO: Install the secondary leads before connecting made and the power applied, unwanted secondary
the primary leads. output might occur possibly resulting in injury,
damage the ignition component, and test equipment.
The high voltage produced by the coil secondary
DO: Take care when working around the ignition
circuit can cause personal injury and/or damage test
system.
equipment.
DO: Proper handling and shipping methods need to
be in place to reduce the risk of damage due to Damaged components can lead to premature failure.
impact, moisture, or contamination.
DO: Avoid unnecessary disconnecting and The electrical connections are not designed for
connecting of the electrical components. repeated connection and disconnection.
DO: Insure the low voltage connectors are entirely This prevents intermittent electrical connections
seated and the locking mechanism is engaged. leading to an improper ignition system operation.
DO: Use approved connector breakouts when
Connector and/or component damage may occur.
testing the ignition system.
Liquid intrusion into the terminal connection area
DO: Insure the appropriate seals are included in the might occur causing an electrical intermittent or short
connector system. condition. In the event of severe terminal corrosion,
an open condition might occur.
DO: Operate with gasoline based internal Other fuels or combustion designs may require
combustion engines. additional design considerations.
This could protect the system in the event of an
DO: The power feed line should be fused.
electrical short.
DO: The module heat sink and back plate must not The high level of voltage and current which the
be used as a connection point when jump starting module could be subjected to, could cause module
the engine. performance degradation or failure.
DO: Connection of the module back plate to vehicle This greatly reduce potential ground loops and acts
ground is desirable whenever possible. as a heat transfer source from the module.
DO: The ignition system ground wire should be kept
as short as possible. And, when permissible, should This would greatly reduce the possible of unwanted
be grounded at the same engine block position as electrical ground loops.
the engine controller.
DO: The electrical wiring to the ignition system Helps prevent electrical intermittent, open or shorted
should be routed so that the conductors are
protected from excessive heat, damage, and wear. operating conditions.
Voltage spikes can be transmitted from the

DO: Ignition secondary leads should not be routed
secondary cables into other leads which are in close.
with the ignition primary harness or any other
This could create a component performance
electrical harness.
degradation or failure condition.
DO: Spark plug wires(secondary leads) & primary
wiring:
- must not contact sharp surface.
- must not be under tension between fixed points. - Spark plug wires carry very high voltage (30,000
volt). If the secondary lead loses its dielectric
- must be clear of moving parts (belts, fan, etc…). characteristics thru being nicked, cut , chaffed, then
- must be protected from or kept at least 125 mm an arc thru to a near by ground could take place.
away from radiant heat source exceeding 400 F. This kind of condition could lead to misfire, no start,
- must be protected from environmental damage or premature failure of ignition system.
(dirt, splash, oils, fluids, etc….).
- must be retained, secured or insulated to prevent
pinching, mis-routing, rattles, and squeaks.
DO: Not all fasteners are designed for repeat use. Adequate retention force might not be achieved if the
Beware of fastener specifications. All harnesses fastener is not designed to be reused. Mating
should be supported within 6" of a mating connections are not designed to support the weight
connection. of the harness assembly.
DO: For removing spark plugs follow the following
steps: To remove spark plugs from Aluminum heads, allow
1- Grasp the spark plug boot and gently rotate 90°; the engine to cool. The heat of the engine, in
and then pull the spark plug boot and cable away combination with a spark plug that is still hot, may
from the spark plug. cause the spark plug threads to strip the cylinder
2- Before removing spark plug, brush or air blast dirt head upon removal.
away from the well areas. Use goggles to protect eyes from dirt when applying
3- Use correct size deep socket wrench to loosen compressed air to spark plug wells.
each spark plug one or two turns.
DO: Cleaning a spark plug could be done as follow:
- Cleaning a spark plug will reduce the voltage
1- wipe all spark plug surfaces clean….remove oil, required for an electrical arc(spark) across the
water, dirt and moist residues. electrodes.
2- If the firing end of spark plug has oily or wet - Cleaning & re-gapping will not restore a used spark
deposit, brush the spark plug in an approved, plug to a new condition. It may be more economical
non-flammable and non-toxic solvent. Then dry the and efficient to replace used spark plugs with new
spark plug thoroughly with compressed air. plugs instead of cleaning.
3- Use a propane torch to dry wet-fuel fouled plugs. - Sooted plugs should be replaced.
Allow the torch flame to enter up the center electrode
- Do not cool by using water or any liquid.
insulator. Allow plug to cool down.
- Clean threads permit easier installation and proper
4- If the spark plug threads have carbon & scale
seating which will maximize transfer heat away from
deposits, clean with wire brush, taking care not to
the plug.
injure the electrode or the insulator tip.
DO: Regap spark plugs to the exact measurement - Too wide a gap could cause the plug to

specified by the engine manufacturer to keep the misfire(higher required ignition voltage).
best fuel economy and proper engine performance: - Too narrow of a gap could affect idle stability.
- Use round wire-type gauge for an accurate - A flat gauge can’t accurately measure the spark
measure of gap on all used spark plugs. plug on used plugs.
- when gapping a spark plug only the side electrode
is moved. The center electrode must not be moved.
- Higher heat range plug(hotter plug) could lead to
DO: When replacing spark plugs with new ones, pre-ignition & possible piston damage.
always use equivalent plugs with same heat range,
- Lower heat range (colder plug) could lead to cold
thread, size, etc….
fouling & emission problem.
- If the thread is damage, it prevents a good heat
DO: For installing spark plugs follow the following
transform from the shell to the cylinder head.
steps:
- Do not use any type of anti-seize compound on
1- make sure the cylinder head threads and spark
spark plug threads. Doing this will decrease the
plug threads are clean. Make sure the spark plug
amount of friction between the threads. The result of
thread is free of dings and burrs. If necessary, use a
the lowered friction is that when the spark plug is
thread chaser and seat cleaning tool.
torqued to the proper specification, the spark plug is
2- Make sure the spark plug gasket seat is clean, turned too far into the cylinder head. This increases
then thread the gasket to fit flush against the gasket the likelihood of pulling or stripping the threads in the
seat. Tapered seat plugs do not require gaskets cylinder head.
3- Screw the spark plugs finger-tight into the cylinder - Over-tightening of a spark plug can cause
head. Then, use a torque wrench to tighten spark stretching of the spark plug shell and could allow
plugs following manufacturer’s recommendation. blowby to pass thru the gasket seal between the
Torque is different for various plug type & cylinder shell and insulator. Over-tightening also results in
head material.
extremely difficult removal.
3.5.8 Fuel Pump Module

Fuel Pump Module supplies fuel to engine at system pressure. Fuel Pump Module is mounted
to fuel tank at top and supplies fuel to engine through hoses. Fuel Pump module consists of Fuel
Pump to generate the fuel flow and pressure regulator to regulate the fuel pressure.
When power is supplied to fuel pump, motor in pump assembly rotates the impeller. Impeller
in turn draws the fuel from strainer and pumps the flow to generate the system pressure.
Pressure Regulator is a diaphragm type mechanical device. Fuel flow from filter enters in the
inlet of pressure regulator. Pressure regulator regulates the fuel pressure at a set pressure by
releasing the excessive fuel flow to fuel tank.
3.5.8.2 Appearance

3.5.8.3 Operating Conditions

● Fuel Pump Module needs to be mounted on Fuel Tank Top according to the installation
instructions.
● Fuel Pump Module is intended to use with gasoline. However if the fuel contains ethanol,
please contact vehicle manufacture to check whether the fuel pump module itself can survive or
not.
● Make sure there is at least 3 liters of gasoline in the fuel tank before priming for first time (do
not run the pump dry).
3.5.8.4 Service Procedure

Precautions:
Before attempting any service on fuel system, following cautions should be always followed
for personal safety and to avoid system damages.
● Disconnect negative cable at battery.
● DO NOT smoke, and place ‘No SMOKING” sign near work area.
● Make sure to have fire extinguisher handy.
● Make sure to perform work in well ventilated area and away from any open fire/flames.
● Wear Safety glasses.
● To relieve fuel vapor pressure in fuel tank, remove fuel filler cap fuel filler neck and then
reinstall it.
● As fuel lines are at high pressures when the engine is stopped, loosening or disconnecting
fuel line will cause dangerous spout of fuel. Before loosening/ disconnecting fuel lines, please
follow the “Fuel Pressure Relief Procedure” described in this section.
● Small amount of fuel may drip after the fuel lines are disconnected. In order to reduce the risk
of personal injury, cover the pipe/ hose ends with suitable blind with no rust or contamination.
● After servicing, make sure that the fuel hoses and clamps are connected according to the
hose fitment instructions given in vehicle instruction manual.
● After servicing, please follow the ‘Fuel Leakage Check Procedure’ described in this section.
● After servicing make sure to fill at least 3 liters gasoline before pump is primed (ignition key
should be turned on only after ensuring there is minimum 3 liters of fuel in the fuel tank)

Fuel Module Diagnosis:

Step Action Yes No
Switch on Ignition key. Fuel Pump
primes for 3 seconds when the ignition If fuel pump running noise
If fuel pump running noise
1 key is ON. can not be heard, go to step
can be heard, go to step 4.
Check for fuel pump running noise for 2.
3 seconds after ignition key is ON.
Disconnect fuel module coupler.
Check the electrical circuit
2 Check voltage at harness coupler. Is Go to step 3
from Ignition to fuel module.
the voltage within 10-14V?
Connect 12V DC power supply
(battery) to fuel module.
1.Check electrical circuit 1. Check Fuel Pump Harness
Make sure that enough fuel available
3 from fuel module to ECU. integrity.
in fuel tank to avoid fuel pump running
2. Check ECU. 2. Check Fuel Pump.
dry.
Is the fuel pump running?
Check fuel system pressure at Injector
inlet (with a T-joint) while engine is Fuel Module Operation
4 running in idle condition. Go to Step 5
Normal
Is the pressure about 300 kPa?
1. Check for leakages from
1. Clogged Filter
hoses, hose joints
Is the Pressure below 300kPa too 2. Kink/ Blockage in Fuel
5 2. Check Fuel Pump
much? Hoses
3. Check Pressure 3. Check Re
Regulator
3.5.8.5 Fuel Module Removal

● Relieve fuel pressure in fuel lines referring to the ‘Fuel Pressure Relief Procedure’ (3.5.8.7)
provided in this section.
● Disconnect negative cable at battery.
● Disconnect fuel module wire coupler.
● Drain the fuel in fuel tank thru fuel filler with help of hand pump (siphon). Collect the fuel in
approved container for contamination and safety.
● Disconnect the fuel hoses from fuel module by using standard tools
● Remove the fuel tank from vehicle.
● Place the fuel tank with bottom up condition. Care to be taken not to cause any scratches/
damages on fuel tank.
● Open the fuel module mounting bolts.
● Take out fuel module assembly from fuel tank with care
● Care to be taken not to damage the strainer while removing fuel module from tank.
3.5.8.6 Fuel Module Installation
● Replace the fuel module gasket in fuel module assembly with a new one. Old/ used gaskets
can cause leakages.
● Fold strainer towards fuel pump and insert fuel module in tank opening with care. Care should
be taken not to cause any damages on strainer. Make sure that the fuel tank surface at module
mounting area is clean and free of surface defects.
● Place the bolts on module cover and tighten the bolts gradually in star pattern sequence to
apply equal compression on gasket. It is shown as below:
Bolt Tightening Torque: 10 Nm. Fuel module is installed with the M6×10 bolts. Use
designated bolts only. Follow the tightening torque and tightening sequence instruction. Over
torque and miss-sequence can cause unequal compression of gasket and leakage.
● Install the fuel tank to vehicle.
● Connect for fuel hoses with suitable hose clamps.
● Connect fuel module coupler
● Follow ‘ Fuel Leakage Check Procedure’ (3.5.8.7) to check any leakage before the engine
is started.
3.5.8.7 Fuel Pressure Relief Procedure
Caution: This work must not be done when engine is hot. If done so, it may cause adverse
effect to catalyst (if equipped)
After making sure that engine is cold, relieve fuel pressure as follows.
● Place vehicle gear in ‘Neutral’.
● Disconnect fuel module electrical coupler from vehicle harness.
● Start engine and run till it stops due to lack of fuel. Repeat ignition key ON and OFF for 2 ~ 3
times of about 3 seconds each time to relieve fuel pressure in lines. Fuel Connections are now
safe for servicing.
● Upon the completion of servicing, Connect Fuel Module Connector to Vehicle Harness.
3.5.8.8 Fuel Leakage Check Procedure:

After performing any service on fuel system, check to make sure that there are no fuel
leakages as below.
● Fill about 3 ~ 5 liters of fuel in tank.
● Turn Ignition key to ON position for 3 seconds (to operate fuel pump) and then turn to OFF
position. Repeat this for 3 ~ 4 times to apply fuel pressure in fuel lines.
● In this state, check to see that there are no fuel leakage from any part of fuel system (Fuel
Tank, Hoses, Hose Joints, etc)
3.5.9 Motor Scanner ( for MT05 EMS)

3.5.9.1 Precautions
● Motor-Scanner is a precision instrument and should be protected from vibration and impact.
● If the unit does not run correctly or the screen is unstable when first turned on, disconnect it
from the main lead and try again.
● Make sure the DLC is always firmly inserted into the diagnostic socket.
● Never test electrical signals that exceed the limit of specifications.

● Test cannot be performed by the person who is driving the car.
● This unit should be used and stored in the following conditions:
Ambient temperature: 0~50℃
Relative humidity: <90%
3.5.9.2 Configurations
Delphi Motor scanner consists of 2 main part: the main units (with diagnostic main cable) and
diagnostic connector link (one end is 6PIN connector; the other is the interface for connecting
diagnostic main cable). They are shown as below:
Delphi Motor scanner Outline of Main Unit
A: Main Unit
B: Diagnostic Main Cable
C: Diagnostic Connector Link
The 6 PIN diagnostic connector link cable and USB type main unit’s software update cable
are in the delivered package.
3.5.9.3 Preparations Connection
● Find the 6PIN diagnostic socket on the motor.
● Connect one end of the diagnostic main cable to the main unit, and the other end to
diagnostic socket on the motor, tighten the screws.
Normal Power – on Display
When power is on normally, the unit will display:

Seconds later, the unit will display:
3.5.9.4 Functions
Delphi Motor-Scanner can be used to diagnose Delphi Engine Management System with
functions: Read DTC, Clear DTC, Data Stream, Status Stream, and Record Data.
Operations
When the unit is powered up, the screen will display the interface as below.
Here, we take diagnostic function for demonstration.
Select 1 and press key, it will display an interface for language selection, as shown below:

Select ‘English’ and press key, it will display information about the diagnostic software
version, press to continue, the interface will display as below:
Diagnostic Function
Here, we take ‘diagnostic function’ for demonstration.
Select ‘diagnostic function’ and press , the screen will display an interface to indicate
‘Delphi-3’ diagnostic connector should be used.
Press , the screen will display engine information as below:

Press , with ‘accessing system’ fleeting on the screen, then, it will display as below:
Available functions are as follows:

● Read DTC
● Clear DTC
● Data Stream
● Status Stream
● Record Data
Press or key to select function you needed.
1. Read DTC
Select ‘Read DTC’, and press , it will display fault code as below:
Press or key to move ‘.’ icon, and select fault code, take ‘P0118’ for example, it’s
selected when there is ‘.’ in front of it, press , the screen will display detailed information of
the code, as below:

2. Clear DTC
Select ‘Clear DTC’ and press , it will display as below:
3. Data Stream
Select ‘Data Stream’ and press , it will display as below:
Press or key for page up/down to view more. Press key to exit.
4. Status Stream
Select ‘Status Stream’ and press , the interface will display as below:
Press or key for page up/down to view more. Press key to exit.

3.5.9.5 MT05 ECU Malf Code

Malf code Description
P0107 MAP Circuit Low Voltage or Open
P0108 MAP Circuit High Voltage
P0112 IAT Circuit Low Voltage
P0113 IAT Circuit High Voltage or Open
P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage
P0118 Coolant/Oil Temperature Sensor Circuit High Voltage or Open
P0122 TPS Circuit Low Voltage or Open
P0123 TPS Circuit High Voltage
P0131 O2A Circuit Low Voltage
P0132 O2A Circuit High Voltage
P0031 O2A Heater Circuit High Voltage
P0032 O2A Heater Circuit Low Voltage
P0201 Injector 1 Circuit Malfunction
P0202 Injector 2 Circuit Malfunction
P0230 FPR Coil Circuit Low Voltage or Open
P0232 FPR Coil Circuit High Voltage
P0336 CKP Sensor Noisy Signal
P0337 CKP Sensor No Signal
P0351 Cylinder 1 Ignition Coil Malfunction
P0352 Cylinder 2 Ignition Coil Malfunction
P0505 Idle Speed Control Error
P0562 System Voltage Low
P0563 System Voltage High
P0650 MIL Circuit Malfunction
P1693 Tachometer Circuit Low Voltage
P1694 Tachometer Circuit High Voltage

3.6. Cooling and Lubrication System
Engine Coolant………………………………………………………3.6.1
Inspection of Cooling Circuit……………………….………………3.6.2
Inspection and Cleaning of Radiator and Water Hoses…………3.6.3
Inspection of Fan Motor……………………………………….……3.6.4
Inspection of Water Temperature Sensor…………………………3.6.5
Inspection of Thermostat……………………………………………3.6.6
Water Pump……………………………………………………….…3.6.7
Water Pump Removal and Disassembly……………………3.6.7.1
Inspection………………………………………………………3.6.7.2
Water Pump Assembly and Installation………..……………3.6.7.3
Lubrication System Illustration………………………………..……3..6.8

3.6.1 Engine Coolant

The coolant used in cooling system is a 100% ethylene
glycol antifreeze.
Warning !
DO NOT open radiator cap when the engine is still
hot. Or you may be injured by scalding fluid or
steam;
Coolant is harmful. DO NOT swallow or stain your
skin or eyes with coolant. In case of accidental
swallow or stains, flush with plenty of water and
consult the doctor immediately.
Keep coolant away from reach of children.
3.6.2 Inspection of Cooling Circuit

Remove radiator cap① and connect tester ② to
filler.
Warning!
Do not open the radiator cap when the engine is still hot.
Give a pressure of 120 kPa and check if the cooling

system can hold this pressure for 10 seconds.
If the pressure drops during this 10 seconds, it

indicates that the there is leakage with the cooling
system. In this case, check the complete system
and replace the leaking parts or components.
Warning!
When removing the radiator cap tester, put a rag on
the filler to prevent splash of coolant.
Warning!
Do not allow a pressure to exceed the radiator cap
release pressure.

3.6.3 Inspection and Cleaning of Radiator and

Water Hoses
Radiator Cap
Remove radiator cap①
Install radiator cap to cap tester②
Slowly increase pressure to 110-140 kPa and

check if the cap can hold the pressure for at least
10 seconds.
If the cap cannot meet the pressure requirement,

replace it.
Radiator Cap Valve Opening Pressure:

Standard: 110-140 kPa
Tool: Radiator Cap Tester
Radiator Inspection and Cleaning
Remove dirt or trash from radiator with compressed

air;
Correct the radiator fins with a small screwdriver;
Radiator Hose Inspection
Check radiator hoses for leakage or damage.
Leakage or Damage: → Replace
Check tightening of clamps. Replace the clamps if

necessary;
After inspection and cleaning of radiator and hoses,

check coolant level. Fill coolant if necessary.

3.6.4 Inspection of Fan Motor
Remove fan motor from radiator
Turn the vanes and check if they can turn smoothly;
Check fan motor: Make sure that the battery applies

12 volts to the motor and the motor will run at full
speed while the ammeter shall indicate the ampere
not more than 5A.
If the motor does not run or the ampere exceeds the
limit, replace the motor.
Installation: Apply a little thread locker to the bolts

and tighten to the specified torque.
Fan Motor Bolt Tightening Torque: 10N•m
Inspection of Thermoswitch
Remove thermoswitch
Check the thermoswitch for closing or opening by
testing it at the bench as illustrated. Connect the
thermoswitch① to the circuit tester, place it in a
vessel with engine oil. Place the vessel above a
stove.
Heat the oil to raise the temperature slowly and take
the reading from thermometer ② when the
thermoswitch closes and opens.
Tool: ammeter
Thermoswitch Operating Temperature
Standard: (OFF-ON): Approx. 88℃
(ON-OFF): Approx. 82℃
Note:
Avoid sharp impact on thermoswitch.
Avoid contact of thermoswitch with thermometer or
vessel
Installation: Use a new O-ring③ and tighten the
thermoswitch to the specified torque:
Thermoswitch Tightening Torque: 17N•m
Check coolant level after installation of

thermoswitch. Fill coolant if necessary.

3.6.5 Inspection of Water Temperature Sensor
Place a rag under water temperature sensor① and

remove it from cylinder head.
Check the resistance of water temperature sensor

as illustrated on the right. Connect the temperature
sensor② to the circuit tester, place it in a vessel
with engine oil. Place the vessel above a stove.
Heat the oil to raise the temperature slowly and take
the reading from thermometer ③ and ohmmeter ④ .
Water Temperature and Resistance
Temperature(℃) 50 80 100 120

Resistance(Ω) 154±16 52±4 27±3 16±2
Installation: Apply a little thread locker and install it to

the cylinder head by tightening to the specified torque.
Water Temperature Sensor

Tightening Torque: 10N•m
Note:
Avoid sharp impact on temperature sensor
Avoid contact of temperature sensor with
thermometer or vessel
After installation, check the coolant level. Fill

coolant if necessary.
3.6.6 Inspection of Thermostat
Remove thermostat case
Remove thermostat

Check thermostat pellet for cracks

Test the thermostat in the following steps:
Pass a string between thermostat flange as

illustrated on the right;
Immerse the thermostat in a beaker with water.
Make sure that the thermostat is in the suspended
position without contact to the vessel. Heat the
water by placing the beaker above a stove and
observe the temperature rise on a thermometer;
Take the temperature reading from thermometer
when the thermostat valve opens.
Thermostat Valve Opening Temperature: 68-74℃
Keep heating the water to raise the water

temperature.
Just when the water temperature reaches the

specified value, the thermostat valve should have
been lifted by 3.5-4.5mm
Installation:
Reverse the removal procedure for installation.
Apply coolant to the rubber seal of thermostat.
Install thermostat case. Tighten to the specified

torque:
Tightening Torque: 10N•m
3.6.7 Water Pump
3.6.7.1 Removal and Disassembly
Drain coolant
Note: Before draining coolant, check water pump for oil

or coolant leakage. In case of oil leakage, check the
water pump oil seal, O-ring. In case of coolant leakage,
check the water seal.

Remove clamps and water hoses
Release bolts and remove water pump
Remove O-ring
Note: Do not reuse the O-ring.
Remove the overflow tube
Release water pump cover screws, water pump

cover and gasket
Remove E-ring and impeller
Remove seal ring ①and rubber seal②

Remove mechanical seal with special tool
Note: The mechanical seal does not need to be

removed if there is no abnormal condition.
Note: Do not reuse a removed mechanical seal
Put a rag on the water pump body
Remove oil seal.
Note: The oil seal does not need to be removed if there

is no abnormal condition
Note: Do not reuse a removed oil seal
Remove bearing with special tool.
Note: The bearing does not need to be removed if

there is no abnormal noise.
Note: Do not reuse a removed bearing.
3.6.7.2 Inspection of Water Pump
Bearing
Check the play of bearing by hand while it is still in

the water pump body;
Turn inner race of bearing to check for abnormal
noise and smooth rotation;
Replace the bearing if there is abnormal condition;
Mechanical Seal
Check mechanical seal for damage, pay special

attention to the seal face;
In case of leakage or damage, replace the
mechanical seal. If necessary, also replace the seal
ring.

Oil Seal
Check oil seal for damage. Pay special attention to

the oil seal lip;
In case of damage or leakage, replace the oil seal;
Water Pump Body
Check the mating mace of water pump body with

bearing and mechanical seal.
Damage: →Replace
Impeller
Check the impeller and shaft for damage.

Damage: →Replace
3.6.7.3 Assembly and Installation of Water Pump
Install oil seal with special tool;
Tool: Oil Seal Installer
Note: The stamped mark on the oil seal faces outside
Apply a little grease to the oil seal lip.

Install mechanical seal with a suitable socket

wrench
Note: Apply sealant to side “A” of mechanical seal
Install bearing with special tool
Tool: Bearing Installer
Note: The stamped mark on the bearing faces outside.
Install seal ring to impeller
Clean off the oil and grease from mechanical seal

and install it into the impeller.
Note: “A” side of mechanical seal faces impeller
Apply grease to impeller shaft
Install impeller shaft to water pump body.

Install E-ring to water pump shaft;
Install new gasket to water pump body;
Install water pump cover and tighten the bolts and

bleed bolt.
Water Pump Cover Bolts Tightening Torque: 6N•m
Check impeller for smooth turning.
Install the new O-ring
Note:
Use the new O-ring to prevent oil leakage;
Apply grease to O-ring

Install water pump and tighten the bolts to the

specified torque;
Water pump bolts tightening torque: 10N•m
Note: Set the water pump shaft slot end “B” to oil pump
shaft flat side “A”.
Connect water hoses
Add coolant

3.6.7.8 Lubrication System Illustration

3.7 TROUBLESHOOTING
Electrical system
GENERAL INFORMATION 1. Battery
• Discharged battery
TIP ______________ • Faulty battery
The following glide for troubleshooting does not 2 Fuse(s)
overall the possible causes of trouble. It should • Blown, damaged a incorrect fuse
be helpful, however, as a guide to basic trouble- • Improperly installed fuse
shooting. Refer to the relative procedure in this a Sparkplug
manual for checks, adjustments, and replace- • Incorrect spark plug gap
ment of parts. • Incorrect spark plug heat range
• Fouled spark plug
STARTING FAILURES • Worn a damaged electrode
• Worn a damaged insulator
Engine • Faulty spark plug cap
1. Cylinder and cylinder head 4. Ignition coil
• Loose spark plug • Cracked a broken ignition coil body
• Loose cylinder head or cylinder • Broken a shorted primary or secondary
• Damaged cylinder head gasket coils
• Damaged cylinder gasket • Faulty spark plug lead
• Worn a damaged cylinder 5 Ignition system
•Faulty ECU
• Incorrect valve clearance
• Faulty crankshaft position sensor
• Improperly sealed valve
• Broken generator rotor woodruff key
• Incorrect valve-to-valve-seat contact
6 Switches and wiring
• Incorrect valve timing
• Faulty main switch
• Faulty valve spring
• Broken a shorted wiring
• Seized valve
• Faulty gear position switch
2. Piston and piston ring(s)
• Improperly grounded circuit
• Improperly installed piston ring
• Loose connections
• Damaged, worn a fatigued piston ring
• Faulty brake light switch
• Seized piston ring
7. Starting system
• Seized or damaged piston
• Faulty starter motor
3. Air filter
• Faulty starter relay
• Improperly installed air filter
• Faulty starter clutch
• Clogged air filter element
4. Crankcase and crankshaft INCORRECT ENGINE IDLING SPEED
• Improperly assembled crankcase
• Seized crankshaft Engine
1. Cylinder and cylinder head
Fuel system • Incorrect valve clearance
1. Fuel tank • Damaged valve train components
• Empty fuel tank 2 Air filter
• Clogged fuel tank breather hose joint • Clogged air filter element
• Clogged fuel tank breather hose joint hose
• Deteriorated or contaminated fuel Fuel system
2. Fuel pump 1. Throttle body
• Faulty fuel pump • Damaged a loose throttle body joint
• Faulty fuel injection system relay • Improper throttle cable free play
• Clogged or damaged fuel hose • Flooded throttle body
3. Throttle body • Faulty air induction system
• Deteriorated or contaminated fuel
• Sucked-in air Electrical system
1. Battery
• Discharged battery

• Faulty battery • Broken generator rotor woodruff key

2. Sparkplug
• Incorrect spark plug gap POOR MEDIUM-AND-HIGH-SPEED
• Incorrect spark plug heat range PERFORMANCE
• Fouled spark plug Refer to ‘STARTING FAILURES" on Previous page.
• Worn or damaged electrode
• Worn or damaged insulator Engine
• Faulty spark plug cap 1. Air filter
3. Ignition coil • Clogged air filter element
• Broken or shorted primary or secondary coils
• Faulty spark plug lead Fuel system
• Cracked or broken ignition coil 1. Fuel pump
4. Ignition system • Faulty fuel pump
• Faulty ECU
• Faulty crankshaft position sensor
FAULTY DRIVE TRAIN

The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes
1. A pronounced hesitation or “jerky” movement A. Bearing damage.
during acceleration, deceleration, or sus- B. Improper gear backlash.
tained speed. (This must not be confused C. Gear tooth damage.
with engine surging or transmission charac- D Broken drive shaft.
teristics.) E. Broken gear teeth.
2. A ‘Tolling amble" noticeable at low speed; a F. Seizure due to lack of lubrication.
high-pitched whine; a “clink” from a shaft G. Small foreign objects lodged between the
dive component or area. moving parts.
3. A locked-up condition of the shaft dive
mechanism, no power transmitted from the
engine to the front and/or rear wheels.

TIP ____________________________________________________________
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these components
are damaged, remove the components and check them.
FAULTY GEAR SHIFTING JUMPS OUT OF GEAR
Shifting is difficult Shift forks

Refer to “FAULTY CLUTCH" on next page. •Worn shift fork
EJSDCDICDI
Shift drum
SHIFT LEVER DOES NOT MOVE • Incorrect axial play
• Worn shift drum groove
Shift drum and shift forks
• Foreign object in a shift drum groove Transmission
• Seized shift fork • Worn gear dog
• Bent shift fork guide bar
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission

FAULTY CLUTCH OVERHEATING
Engine operates but vehicle will not move Engine

1. V-belt 1. Clogged coolant passages
• Bent, damaged or worn V-belt 2 Cylinder head and piston
• Slipping V-belt • Heavy carbon buildup
2. Primary pulley cam and primary pulley slider 3.Engine oil
• Damaged or worn primary pulley cam • Incorrect oil level
• Damaged or worn primary pulley slider • Incorrect oil viscosity
3. Clutch spring(s) • Inferior oil quality
• Damaged clutch spring
4. Transmission gear(s) Cooling system
• Damaged transmission gear 1. Coolant
• Low coolant level
Clutch slips 2 Radiator
1. Clutch spring(s) • Damaged or leaking radiator
• Damaged, loose or worn clutch spring • Faulty radiator cap
2. Clutch shoe(s) • Bent or damaged radiator fin
• Damaged or worn clutch shoe 3 Water pump
3. Primary sliding sheave • Damaged or faulty water pump
• Seized primary sliding sheave 4.Thermostat
• Thermostat stays closed
Poor starting performance 5 Oil cooler
1. V-belt • Clogged or damaged oil cooler
•V-belt sips 6 Hose(s) and pipe(s)
• Oil or grease on the V-belt • Damaged hose
2. Primary sliding sheave • Improperly connected hose
• Faulty operation • Damaged pipe
• Worn pin groove • Improperly connected pipe
• Worn pin
3 Clutch shoe Fuel system
• Bent, damaged or worn clutch shoe 1. Throttle body
• Faulty throttle body
Poor speed performance • Damaged or loose throttle body joint
1. V-belt 2 Air filter
• Oil or grease on the V-belt • Clogged air filter element
2. Primary pulley weights)
• Faulty operation Chassis
• Worn primary pulley weight 1. Brake(s)
3. Primary fixed sheave • Dragging brake
• Worn primary fixed sheave
Electrical system
4. Primary sliding sheave
1. Sparkplug
• Worn primary slicing sheave
• Incorrect spark plug gap
5 Secondary fixed sheave
• Incorrect spark plug heat range
• Worn secondary fixed sheave
6. Secondary sliding sheave 2 Ignition system
•Faulty ECU
• Worn secondary sliding sheave
3 Radiator fan
• Faulty fen motor
• Disconnected circuit breaker terminal
• Faulty coolant temperature sensor

OVERCOOUNG 6. Frame
• Bent frame
Cooling system • Damaged frame
1. Thermostat
• Thermostat stays open FAULTY LIGHTING OR SIGNAUNG SYSTEM
POOR BRAKING PERFORMANCE Headlight does not come on

• Worn brake pad • wrong headlight bulb
• Worn brake disc • Too many electrical accessories
• Air in hydraulic brake system • Hard charging
• Leaking brake fluid • Incorrect connection
• Faulty brake caliper kit • Improperly grounded circuit
• Faulty brake caliper seal • Poor contacts (main or light switch)
• Loose union bolt • Bunt-out headlight bulb
• Damaged brake hose
• Oil or grease on the brake disc Headlight bulb bunt out
• Oil or grease on the brake pad • Wrong headlight bulb
• Incorrect brake fluid level • Faulty battery
• Faulty rectifier/regulator
FAULTY SHOCK ABSORBER ASSEMBLY • Improperly grounded circuit
• Faulty main switch
Leaking oil • Faulty light switch
• Bent damaged or rusty damper rod • Headlight bulb life expired
• Cracked or damaged shock absorber
• Damaged oil seal lip Tail/brake light does not come on
• Wrong tail/brake light bulb
Malfunction • Too many electrical accessories
• Fatigued or damaged shock absorber spring • Incorrect connection
• Bent or damaged damper rod • Bunt-out tail/brake light bulb
UNSTABLE HANDING Tail/brake light bulb burnt out

1. Steering wheel • Wrong tail/brake light bulb
• Bent or improperly installed steering wheel • Faulty battery
2. Steering components • Faulty brake light switch
• Incorrect toe-in • Tail/brake light bulb life expired
• Bent steering shaft • Faulty rectifier/regulator
• Improperly installed steering shaft • Improperly grounded circuit
• Damaged bearing or bearing race
•Bent tie-rods
• Deformed steering knuckles
3. Shock absorber assemblies)
• Faulty shock absorber spring
• Leaking oil or gas
4. Tire(s)
• Uneven tire pressures (left and right)
• Incorrect tire pressure
• Uneven tire wear
5 Wheel(s)
• Incorrect wheel balance
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout

NOTES

CHAPTER 4 CHASSIS T-Boss550 SERVICE MANUAL20.0
CHAPTER 4 CHASSIS
WARNING
have almost same appearance. Always refer to Parts Manual of each CUV model for spare
4.1 FRONT A-ARM REPL ACEMENT
4.2 REAR A-ARM REPLACEMENT
4.3 REAR STABILIZER BAR REMOVA L/INSTALLATION
4.4 BOX REMOVAL/INSTALLATION
4.5 STEERING ASSEMBLY REMOVAL/INSTALLATION
CHAPTER 4 CHASSIS PAGE. 4- 1

4.1 FRONT A-ARM REPLACEMENT
1. Carrier Bearing,Front,Lh； 2. Bearing； 3. Circlip 55

4. Nut M12×1.25； 5. Pin 3.2×22； 6. Arm Upper Frt Lh
7. Ball Joint,Upper； 8. Circlip 32； 9. Scr Hxfl,Frt Arm
10. Nut M10； 11. Bushing,Long； 12. Shaft Pivot
13. Arm Lwr Frt Lh； 14. Ball Joint,Lwr； 15. Circlip 34
16. Cover，Arm Lwr Frt Lh； 17. Screw M5X10； 18. Grease Fitting M6
19. Front Shock Absorber Assy； 20. Bolt M10X1.25X57； 21. Arm Upper Frt Lh Assy
22. Arm Lwr Frt Lh Assy； 23. Carrier Bearing Wheel Lh Assy
1.Elevate and safely support vehicle with weight removed from front wheel(s).
2.Remove the wheel nuts and wheel.

NOTE: To ease the removal of the spindle bolt,remove the hub cap and loosen the spindle
bolts before removing the wheel.
3.Remove the brake caliper. Suspend the brake caliper from the frame with a wire.
NOTE: Do not let the brake caliper hand from the brake line or damage may occur.

4.Remove the spindle nut, and washer. Remove the hub assy by sliding it off of the shaft.
5.Remove cotter pin from ball joint stud at wheel end of A- arm and loosen nut until it is flush
with end of stud.
6.Using a soft face hammer, peen nut to loosen A- arm from bolt. Remove nut and A-arm from
hub strut assembly.
7.Loosen and remove two bolts on A-arm, and remove A-arm.
8.Examine A-arm bushing. Replace if worn or tore. Discard hardware.
9.Install new A-arm assembly onto vehicle frame. Install new bolts and new nuts.
NOTE:
Tighten the nuts only finger-tighten at this time. They will be tightened to the final torque after
the front wheels are installed and the vehicle is on the ground.
DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during
operation.
10.Attach A-arm to strut assembly. Tighten ball joint nut to 25 ft. lbs. (35 Nm). If cotter pin holes
are not aligned, tighten nut slightly to align. Install a new cotter pin with open ends toward rear
of machine. Bend both ends in opposite directions around nut.
11. Re-install the hub assy. Install washer, and the spindle nut to 103 ft.lbs (140Nm). Aim the
gap of the shaft for use the chisel to hit the nut until it locked.
12.Install the brake caliper. Apply Loctite™ 243 to screw threads of the bolts and torque bolts to
18ft. lbs. (25 Nm ).
13.Install the wheel and torque nuts to 55ft. lbs. (75 Nm ).
14.lower the vehicle to the ground. Apply Loctite™ 243 to screw threads of the A arm bolts and
torque bolts to 37-44 ft. lbs. (50-60 Nm ).
Upon A-arm installation completion, test vehicle at low speeds before putting into regular
service.

4.2 REAR A-ARM REPLACEMENT
1. Carrier Bearing Wheel Rear Lh；2. Grease Fitting M6； 3. Bearing

4. Circlip 63； 5. Shaft Pivot ,Lwr； 6. Scr Hxfl,Rear Arm,Lwr
7. Shaft Pivot ,Upper； 8. Bolt M10X1.25X90； 9.Nut M10
10. Bushing,Short； 11. Arm Upper Rear Lh； 12. Bushing,Long
13. Shaft,Rear Upper Arm； 14. Scr Hxfl，Rear Upper Arm； 15. Square Rubber Plug
16. Arm Lwr Rear Lh； 17. Plug； 18. Shaft,Rear Lwr Arm
19. Cover，Arm Lwr Rear Lh； 20. Screw M5X10； 21. Rear Shock Absorber Assy
22. Bolt M10X1.25X62.5； 23. Bolt M10X1.25X57； 24. Stabilizer Bar
25. Ball Pin, Lh； 26. Ball Pin, Rh； 27. Bracket Stabilizer
28. Bushing Stabilizer； 29. Bolt M8X20； 30. Nut M8
31. Arm Lwr Rear Lh Assy； 32. Arm Upper Rear Lh Assy；
33. Carrier Bearing Wheel Rear Lh Assy
1. Elevate and safely support vehicle with weight

removed from the rear wheel(s).
2. Remove the wheel nuts and wheel.

NOTE: To ease the removal of the spindle bolt,
remove the hub cap and loosen the spindle bolts
before removing the wheel.

3. Remove the brake caliper. Suspend the brake

caliper from the frame with a wire.
NOTE: Do not let the brake caliper hand from
the brake line or damage may occur.
4. Remove the spindle nut, and washer. Remove

the hub assy by sliding it off of the shaft.
5. Loosen two bolts that secure the rear knuckle to

the A-arm. Remove the rear knuckle assembly
by sliding it off of the shaft.
6. Remove the bolt that secures the shock and coil

to the lower A-arm.
7. Loosen two bolts that secure the A-arm to frame

by alternating each about 1/3 of the way until
A-arm can be removed. Perform this procedure
on the upper A-arm.

8. Examine the A-arm bushing and A-arm shaft.

Replace if worn. Discard hardware.
9. Remove the bottom stabilizer bar nut.
10. Loosen two bolts that secure the A –arm bushing to frame by alternating each about 1/3 of
the way until the A-arm can be removed. The lower A-arm should now be free to remove.
11. Insert new A-arm bushings and new A-arm shaft into new A-arm.
12. Install new A-arm assembly onto vehicle frame. Apply Loctite™ 242 to screw threads of the
A arm bolts and torque bolts to 44 ft. lbs. (60 Nm ).
DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during
operation.
13. Attach A-arm to rear knuckle. Tighten upper and lower bolts to 44 ft. lbs. (60 Nm ).
14. Install the shock and tighten shock bolt to 44 ft. lbs. (60 Nm ).
15. Install the stabilizer and tighten nut.
16. Re-install the hub assy. Install washer, and the spindle nut to 103 ft.lbs (140Nm). Aim the
gap of the shaft for use the chisel to hit the nut until it locked.
17. Install the brake caliper. Apply Loctite™ 243 to screw threads of the bolts and torque bolts
to 18ft. lbs. (25 Nm ).
18. Install the wheel and torque nuts to 55ft. lbs. (75 Nm ).
19. lower the vehicle to the ground. Apply Loctite™ 243 to screw threads of the A arm bolts and
torque bolts to 44 ft. lbs. (60 Nm ).
Upon A-arm installation completion, test vehicle at low speeds before putting into regular
service.

4.3 REAR STABILIZER BAR REMOVAL/INSTALLATION
1. Elevate and safely support vehicle with weight

removed from the rear wheel(s).
2. Remove the rear wheel to gain access to the

stabilizer bar, each side.
3. Remove the stabilizer bar nut from the lower

A-arm, each side.
4. Remove the two bolts that secure the stabilizer

bar to the main frame, each side.
5. Remove the stabilizer from the frame.
6. Inspect the stabilizer bar. Inspect the bushings
and replace if needed.
7. Inspect the stabilizer joint and replace if needed.
8. Reverse the procedure for installation.Torque the
stabilizer bolts to 18.5 ft.lbs (25 Nm).

4.4 BOX REMOVAL/INSTALLATION

Box Removal
1. Disconnect taillight transition line at lower right of
the Box from the wiring harness.
2. Lift the box into the dump position.
3. Remove the box shock pin from the frame.
4. Remove the shocks from the shock brackets. Let
the shocks fully extend.
CAUTION: Safely support the box during the rest of
the removal process. The box is not as stable with
the shocks removed.
5. Remove the cotter pin from the hinge pin.
6. Remove the hinge pin.
CAUTION: Safely support the box during the rest of
the removal process. The box is not as stable with
the hinge pin removed.
7. With the hinge pins removed, remove the box
from the frame. Two people maybe needed to
remove the bed from the frame.
CAUTION: Use caution when removing the box. It is
recommended to have two people to carefully
remove the box from the frame.
Box Installation
1. Place the box onto the frame. Align the hinges of
the box with the frame.
2. Install the box hinges.
3. Secure the box hinges with the bolts.
4. With the hinges installed, decompress the box
shocks and place them into the shock brackets
on the frame.
5. Secure the box shocks with the shock pin.
6. Lower the box and secure the latch.
7. Connect taillight transition line to the wiring
harness.

4.5 STEERING ASSEMBLY REMOVAL/INSTALLATION
1. Pin 2.5×25； 2.Nut M10X1.25； 3. Steering Tie-Rod,Rh

4. Steering Tie-Rod,Rh； 5. Steering Motor； 6. Bolt M8X90
7. Bolt M8X90； 8. Bolt M8X20； 9. Nut M8
10. Steering Tie-Rod,Lh； 11. Steering Tie-Rod,Lh； 12. Steering Wheel
13. Steering Wheel Holder； 14. Steering Wheel Holder； 15. Screw M5X10
16. Steering Column Assy.； 17. Washer 12； 18. Washer Spring 12
19. Nut M12； 20. Shoulder Bolt M10×1.25×30； 21. Bushing For Adjustable Steering Wheel
22. Nut M10； 23. Nut M10； 24. Adjustment Cylinder
25. Shoulder Bolt M8×1.25×30；26. Washer 6； 27. Bolt M6X12
1. With the steering wheel cover bolts removed, remove the steering wheel cover and the
steering wheel.
2. With the steering wheel holder nut removed, remove the steering wheel holder.
3. Remove the steering column bolts.
4. Remove the upper of the steering column.
5. Remove the cotter pins and the tie rod end bolts (both sides).
6. With the cover bolts removed, remove the steering assy and the lower of the steering
column.
7. Reverse the procedure for installation.

NOTES

CHAPTER 5 FINAL DRIVE T-Boss550 SERVICE MANUAL 20.0
CHAPTER 5 FINAL DRIVE

WARNING
have almost same appearance. Always refer to Parts Manual of each CUV model for spare
5.1 W HEEL, HUB , AND SPINDLE TORQUE TABLE

5.2 FRONT HUB EXPLODED VIEW
5.3 FRONT HUB REMOVAL/INSPECTION
5.4 FRONT HUB INSTALLATION
5.5 FRONT HUB BEARING REPLACEMENT
5.6 FRONT DRIVE AXLE REMOVAL / INSPECTION
5.7 FRONT DRIVE AXLE INSTALLATION
5.8 FRONT DRIVE AXLE DISASSEMBLY/ INSPECTION
5.9 FRONT DRIVE AXLE ASSEMBLY
5.10 REAR HUB EXPLODED VIEW
5.11 REAR HUB AND KNUCKLE REMOVAL/ INSPECTION
5.12 REAR HUB A ND KNUCKLE INSTALLATION
5.13 REAR DRIVE SHAFT REMOVAL
5.14 REAR DRIVE SHAFT INSTALLATION
5.15 REAR GEARCASE EXPLODED VI EW
5.16 REAR GEARCASE DISASSEMBLY
5.17 REAR GEARCASE ASSEMBLY
5.18 FRONT GEARCASE EXPLODED VIEW
5.19 FRONT GEARCASE DISASSEMBLY
5.20 FRONT GEARCASE ASSEMBLY
CHAPTER 5 FINAL DRIVE. 5- 1

5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE
Item Specification
Front Wheel Nuts 55 Ft.Lbs 75 Nm
Rear Wheel Nuts 55 Ft.Lbs 75 Nm
Front Hub Nut on Spindle/ outer CV joint 103 Ft.Lbs 140 Nm
Rear Hub Retaining Nut 103Ft.Lbs 140 Nm

Refer to exploded views and text for torque values of other fasteners.
CAUTION: Locking nuts, and bolts with pre-applied locking agent should be replaced if
removed. The self- locking properties of the nut or bolt are reduced or destroyed during
removal.
5.2 FRONT HUB EXPLODED VIEW
5.3 FRONT HUB REMOVAL/INSPECTION

1. Elevate front end and safely support machine
under footrest/frame area.
CAUTION: Serious injury may result if machine tips
or falls. Be sure machine is secure before beginning
this service procedure. Wear eye protection when
removing bearings and seals.
2. Check bearings for side play by grasping the
tire/Wheel firmly and checking for movement.

3. Grasp the top and bottom of the tire. The tire

should rotate smoothly without binding or rough
spots.
4. Remove wheel nuts and wheel.
5. Remove the two brake caliper mounting bolts.
CAUTION: Do not hang the caliper by the brake line.

Use wire to hang the caliper to prevent possible
damage to the brake line.
6. Remove front spindle nut, and washer.

7. Remove front hub assembly.
8. Rotate each bearing by hand and check for

smooth rotation. Visually inspect bearing for
moisture, dirt, or corrosion, or roughness is
evident.
5.4 FRONT HUB INSTALLATION

1. Inspect the hub strut bearing surface for wear or
damage.
2. Apply grease to drive axle spindle.
3. Install spindle through the backside of the hub
strut. Install the hub onto the spindle.
4. Install spindle nut and tighten to 103 ft.lbs (140Nm).
5. Knock on the edge of the spindle nut, so that it
can be clamped into the limit slot.
6. Install brake caliper using new bolts. (Apply

Loctite™ 243 to threads) Tighten bolts to 18 ft.lbs
(25Nm)
CAUTION: New bolts have a pre-applied locking
agent which is destroyed bolts upon removal. Always
use new brake caliper mounting bolts upon
assembly.
7. Install wheel and wheel nuts and tighten evenly in
a cross pattern to specified torque.

5.5 FRONT HUB BEARING REPLACEMENT

1. Remove outer snap ring.
2. From the back side, tap on the outer bearing race

with a drift punch in the reliefs as shown.
3. Drive bearing out evenly by tapping on outer race
only. Once bearing is at bottom of casting,
support casting on outer edges so bearing can be
removed.
4. Inspect bearing.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by hand,
inspect for rough spots, discoloration, or corrosion.
The bearings should turn smoothly and quietly, with
no detectable up and down movement and minimal
movement sideways between inner and outer race.
5. Inspect bearing housing for scratches, wear or
damage. Replace new if damaged.
5.6 FRONT DRIVE AXLE REMOVAL/INSPECTION

NOTE: The outer CV joint cannot be

disassembled or repaired, if damage or
faulty the drive axle assembly must be
replace.
1. Drive Axle/Outer CV Joint Assembly.
2. Boot Band “A”.
3. Outer Board Boot.
4. Boot Band “B”.
5. Stopper Ring
6. Plunging Joint
7. Circlip
8. Bearing
9. Stopper Ring
10. Inboard boot.
NOTE: Always order and replace 6 and 8 together.
REMOVAL
1. Place the vehicle on level ground and set the
parking brake, Block the rear wheels so the
vehicle will not roll in either direction.
2. Remove the front wheels, steering tie rods,
disconnect the A arm on the ball joint end as
described in this Chapter and Chapter 4.
CAUTION：To avoid damage to the front gearcase oil
seal, hold the front drive shaft horizontal and straight
out from the front differential during removal.
3. Hold the drive shaft straight out.
4. Place a tire lever between the inner CV joint and
the differential housing, with a small piece of
wood against the housing to help get "leverage"
and protect the casting. "pop" the in inner CV
joint out from the front gearcase.
INSPECTION
NOTE: The boots are subjected to a lot of abuse if
the vehicle is ridden in rough terrain. If the boots are
damage and left un-repaired, the driveshaft joints will
fair prematurely by allowing the joint to be exposed
to dirt, mud and moisture. This also allow the loss of
critical lubrication.
1. Check the rubber boots for wear, cuts or damage
and replace if necessary as described under the
Disassembly / Assembly procedure in this

chapter.
2. Move each end of the drive shaft in a circular
motion (and also a reciprocate for inner one) and
check the drive shaft joints for excessive wear or
play.
3. This inner CV joint (inboard pivot joint) can be
serviced if there is wear or play. The outer CV
joint (outboard pivot joint) cannot be serviced if
worn or damage and if necessary, the drive shaft
assembly must be replaced.
5.7 FRONT DRIVE AXLE INSTALLATION

CAUTION：To avoid damage to the front gearcase oil
seal and the strut oil seal, hold the front drive shaft
horizontal and straight into the strut during
installation.
1. Hold the drive shaft straight in from the front
differential.
2. Push the drive shaft straight into the front
differential and push it in all the way until it
bottoms out. If necessary, carefully tap on the
outer end of the drive shaft with a rubber mallet
or soft-faced mallet.
3. After the drive shaft is installed, pull the inner CV
joint a little to make sure the drive shaft stopper
ring has locked into the front differential side gear
groove.
4. Carefully install the outer CV joint (spindle) into
the strut，install the front hub and wheel.
5. Install the ball joint on the A arm, the steering tie
rods, the hubs and the wheels as described in
this Chapter and Chapter 4.
5.8 FRONT DRIVE AXLE DISASSEMBLY/ INSPECTION

INNER CV JOINT DISASSEMBLY
NOTE: The outer CV joint cannot be disassembled
or repaired, if damage or faulty the drive axle
assembly must be replace.
1. Open the clamps on both boot band ”A” and ”B”
on the inner CV joint, then remove boot band ”B”.

Discard the boot band, it cannot be reused.

2. Carefully slide the boot (A) onto the drive axle
and off the inboard joint.
3. Wipe out all of the molybdenum disulfide grease
within the inboard joint cavity.
4. Remove the stopper ring from the inboard joint.
5. Remove the inner CV joint.
6. Remove the circlip and slide off the bearing
assembly. Be careful not to drop any of the steel
balls from the bearing cage.
7. Slide the inner CV off the drive axle and discard
the boot band ”A”, it cannot be reused.
8. If the outboard boot requires replacement,
perform the following:
a. Open the clamps on both boot bands ”A”
and ”B” on the outer CV joint, then remove
boot band ”B”. Discard the boot band, it
cannot be reused.
b. Slide the outboard boot off the drive axle and
discard the boot band ”A”, it cannot be
reused.
9. Inspect the drive axle as described in this chapter.
INNER CV JOINT INSPECTION

1. Clean the bearing assembly in solvent and
thoroughly dry.
2. Inspect the steel balls, bearing case and the
bearing race for wear or damage.
3. Check for wear or damage to the inner splines of
the bearing race.
4. If necessary, disassembly the bearing assembly
for further inspection. Carefully remove the steel
balls from the bearing cage then remove the
bearing race from the bearing cage.
5. If any of the components of the bearing assembly
are damaged, replace the entire assembly as no
replacement parts are available.
6. Clean the inner CV joint in solvent and thoroughly
dry.
7. Inspect the interior of the inboard joint where the
steel balls ride. Check for wear or damage and
replace the joint if necessary.
8. Inspect the snap ring groove on the inboard joint
for wear or damage.

9. Inspect the splines on the inner CV joint for wear

or damage.
10. Check the stopper ring in the end of the inboard
joint. Make sure it seats in the groove correctly, if
damage the ring must be replaced. See right
picture.
11. Inspect the exterior of the inner CV joint for
cracks or damage, replace if necessary. Check
the movement of the joint for excessive play or
noise by moving the drive axle in a circular and
reciprocate direction.
12. Inspect the drive axle for bending, wear or damage.
13. Inspect the inner end splines, the outer end
splines and the front hub cotter pin hole for wear
or damage. If any of these areas are worn or
damaged, replace the drive axle.
Check the movement of the joint
NOTE: Inner CV joint must be replaced with the bearing as an assembly.
5.9 FRONT DRIVE AXLE ASSEMBLY

1. The rubber boots are not identical and must be
installed on the correct joint. The boots are
marked as follows:
a. Inner CV joint boot : “inner”,
b. Outer CV joint boot: “outer”.
2. If the outboard boot was removed, install a new
boot onto the drive axle at this time.
NOTE: Position the new boot bands with their tabs
facing toward the rear of the vehicle.
3. Install two new small boot bands onto the drive
axle.
4. Install the inboard boot and move the small boot
band onto the boot. Bend down the tab on the
boot band and secure the tab with the locking

clips and tap them with a plastic hammer. Make

sure they are locked in place.
5. If the bearing assembly was disassembled,
assemble the bearing as follows:
a. Position the bearing race and install the race
into the bearing case. Align the steel ball
receptacles in both parts.
b. Install the steel balls into their receptacles in
the bearing case.
c. Pack the bearing assembly with molybdenum
disulfide grease. This will help hold the steel
balls in place.
6. Position the bearing assembly with the small end
of the bearing going on first and install the
bearing onto the drive axle.
7. Push the bearing assembly on until it stops, then
install the circlip, Make sure the circlip seats
correctly in the drive axle groove.
8. Apply a liberal amount of molybdenum disulfide
grease to the bearing assembly. Work the grease
in between the balls, the race and the case.
Make sure all voids are filled with grease.
9. Apply a liberal amount of molybdenum disulfide
grease to the inner surfaces of the inboard joint.
10. Install the inboard joint over the bearing
assembly and install the stopper ring. Make sure
it is seated correctly in the inboard joint groove.
11. After the stopper ring is in place, fill the inboard
joint cavity behind the bearing assembly with
additional molybdenum disulfide grease.
12. Pack each boot with the following amounts of
molybdenum disulfide grease:
a. Inboard boot:35-55grams(1.2-1.9oz.).
b. Outboard boot:30-50grams(1.1-1.8oz.).
13. Move the inboard boot onto the inner CV joint.
14.Move the inboard joint on the drive axle.
NOTE: Position the new boot bands with their tabs
facing toward the rear of the vehicle .
14. Move the small boot band onto the boot. Bend
down the tab on the boot band and secure the
tab with the locking clips and tap them with a
plastic hammer. Make sure they are locked in
place.
15. Install the large boot bands onto each boot.

CAUTION: It is critical to avoid undue stress on the

rubber boots after the drive axle is installed and the
vehicle is run. Don’t twist the boot, and always set
the both ends in designed position.
16. Secure all large boot bands. Bend down the tab
on the boot band and secure the tab with the
locking clip and tap them with a plastic hammer.
Make sure they are locked in place.
17. If removed, install the stopper ring and make sure
it is seated correctly in the drive axle groove.
18. Apply molybdenum disulfide grease to the end
splines.
5.10 REAR HUB EXPLODED VIEW
5.11 RE AR HUB AND KNUCKLE REMOVAL/ INSPECTION

1. Elevate rear end and safely support machine
under main frame area.
C AUTIO N: Serious injury may result if machine
tips or falls. Be sure machine is secure before
beginning this service procedure. Wear eye
protection when removing bearings and seals.
2. Check bearings for side play by grasping the
tire/Wheel firmly and checking for movement.
Grasp the top and bottom of the tire. The tire
should rotate smoothly without binding or rough
spots.
3. Remove wheel nuts and wheel.

4. Remove the two brake caliper attaching bolts.

CAUTION: Do not hang the caliper by the brake line.
Use wire to hang the caliper to prevent possible
damage to the brake line.
5. Remove rear spindle nut, and washer.
6. Remove the upper and lower control arm bolts.
7. Slide the rear hub and knuckle from the rear drive
axle.
8. Inspect the rear hub and knuckle assembly by
hand for smoothness and side to side movement,
replace as needed.
5.12 RE AR HUB AND KNUCKLE INSTALL ATION

1. Start the rear hub and knuckle assembly onto the
drive shaft.
2. Align the bottom of knuckle and lower control arm.
Secure with the lower control arm bolt.
3. With the driveshaft placed in the knuckle, align
the knuckle with the top control arm. Secure with
the upper control arm bolt.
4. Torque the top and bottom A-arm bolts as shown

in the photo.
5. Install the washer and the new spindle nut.

6. Lower the vehicle. Torque the spindle nut to 103
ft.lbs. (140 Nm).
(24 Nm).
9. Install the wheel and wheel nuts. Torque wheel

nuts to 55 ft.lbs. (75 Nm).

5.13 RE AR DRIVE SHAFT REMOVAL

1. Repeat of the steps in the “REAR HUB AND
KNUCKLE REMOVAL” section.
2. Slide the rear drive axle out of the knuckle by
pulling the hub and knuckle assembly outward
and down.
3. Pull the rear drive axle straight out of the frame.

Use short sharp jerks to free the circlip from the
gearcase. The circlip holds the axle in the
gearcase.
4. Inspect the axle splines and CV boots for any
damage.
5.14 RE AR DRIVE SHAFT INSTALL ATION

1. Install a new circlip onto the rear drive shaft.
Apply Anti-Seize Compound onto the rear
driveshaft splines (both ends).
2. Reinstall the rear driveshaft into the rear

gearcase. Be sure the circlip is securely fit into
the rear gearcase. Use a rubber mallet to tap on
the outboard end of the driveshaft if necessary.

3. Slide the rear drive axle into the knuckle.
4. Lift knuckle into place and install bolt to upper

and lower control arm. Torque bolt to 45 ft.lbs (60
Nm).
5. Install the washer and the new spindle nut.
6. Lower the vehicle. Torque the spindle retaining
nut to 103 ft.lbs. (140 Nm).
(24 Nm)
9. Install the wheel and wheel nuts. Torque wheel
nuts to 55ft.lbs. (75 Nm).

5.15 RE AR GE ARCASE EXPLODED VIEW

REAR GEARCASE EXPLODED VIEW

1 Nut, Rear Output Shaft 1 25 Clutch Gear 1

2 Washer, Rear Output Shaft Nut 1 26 Bearing 6210 1
3 Coupler, Rear Axle 1 27 Bevel Gear -Driven 1
4 Bolt M8×50 4 28 Diff Case 1
5 Mount Bracket-Parking Braking 1 29 Hexagon Flange Bolt M10×1.25×16 8
6 Oil Seal 35×61×9 1 30 Bearing 110 1
7 Bearing 30205 1 31 O-Ring 151×3 1
8 Bevel Gear Bearing Housing 1 32 Adjusting Shim AR
9 O-Ring 69×3 1 33 Rear Axle Box Cover 1
10 Bearing Sleeve AR 34 Bolt M8×25 8
11 Adjusting Shim,Bevel Gear -Driving 1 35 Wearing Ring 2
12 Bearing 30206 1 36 Planetary Gear 2
13 Bevel Gear -Driving 1 37 Gear Shaft 1
14 Diff Solenoid 1 38 Pin 4×30 1
15 O-Ring 17×3 1 39 Side Gear Thrust-Washer 2
16 Oil Seal 30×50×13.5 2 40 Diff Side Gear 2
17 Vent Nozzle 1 41 Shift Return Spring 2
18 Clip 2 42 Shift Lever Spring 1
19 Vent Pipe 1 43 Shift Lever 1
20 Bolt M18×1.25 1 44 Shift Bar 1
21 Washer 18 1 45 Shift Yoke 1
22 Gear Case,Rear Axle 1 46 Shift Pin 1
23 Drain Plug 1 47 Rear gearcase 1
24 Washer 1 48 Breathing airbag 1
5.16 REAR GEARCASE DISASSEMBLY

Important: Before staring any operation

On the gearbox， make sure that never clean
the gearbox with a high pressure water jet.
The pinion gear assembly (A) is NOT
intended to be disassembled from the case,
as it requires special tooling in order to
properly reassemble. If there is any damage
to the pinion gear, bearings or case, the
assembly must be replaced. Pinion and ring
gear shimming information is NOT provided
due to manufacturing requirement.
1.remove the breathing airbag(NO.48).

→Fig 0 Fig 1
3.Remove the differential solenoid (NO.14)

from the gearcase cover if servicing the
solenoid, shift lever, shift lever spring, or shift
yoke. If none of these items are being
serviced. The solenoid can remain installed in
the gearcase cover. →Fig 1
Fig 0
2.Remove the oil drain plug (NO.23) and let the

oil drain from the gearbox.
Important: Clean the plug carefully.
Replace the sealing washer (NO.24) before it’s Fig 2
assembled. →Fig 1
4.Remove the Bolts M8×50 (NO.4), Remove
assembly (A). →Fig 3

Fig 5
7.Remove the shims from the differential
assembly. Be sure to keep the shims together
for reassembly. →Fig 6
Fig 3
5.Remove Bolts M8×25 (NO.34) that secure
the housing. →Fig 4
Fig 6
8.Inspect the bevel gear for chipped, worn, or
broken teeth.
Important: Do not disassemble the differential
assebly (B). Replace as an assembly if
Fig 4 damage or worn. →Fig 7
6.Remove the differential assembly (B) from the

housing.. →Fig 5

proceed to “Rear Gearcase Assembly.” →Fig 9
Fig 9
11.Loosen the lock shift pin (NO.46). →Fig 10
Fig 7
NOTE: The PINION GEAR ASSY (A) AND

THE DIFFERERNTIAL ASSEMBLY ( B)
MUST BE REPLACED
SIMULTANEOUSLY,NOT SEPARATELY.
9.Remove the clutch gear (NO.25) from the
gearcase cover. →Fig 8
Fig 10
12.Remove the pin from the gearcase cover.
→Fig 11
Fig 8
10.Inspect the shift lever (NO.43), shift level

spring (NO.42), shift return spring (NO.41), and
shift yoke (NO.45) for excessive wear or
damage. If disassembly is required proceed to
the next step. If no disassembly is required Fig 11

intend to be disassembled from the case,

13.Carefully remove the shift yoke assembly as it requires special tooling in order to
from the gearcase cover. →Fig 12 properly reassemble. If there is any
damage to the pinion gear, bearings or
case, the assembly must be replace.
→Fig14
Fig 12
2.Replace the Oil Seal 30×50×13.5(NO.16)
14.Inspect the shift lever (NO.43), shift level located in the main gearcase and gearcase
spring (NO.42), shift return spring (NO.41), cover
shift yoke(NO.45), and lock shift bar (NO.44), →Fig 15
Inspect the components for excessive wear or
damage and replace as needed. →Fig 13
Fig 15
3.Replace all worn components.

4.If previously removed; assembly the shaft
lever, shift lever spring, shift return springs,
shift yoke, and lock pin bushing. →Fig 13
5.Carefully install the shift yoke assembly into
the gearcase cover.→Fig 12
6.Install the lock shift (NO.46) pin and tighten.
Fig 13 →Fig 11
7.Install the clutch gear (NO.25) and the
original shims into the gearcase.→Fig 16
5.17 REAR GEARCASE ASSEMBLY

on the gearbox，to ensure that the surface of
all parts is clean.
1.NOTE: The pinion gear assembly is NOT

Fig 18
Fig 16 10.Install the pinion gear assembly. Torque
8.Install the differential assembly into the the bolts in a criss cross pattern to 25-30Nm.
carrier housing. →Fig 17 →Fig 19
Fig 17
9.Install the original shims(NO.32) and the Fig 19
new O-ring(NO.31) onto the Rear Axle Box 11.If previously removed, install the Diff
Cover(NO.33), then assemble the Rear Axle Solenoid (NO.14) into the carrier cover.
Box Cover(NO.33) and install the bolts that Torque solenoid to 40-55Nm. →Fig 20
secure the cover to the housing. Torque the
bolts in a criss cross pattern to 25-30Nm.
→Fig 18

Fig20
12.Mount the oil drain bolt (NO.23) and
washer (NO.24). Add 250 ± 25mL
oil(85W/90GL-4). Fig 21
Fig21
13.Assamble the breath airbag(NO.48).
→Fig 22
Fig22

5.18 FRONT GEARCASE EXPLODED VIEW

FRONT GEARCASE EXPLODED VIEW

1 Nut, Front Output Shaft 1 26 Bearing 16007 1

Washer, Front Output Shaft
2 1 27 O-Ring 141×2.4 1
Nut
3 O-Ring 1 28 Gear Case, Front Axle 1
4 Coupler, Front Axle 1 29 Bolt M8×25 6
5 Oil Seal 48×65×9 1 30 Screw M8×8 1
6 Bearing Retainer 1 31 Washer 8 1
7 Bearing 6007 2 32 Vent Nozzle 1
8 Bevel Gear -Driving 1 33 Clip 1
9 Needle Bearing 1 34 Vent Pipe 1
10 Oil Seal 24×38×8 2 35 O-Ring 81.2×1.9 1
11 Fill Plug 1 36 Gear Motor 1
12 O-Ring 30.5×3 1 37 Screw M8×20 4
13 Drain Bolt 1 38 Pin Shaft 1
14 Washer 10 1 39 Shift Fork 1
15 Front Axle Box Cover 1 40 Drive Gear 1
16 Adjusting Shim(61×48) as needed 41 Pin 5×25 1
17 Bevel Gear -Driven 1 42 Wearing Ring 2
18 Top Bracket,Differential Gear 1 43 Gear(Center), Differential 2
19 Bracket,Differential 1 44 Washer 1
20 Bolt M10×1.25×20 6 45 Shim 1
21 Bearing 61912 1 46 Driven Gear 1
22 Adjusting Shim(83×71) as needed 47 Gear Shaft 1
23 Drive Clutch 1 48 Front Axle 1
24 Drive Clutch Cover 1 49
25 Circlip 62 1 50

5.19 FRONT GEARCASE DISASSEMBLY

On the gearbox make sure GEAR MOTOR
(NO.36) is protected (if mounted). Never clean
the gearbox with a high pressure water jet.
→Fig 0.
Fig 2
3. Remove the O-RING (NO.3) .
→Fig 3.
Fig 0
1. Remove the DRAIN BOLT (NO.13) and let the
oil drain from the gearbox.
Important: Clean the plug carefully and
Replace WASHER 10 (NO.14) before
Its assembled. →Fig 1.
Fig 3
4. Remove the COUPLER (NO.4).

→Fig 4.
Fig 1
2. Remove the NUT (NO.1) and the washer
(NO.2).
→Fig 2
.
Fig 4

5. Remove the OIL SEAL (NO.5) and repalce

with a new seal.
→Fig 5.
Fig 5
6. Remove the four SCREW (NO.37). Fig 7
→Fig 6. 8. Remove the six bolts M8 X L28 （NO.29）.
→Fig 8.
Fig 8
Fig 6 9. Remove the GEAR CASE ASSY, FRONT
7. Remove the GEAR MOTOR (NO.36). AXLE (NO.28) and CASE COVER ASSY,
→Fig 7. FRONT AXLE (NO.15) .
→Fig 9.

Fig 9
Fig 11
10. Remove the DIFFERENTIAL GEAR ASSY 12. Remove the shims from the differential
A from the housing. assembly. Be sure to keep the shims
→Fig 10 together for reassembly.
→Fig 12.
Fig 12
12. Remove the SCREW (NO.30) and the

WASHER (NO.31).
→Fig 13.
Fig 10
11.Inspect the bevel gear for chipped, worn or
broken teeth.
NOTE: The DIFFERENTIAL GEAR ASSY (A)
is NOT intended to be disassembled , as
it requires special tooling in order to
properly reassemble. If there is any
damage to the gear, bearings or others,
the assembly must be repalced.
→Fig 11
Fig 13

13. Remove the PIN SHAFT (NO.38), SHIFT

FORK (NO.39).
→Fig 14
Fig 16
16．Remove the DRIVE CLUTCH COVER
Fig 14 (NO.24).
→Fig 17.
14．Remove the DRIVE CLUTCH (NO.23).
→Fig 15.
Fig 17
Fig 15
15．Inspect the bearing (NO.26). If the bearing 18．Remove the OIL SEAL (NO.5).
was damaged, remove the RETAINER (NO.25) →Fig 18.
first, and then remove the bearing (NO.26).
→Fig 16.

Fig 18
19．Remove the BEARING RETAINER (NO.6) Fig 20

with special tool. NOTE: The DIFFERENTIAL GEAR ASSY (A)
→Fig 19. AND THE DRIVE PINION GEAR B MUST BE
REPLACED SIMULTANEOUSLY,NOT
SEPARAT
5.20 FRONT GEARCASE ASSEMBLY

Note:Grease all seals and O-rings with all
season Grease upon assembly
1. Mount the drive clutch cover (NO.24).

→Fig 1
Fig 19
20. Remove the DRIVE PINION GEAR B.

→Fig 20.
Fig 1

2. Mount the retainer 62 (NO.25) .

→Fig 2.
Fig 4
5.Install the screw (NO.30) and washer (NO.29),
then mount the screw (NO.30) .
Fig 2 →Fig 5.
3. Mount the drive clutch (NO.23).

→Fig3.
Fig 5
6. Mount the adjust shim (NO.22).

Fig 3 →Fig 6.
4.Mount the pin shaft (NO.38) and the shift fork
(NO.39) .
→Fig 4.

Fig 8
9.Install a new OIL SEAL (NO.5)
Fig 6 .→Fig 9
7.Install the DIFFERENTIAL GEAR ASSY

A into the carrier housing.
→Fig 7
Fig 9
10.Mount the adjust shim (NO.16).
→Fig 10
Fig 7
8.Install the DRIVE PINION GEAR B and
install the BEARING RETAINER (NO.6) with
special tool
→Fig 8.

Fig 10
11.Assemble the gearcase halves and install
the bolts (NO.29) that secure the cover to the
housing. Torque the bolts in a criss cross
pattern to 20~25Nm. →Fig 11
Fig 12
13. Mount the four screws (NO.37) .
→Fig 13.
Fig 11
12. Mount the gear motor A.

Important: Before assemble the gear motor
(NO.36), make sure that the shift fork (NO.39) is
in their correct position as shown.
→Fig 12.
Fig 13

14. Mount the coupler (NO.4) .

→Fig 14
Fig 16
17.Add 200-250mL oil(85W/90GL-4).
Fig 14
15. Mount the O-ring(NO.3).

→Fig 15
Fig 15
16. Apply some Loctite 263 thread locker on
screw thread, mount the nut(NO.3), tighten it
to a torque of 50~60Nm.
→Fig 16.

CHAPTER 5 FINAL DRIVE T-Boss550 SERVICE MANUAL18.0
NOTES

CHAPTER 6 BRAKES T-Boss 550 SERVICE MANUAL20.0
CHAPTER 6 BRAKES
WARNING
have almost same appearance. Always refer to Parts Manual of eachUTV model for spare parts
information and service.
NOTE: Also See Chapter 2 for Maintenance Information.
6.1 SPECIFICATIONS
6.2 TORQUE
6.3 BRAKE SYSTEM SERVICE NOTES
6.4 BURNISHING PROCEDURE
6.5 BRAKE BLEEDING-FLUID CHANGE
6.6 PARKING BRAKE AND BRAKE LINE INSPECTION
6.7 PARKING BRAKE ADJUSTMENT
6.8 PARKING BRAKE REAR CALIPER REMOVAL/INSTALL
6.9 FRONT PAD INSPECTION / REMOVAL / REPLACEMENT
6.10 FRONT DISC INSPECTION / REMOVAL / REPLACEMENT
6.11 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION
6.12 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION
6.13 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION
6.14 REAR BRAKE DISC INSPECTION / REMOVAL / REPLACEMENT
CHAPTER 7 BRAKES PAGE. 7- 1

6.1 SPECIFICATIONS
Front Brake Caliper
Item Standard Service Limit
Brake Pad Friction material
0.157"/ 5.5mm 0.04"/ 1mm
Thickness
Brake Disc Thickness 0.150- 0.164"/3.810- 4.166mm 0.140"/ 3.556mm
Brake Disc Thickness Variance
- 0.002 "/ .051m m
Between Measurements
Brake Disc Runout - 0.005 "/ .127mm
Rear Brake Caliper
Item Standard Service Limit
Brake Pad hydraulic 0.157"/ 5.5mm
Friction Hydraulic with
0.236"/ 6mm 0.04"/ 1mm
material mechanics park
Thickness mechanics park 0.197"/ 5mm
Brake Disc Thickness 0.177-0.187"/4.496-4.750m m 0.167"/4.242mm
Brake Disc Thickness
Variance - 0.002 "/ 0.051mm
Between Measurements
Brake Disc Run out - 0.005 "/ 0.127mm
6.2 TORQUE
Torque Torque
Item
(ft. lbs. except where noted*) (Nm )
Front Caliper Mounting Bolts 18.0 25
Rear Caliper Mounting Bolts 18.0 25
Front Brake Disc 18.0 25
Rear Brake Disc 18.0 25
Park Brake Mouting Bolts 33 45
Banjo Bolt 15.0 21
6.3 BRAKE SYSTEM SERVICE NOTES

 It is strongly recommended always change the caliper and (or) the master cylinder as an
assembly. The parts inside maybe not interchangeable due to different brake manufactures
and (or) different brake type.
 Do not over – fill the master cylinder fluid reservoir.
 Make sure the brake lever and pedal returns freely and completely.

 Check and adjust master cylinder reservoir fluid level after pad service.
 Make sure atmospheric vent on reservoir is unobstructed.
 Adjust foot brake after pad service.
 Test for brake drag after any brake system service and investigate cause if brake drag is
evident.
 Make sure caliper moves freely on guide pins (where applicable) .
 Inspect caliper piston seals for foreign material that could prevent caliper pistons from
returning freely.
 Perform a brake burnishing procedure after install new pads to maximize service life.
 DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use
only approved brake cleaning products.
6.4 BURNISHING PROCEDURE

Brake pads (both hydraulic and mechanical) must be burnished to achieve full braking
effectiveness. Braking distance will be extended until brake pads are properly burnished. To
properly burnish the brake pads, use the following procedure.
1. Choose an area large enough to safely accelerate the CUV to 50 km/h (30 mph ) and to
brake to a stop.
2. Using hi gear, accelerate to 50 km/h (30 mph); then compress brake lever (pedal) to
decelerate to 0-8km/h (5 mph).
3. Repeat procedure on each brake system 20 times until brake pads are burnished.
4. Adjust the mechanical parking brake (if necessary).)
5. Verify that the brake light illuminates when the hand lever is compressed or the brake pedal
is depressed.
Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.
Brake loss can result in severe injury.
6.5 BRAKE BLEEDING-FLUID CHANGE

NOTE: When bleeding the brakes or replacing the fluid always start with the caliper farthest
from the master cylinder.
CAUTION:
Always wear safety glasses.
CAUTION:
Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the CUV.

This procedure should be used to change fluid or bleed

brakes during regular maintenance.
1. Clean reservoir cover thoroughly.
2. Remove cover from reservoir.
3. If changing fluid, remove old fluid from reservoir

with a brake fluid pump or similar tool.
4. Add brake fluid up to the indicated MAX level on
the reservoir.
DOT 3 Brake Fluid
5. Begin bleeding procedure with the caliper that is
farthest from the master cylinder. Install a box
end wrench on the caliper bleeder screw. Attach
a clean, clear hose to the fitting and place the
other end in a clean container. Be sure the hose
fits tightly on the fitting.
6. Slowly pump foot pedal until pressure builds and
holds.
7. Hold brake pedal on to maintain pedal pressure,
and open bleeder screw. Close bleeder screw
and release foot pedal.
NOTE: Do not release foot pedal before bleeder
screw is tight or air may be drawn into master
cylinder.
8. Repeat procedure until clean fluid appears in
bleeder hose and al air has been purged. Add
fluid as necessary to maintain level in reservoir.
CAUTION:
Maintain at least 1/2 "( 13mm) of brake fluid in the
reservoir to prevent air from entering the master
cylinder.
9. Tighten bleeder screw securely and remove
bleeder hose.
10. Repeat procedure steps 5- 9 for the remaining

calipers.
11. Add brake fluid to MAX level inside reservoir.
Master Cylinder Fluid Level
Between the MIN line and the MAX line of
reservoir.
12. Install master cylinder reservoir cover.
13. Field test machine at low speed before putting
into service. Check for proper braking action and
pedal reserve. With pedal firmly applied, pedal
reserve should be no less than 1/2 " (13mm ).
14. Check brake system for fluid leaks and inspect all
hoses and lines for wear or abrasion. Replace hose
if wear or abrasion is found.
6.6 PARKING BRAKE AND BRAKE LINE INSPECTION

1. Inspect the spring on the parking brake lever
assembly.

2. Inspect the parking brake cable at the parking

brake lever assembly on the brake caliper.
3. Inspect the brake lines and brake line

connections for possible leaks or loose lines.
6.7 PARKING BRAKE ADJUSTMENT

Parking Brake Inspection
1. Push the parking brake up with your hand.
2. After 2 to 4 clicks of lever travel, the vehicle
should not roll while parked.
3. If the vehicle moves, adjustment is necessary.
4. Adjust the parking brake where the cable
attaches to the lever assembly on the rear brake
caliper.
Parking Brake Adjustment

1. Place the vehicle in neutral on a flat level surface.
2. Carefully lift the rear of the vehicle off the ground
and stabilize on jack stands.
3. Loosen the jam nut (A) on the rear caliper
adjustment bolt (B).
4. Tighten the adjustment bolt (B) until the rear tire
will not roate.
5. Back the adjustment bolt (B) out 1/4 turn.
6. Tighten the jam nut (A) while holding the
adjustment nut (B) in place.

6.8 PARKING BRAKE REAR CALIPER REMOVAL / INSTALL

Park Brake Caliper Disassembly / Pad Inspection
NOTE: Do not get oil, grease, or fluid on the park
brake pads. Damage to the pads may cause the
pads to function improperly.
1. Loosen the two brake caliper bolts in equal
increments. Remove the bolts from the bracket
and lift park brake assembly out.
2. Measure the thickness of the caliper parking

brake pads. Replace pads if worn beyond the
service limit.
Service Limit 0.3/64"(1 mm)
Park Brake Caliper Installation

1. Install the park brake assembly into place.
Tighten the two bolts in increments for proper
installation.
2. Torque the two bolts to 33ft.lbs. (45 Nm).

3. Test the park brake for proper function.
6.9 FRONT PAD REMOVAL / INSPECTION / INSTALLATION

NOTE: The brake pads should be replaced as a set.
REMOVAL
1. Elevate and support front of CUV safely.

CAUTION:
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur if machine tips or
falls.
2. Remove the front wheel.
3. Remove the two caliper bolts and caliper from

mounting bracket.
4. Push caliper piston into caliper bore slowly using

a C-clamp or locking pliers with pads installed.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
5. Push mounting bracket inward and slip outer
brake pad past edge. Remove inner pad.
INSPECTION
Measure the thickness of the pad friction material.
Replace pads if worn beyond the service limit.

INSTALLATION
1. Lubricate mounting bracket pins with a light film
of All Season Grease, and install rubber dust
boots.
2. Compress mounting bracket and make sure dust
boots are fully seated. Install pads with friction
material facing each other. Be sure pads and disc
are free of dirt or grease.
3. Install caliper on hub strut, and torque mounting
bolts.
Front Caliper Mounting Bolts
Torque 18 ft. lbs. (25 Nm )
4. Slowly pump the brake lever until pressure has
been built up. Maintain at least 1/2 "(13 mm) of
brake fluid in the reservoir to prevent air from
entering the brake system.
5. Install the adjuster screw and turn clockwise until
stationary pad contacts disc, then back off 1/2
turn (counter clockwise).
6. Be sure fluid level in reservoir is up to MAX line
inside reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
7. Install wheels and torque wheel nuts.
8. It is recommended that a burnishing procedure
be performed after installation of new brake pads
to extend service life and reduce noise. Start
machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Repeat
procedure 10 times.
6.10 FRONT DISC INSPECTION / REMOVAL / REPLACEMENT

INSPECTION
1. Visually inspect the brake disc for nicks,
scratches, or damage.
2. Measure the disc thickness at 8 different points
around the pad contact surface using a 0-1"
micrometer and a dial indicator. Replace disc if
worn beyond service limit.
New 0.150-0.164" (3.810 - 4.166 mm)
Service Limit 0.140"（3.556 mm）


Service Limit 0.002 " (0.051 mm)
difference between measurements
3. Mount dial indicator as shown to measure disc
runout on the dial indicator. Replace the disc if
runout exceeds specifications.
Brake Disc Runout
Service Limit 0.005" (0.127 mm)
REMOVAL/ REPLACEMENT
1. Removal caliper and hub. Apply heat to the hub
in the area of the brake disc mounting bolts to
soften the bolt locking agent.
2. Remove bolts and disc.
3. Clean mating surface of disc and hub.
4. Install new disc on hub and tighten to specified.
CAUTION:
Always use new brake disc mounting bolts.
Front Brake Disc Mounting Bolt Torque :
18 ft. lbs. (25 Nm )
6.11 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION
CAUTION:
The caliper is a non-serviceable component; it must
be replaced as an assembly.
NOTE: If any special service needed, contact the

CUV manufacture via the agent for the parts and
special instruction.
REMOVAL
1. Remove wheel, remove caliper from the strut.
2. Loosen and remove brake hose to caliper. Place
a container under caliper to catch fluid draining.

INSPECTION
Inspect caliper body for nicks, scratches or worn.
Replace caliper as an assembly if any problem
exists.
INSTALLATION
1. Install caliper on hub strut, Apply Loctite™ 243 to
screw threads and Install new bolts.
Front Caliper Mounting Bolt Torque
18 ft. lbs. (25 Nm )
2. Install brake hose and tighten to specified
torque.
Banjo Bolt Torque: 15 ft. lbs. (21 Nm)
NOTE: If new brake pads are installed, it is
recommended that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise. Start machine
and slowly increase speed to 30 mph. Gradually
apply brakes to stop machine. Repeat procedure 10
times.
6.12 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION

NOTE: The brake pads should be replaced as a set.
REMOVAL
1. Elevate and support rear of CUV safely.
CAUTION:
falls.
2. Remove the rear wheel.

3. Remove the two caliper bolts and lift caliper off of
disc.
NOTE: When removing caliper, be careful not to
damage brake line. Support caliper so as not to kink
or bend brake line.
4. Push caliper piston into caliper bore slowly using
a C-clamp or locking pliers with pads installed.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.

Remove excess fluid from reservoir as required.

5. Remove the brake pads.
6. Clean the caliper with brake cleaner or alcohol.
INSPECTION
Measure the thickness of the pad friction material.
Replace pads if worn beyond the service limit.
INSTALLATION
1. Install new pads in caliper body.
2. Install caliper and torque mounting bolts.
Brake Caliper Torque: 18 ft. lbs. (25 Nm )
3. Turn adjuster screw back in finger tight using a
hex wrench.
4. Slowly pump the brake lever until pressure has
been built up. Maintain at least 1/2 "(13 mm) of
brake fluid in the reservoir to prevent air from
entering the brake system.
5. Install wheels, burnishing procedure should be performed.
6.13 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION
CAUTION:
The caliper is a non-serviceable Component; it must
be replaced as an assembly.
NOTE: If any special service needed, contact the
CUV manufacture via the agent for the parts and
special instruction.
CAUTION:
falls.
1. Safely support the rear of the machine.
2. Use a wrench to remove the brake line. Place a
container to catch brake fluid draining from brake

lines.
3. After the fluid has drained into the container,
remove the caliper mounting bolts and remove
caliper.
4. Remove brake pad as described above.
5. Inspect surface of caliper for nicks, scratches or
damage and replace if necessary.
6. Install brake pads in caliper body with friction
material facing each other, with the spacer
between the pads. Install retaining pin through
outer pad, pad spacer and inner pad.
7. Install caliper and torque mounting bolts to 18
ft.lbs. (25 Nm).
8. Install brake hose and tighten to specified
torque.
Banjo Bolt Torque: 15 ft. lbs. (21 Nm)
9. Bleed.
10. Field test unit for proper braking action before
putting into service. Inspect for fluid leaks and
firm brakes. Make sure the brake is not dragging
when lever is released. If the brake drags,
recheck assembly and installation.
11. Install the rear wheel and wheel nuts. Carefully
lower the vehicle.
NOTE: If new brake pads are installed, it is
recommended that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise.
6.14 REAR BRAKE DISC INSPECTION / REMOVAL / REPLACEMENT

INSPECTION
1. Visually inspect the brake disc for nicks,
scratches, or damage.
2. Measure the disc thickness at 8 different points
around the pad contact surface using a 0-1"
micrometer and a dial indicator. Replace disc if
worn beyond service limit.
New 0.177-0.187" (4.496 - 4.750 mm)
Service Limit 0.167" / 4.242 mm
Service Limit 0.002 " (0.051 mm)

difference between measurements

3. Mount dial indicator as shown to measure disc
runout on the dial indicator. Replace the disc if
runout exceeds specifications.
Brake Disc Runout
Service Limit 0.005" (0.127 mm)
REMOVAL/ REPLACEMENT
1. Removal wheel/ hub and caliper.
2. Remove bolts and disc from the flange.
3. Clean mating surface of disc and hub.
4. Install new disc on flange.
Tighten to specified.
Rear Brake Disc Mounting Bolt Torque :
18 ft. lbs. (25 Nm )
CAUTION:
Always use new brake disc mounting bolts.

NOTES

CHAPTER 7 ELECTRICAL T-Boss550 SERVICE MANUAL 20.0
CHAPTER 7 ELECTRICAL
7.1 PARTS INSPECTION AND SERVICE
7.2 BATTERY
7.3 IGNITION SYSTEM
7.4 CHARGING SYSTEM
7.5 ELECTRICS STARTING SYSTEM
7.6 COOLING SYSTEM
7.7 LIGHTING SYSTEM
7.8 GEAR SHIFT SWITCH TEST
7.9 SPEEDOMETER SYSTEM
7.10 SWITCHES
7.11 FUEL GAUGE/ FUEL LEVEL SENSOR
7.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT
7.13 WIRING DIAGRAM
CHAPTER 7 ELECTRICAL PAGE.7- 1

7.1 PARTS INSPECTION AND SERVICE
HEADLIGHT LAMP REPLACEMENT
1. Disassemble the lamp from the Head Light Cover.

2. Pull the cable plug off the conducting
strip in the socket, remove the clip ①
before dismounting the bulb.
3. Fit a new bulb into the socket, sitting
properly in the three slots, install the
clip as shown in the fig. and connect
the cable plug to the conducting strip.
4. Use bulb 12V 35W/35W.
HEADLIGHT ADJUSTMENT
1. The headlight beam can be adjusted vertically (all models) and horizontally.
2. Place the vehicle on a level surface with the headlight approximately 25’(7.6m) from a wall.
3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at
the same height.
4. Start the engine and turn the headlight switch to high beam.
5. Observe headlight aim. The most intense part of the headlight beam should be aimed 2’ (51mm)
below the mark placed on the wall in step 2. NOTE : Riding weight must be included on the
seat.
6. Loosen but not remove pivot bolt/ screw and adjust beam to desired position.
7. Tighten nut and bolt / screw.

7.2 BATTERY
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with
skin, eyes or clothing Antidote:
External: Flush with water.
lnternal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always shield eyes when working near batteries.
KEER OUT OF REACH OF CHILDREN
WARNING: The gases given off by a battery are explosive. Any spark or open flame near a battery
can cause an explosion which will spray battery acid on anyone close to it. If battery acid gets on
anyone, wash the affected area with large quantities of cool water and seek immediate medical
attention.
Battery Maintenance
1. If the vehicle will not be used for more than one month, remove the battery, fully charge it,
and then place it in a cool, dry place. If the battery will be stored for more than two months,
check it at least once a month and fully charge it if necessar y.
CAUTION
To charge this battery, a specified battery charger is required. Using a conventional battery
charger will damage the battery.
2. Ensure to the cables are properly routed when installing the battery.
BATTERY TESTING
Whenever a service complaint is related to either the starting or charging systems, the battery
should be checked first.
Following are three tests which can easily be made on a battery to determine its condition: OCV
Test, Specific Gravity Test and Load Test.
MF (Maintenance Free) battery does not require the Specific Gravity Test and Refill
Open Circuit Voltage Test

Battery voltage should be checked with a digital multitester. Readings of 12.6 or less require
further battery testing and charging.
NOTE: Lead acid batteries should be kept at or near a full charge as possible.

Load test
CAUTION: Remove spark plug high tension leads and connect securely to engine ground before
proceeding.
NOTE: This test can only be performed on machines with electric starters. This test cannot be
performed with an engine or starting system that is not working properly.
A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still
may not have the storage capacity necessary to properly function in the electrical system. For this
reason, a battery capacity or load test should be conducted whenever poor battery performance is
encountered. To perform this test, hook a multitester to the battery in the same manner as was
done in the OCV test. The reading should be 12.6 volts or greater. Engage the electric starter and
view the registered battery voltage while cranking the engine. Continue the test for 15 seconds.
During this cranking period, the observed voltage should not drop below 9.5 volts. If the beginning
voltage is 12.6 or higher and the cranking voltage drops below 9.5 volts during the test, replace the
battery.

7.3 IGNITION SYSTEM

IGNITION SYSTEM TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
 Spark plug gap incorrect
 Fouled spark plug
 Faulty spark plug cap or poor connection to high tension lead
 Related wiring loose, disconnected, shorted, or corroded
Engine stop switch or ignition switch faulty
 Terminal board or connections wet, corroded
 Poor ignition coil ground (e.g. coil mount loose or corroded)
 Faulty stator (measure resistance of all ignition related windings)
Incorrect wiring (inspect color coding in connectors etc. )
 Faulty ignition coil winding (measure resistance of primary and secondary)
 Worn magneto (RH) end crankshaft bearings
 Sheared flywheel key
 Flywheel loose or damaged
 Trigger coil air gap too wide (where applicable) should be 0.030-0 .050" (0. 75-1.25 mm)
 Excessive crankshaft run out on magneto (RH) end should not exceed 0.005"
(0.13mm)
CIRCUIT DIAGRAM

IF THE IGNITION SYSTEM FAILS TO OPERATE
Procedure
Check:
1. Fuse (Main) 6. Ignition coil
2. Battery 7.Pickup coil resistance
3. Spark plug 8.Main switch
4. lgnition spark gap 9.Wiring connection
5. Spark plug cap resistance
(entire ignition system)
1.Fuse NO CONTINUITY
Check switches
Replace the fuse.
CONTINUITY
2. Battery INCORRECT
 Check the battery condition.  Clean battery terminals.
Refer to "BATTERY  Recharge or replace the battery.
INSPECTION"
CORRECT Standard spark plug: DPR7EA 9 /
NGK
3.Spark plug
OUT OF SPECIFICATION
 Check the spark plug
condition.
 Check the spark plug
type. Repair or replace the spark plug
 Check the spark plug gap.
Spark plug gap: 0.8 ～

0.9mm

4.lgnition spark gap

 Disconnect the spark plug cap from the
spark plug
Connect the ignition tester 1 as shown.
2 Spark plug
Turn the main switch to "ON".
Check the ignition spark gap .
Check the spark by pushing the
MEETS SPECIFICATION
starter switch, and increase the spark
gap until a misfire occurs.
The ignition system is not faulty.
Minimum spark gap:
6mm (0.24 in)
OUT OF
SPECIFICATION Tester (+) lead →
OR Spark plug side
NO SPARK Tester (—) lead→
5.Spark plug cap resistance High tension cord side 
Remover the spark plug cap.
Connect the pocket tester (ΩX1 k) to
the spark plug cap.
NOTE:
 When removing the spark plug cap.
do not pull the spark plug cap from
high tension cord.
Remove→Turning
counterclockwise
Connect→Turning clockwise.
Check the high tension cord
when connecting the spark
plug cap.
 When connecting the spark plug cap,
cut the high tension cord about 5mm.
Spark plug cap
resistance:
Replace the spark plug cap
10KΩ(20 ℃)
CORRECT

* Tester (+) lead

B/Y Terminal
Tester ( -) lead Green
6. Ignition coil resistance Terminal
Disconnect the ignition coil
connector from the wire
harness.
Connect the pocket tester
(1) to the ignition coil.
 Check if the primary coil
has the specified resistance.
Primary coil resistance:

0.5-1.0Ω (20 ℃)
Tester (+) lead
Spark plug lead
Tester (— ) lead
Green Terminal

(Ω×1k ) to the ignition coil.
Check the secondary has the
specified resistance
Secondary coil resistance: OUT OF SPECIFICATION
12kΩ ±2 kΩ (20℃)
BOTH MEET
SPECIFICATION
Replace the ignition coil.
*

7. Pickup coil resistance

 Disconnect the pickup coil coupler
from the wire harness.
Connect the pocket tester (Ω 100) to
the pickup coil coupler.
Tester (+) lead →

BI/Y Terminal 
Tester (- ) lead→
B/R Terminal 
 Check the pickup coil has the
specified resistance.
Replace the pickup coil.
Primary coil resistance:

115 -145Ω (20℃)
MEETS
SPECIFICATION
NO CONTINUITY
8.Main switch
CHECK SWITCHES
Replace the main switch
CONTINIUTY
NO CONTINUITY
9.Wiring connection
Check the connection of the
entire ignition system
Refer to “CIRCUIT DIAGRAM”.
Correct
CORRECT
Replace the igniter unit.

7.4 CHARGING SYSTEM
CHARGING SYSTEM CIRCUIT DIAGRAM
CURRENT DRAW - KEY OFF
CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running.
Damage will occur to light bulbs and speed limiter.
Connect an ammeter in series with the negative battery cable. Check for current draw with the key off,
if the draw is excessive, loads should be disconnected from the system one by one until the draw is
eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate
the draw.
Current draw key off:

Maximum of 0.01DCA(10mA)

CHARGING SYSTEM
Procedure
Check:
1. Fuse (Main) 4.Stator coil resistance
2. Battery 5.Wiring system (entire charging system)
3.Charging voltage
1. fuse NO CONTINUITY
Replace the fuse

2. Battery
Check the battery condition. INCORRECT

Refer to "BATTERY INSPECTION"
Clean battery terminals

Recharge or replace the battery
3.Charging voltage
Connect the engine tachometer
to the spark plug lead.
(DC20V) to the battery
Test (+) lead→
Battery (+) terminal 
Tester (-) lead→
Battery (-) terminal 
Measure the battery terminal
voltage.
start the engine and accelerate to
about 5,000rpm
check the terminal voltage
Measured voltage-terminal MEETS SPECITICATION
Voltage:
0.2-2.5V up
NOTE: Use a fully changed battery.
The charging circuit is not faulty

Replace the battery
OUT OF SPECICATION

4. Starter coil resistance
Remove the A.C. magneto coupler from
wire harness
Connect the pocket tester (ΩX1) to
the stator coil
Tester (+) lead –yellow terminal
Tester (-) lead –yellow terminal OUT OF SPECITICATION
Measure the stator coil resistance
Stator coil resistance 0.5-0.8Ω（20℃）
Replace the stator coil
MEETS SPECIFICATION
5.Wiring connection
check the entire charging system for
connections
Refer to “CIRCUIT DIAGRAM” POOR CONNECTION
correct
CORRECT
Replace the rectifier/regulator

7.5 ELECTRICS STARTING SYSTEM

DI AG R AM
TROUBLESHOOTING
THE STARTER MOTOR OPERATES WHEN THE BRAKE SWITCH IS ON
IF THE STARTER MOTOR FAILS TO OPERATE
CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 13

Procedure
Check:
1. Fuse (Main) 5. main switch
2. Battery 6. brake switch
3. starter motor 7. starter switch
4. starter relay 8. wiring connection (entire starting system)
1. fuse
refer to “CHECKING SWITCHES” NO CONTINUITY
section
Replace the fuse
2. Battery

3. Starter motor DOES NOT MOVE

Connect the battery positive terminal
and starter motor cable using a jumper
lead.
Check the starter motor operation
Repair or replace the starter

motor
WARNING
4.Starter relay
A wire used as a jumper lead
Disconnect the relay unit coupler from must have the equivalent
the wire harness. capacity as that of the battery
Connect the pocket tester (Ωx1) and lead or more, otherwise it
battery (12V) to the relay unit coupler may burn.
terminals. This check is likely to
Battery (+) lead→ produce sparks, so be sure
Green/Yellow terminal  that no flammable gas or fluid
Battery (-) lead→ is in the vicinity
Yellow/Red terminal 
Check the starter relay for continuity.

Test (+) lead →  terminal
Test (-) lead →  terminal
CONTINUITY
Replace the starter replay
4. Main switch
CHECK SWITCHES NO CONTINUITY

1. Brake switch
CHECKING SWITCHES
NO CONTINUITY
Replace the brake switch
7. Starter switch
CHECKING SWITCHES NO CONTINUITY
Replace the handlebar switch
8. Wiring connection
POOR CONNECTION
Check the connections of the entire
starting system.
Refer to “CIRCUIT DIAGRAM
Correct

7.6 COOLING SYSTEM
IF THE FAN MOTOR FAILS TO TURN

Procedure
Check:
1. Fuse (Main, Fan) 4. Fan motor (inspection)
2. Battery 5. Thermo switch
3. Main switch 6. Relay
7.Wiring connection (entire cooling
system)
1.Fuse
Replace the fuse

2. Battery

section

3 Main switch
4.1 Fan motor(inspection 1)

Connect the battery to the fan
motor. DOES NOT MOVE
Battery (+) lead→Green/Blue
terminal 
Battery (-) lead→Green ground 
Check the fan motor operation
Replace fan motor
1.2 Fan motor (inspection 2)

Turn the main switch to off.
Remove the thermo switch lead DOES NOT MOVE
from thermo switch.
Connect jumper lead to thermo
switch leads.
Turn the main switch to on
The wiring circuit from battery to fan

motor is faulty. Repair

5. Thermo switch
Remove the thermo switch from the
radiator.
Connect the pocket tester (ΩX1) to
the thermo switch.
Immerse the thermo switch in the
water 
Check the thermo switch for
continuity.
NOTE:
Measure temperatures while
heating the coolant with the
temperature gauge
WARNING
Handle the thermo switch with
special care.
Never subject it to strong shocks or
allow it to be dropped. Should it be
dropped, it must be replaced.
Do not touch the thermo switch to
the bottom of the heated vessel.
88±3℃Thermo switch “ON” OUT OF SPECIFICATION

80±3 ℃Thermo switch “OFF”
Replace the thermo switch
6.Relay
Disconnect the starting circuit
cut-off relay coupler from the
wireharness.
Connect the pocket tester (Ωx1)
and battery (12V) to the starting
circuit cut-off relay coupler terminals.
Battery (+) lead→ terminal 
Battery (-) lead→ terminal 
Check the starting circuit cut-off
relay for continuity.
Test (+) lead →  terminal
Test (-) lead →  terminal

7.Wring connection
UPPER CONNECTION
Check the connection of the entire
cooling system.
Refer to “CIRCUIT DIAGRAM”
Correct
IF THE HEAT ALARM UNIT WORKING

When the main switch is turned on, the temperature of the engine begins to go up. As it
comes to 88±3℃ the thermostat is connected and the fan starts to work, cooling the
coolant, if the thermostat or the fan, fails to work; the coolant temperature will keep rising.
The heat alarm unit operates the moment the temperature reaches 115±5℃and the signal
flashing. Stop the engine now to have the circuit fixed.
Procedure
Check:
1 .Fuse(Main, Fan) 4. Thermo unit
2. Battery 5. Voltage
3. Main switch 6. Wiring connection (entire cooling system)
1. fuse
Replace the fuse

2. Battery

3.Main switch

Handle the thermo unit with

4.Thermo unit
special care.
Drain the coolant and remove the
Never subject it to strong
thermo unit from the cylinder head.
shocks or allow it to be
Immerse the thermo unit in the
dropped.
coolant .
Should it be dropped, it must be
Thermometer.
replaced.
Do not touch the thermo unit to
the bottom of the heated vessel.
Coolant Resistance
temperature
47.5~56.8Ω
80℃
100℃ 26.2~29.3Ω
Replace the thermo unit
MEETS SPECIFICATION
8. Voltage
Connect the pocket tester (DC20V) to
the Temperature gauge couple.
Tester (+) lead→Green/Blue terminal
Tester (-) lead→Green ground
Turn the main switch to on.
Check for voltage (12V) on the OUT OF SPECIFICATION
temperature gauge lead.
The wiring circuit from main

switch to temperature gauge
is faulty. Repair.
8. Wiring connection check the POOR CONNECTION

connections of the entire cooling
system.
Refer to “CIRCUIT DIAGRAM”
CORRECT
Replace the temperature gauge

7.7 LIGHTING SYSTEM

TROUBLESHOOTING
Procedure
Check:
1. Fuse (Main) 4.High/low beam switch and turn switch
2. Battery 5.Flasher relay and relay
3. Main switch 6. Wiring connection (entire lighting
system)
1.fuse
refer to “CHECKING SWITCHES” NO CONTINUITY
section
Replace the fuse

2. Battery
Refer to “BATTERY INSPECTION” section

3. Main switch
4.High/low beam switch and turn switch

Replace the switch
5. Flasher relay and relay

NO CONTINUITY
Check flasher relay and relay
Check relay refer to “7.6 COOLING
SYSTEM””6.Relay”
Replace the relay

1. Wiring connection
POOR CONNECTIONS
Check the connection of the entire
lighting system
correct
2. check the condition of each of the

lighting system’s circuits
Refer to “LIGHTING SYSTEM CHECK”
LIGHT SYSTEM CHECK

1. If the high/low beam light and direction indicator fail to come on
NO CONTINUITY
1.Blub and bulb socket
CHECK
Replace the bulb and/ or bulb

socket
2. Voltage
Connect the pocket tester (DC20V) to
the high/low beam light and direction
indicator light couplers.
A When the High/low beam switch is on

high beam
High beam light:
Tester (+) lead →Blue lead
Tester negative (-) lead →Green lead
B When the High/low beam switch on low
beam
Low beam light:
Tester (+) lead →White lead
C When the High/low beam switch on
position light
Front/rear position light:
Tester (+) lead →Black lead
D When the turn switch on turn right OUT OF SPECIFICATION
position
Front/rear turn right light(LED)
Tester (+) lead →Light Blue lead
Tester negative (-) lead →Green lead The wiring circuit from the main
E When the turn switch on turn left switch to bulb socket connector
position is faulty. Repair
Front/rear turn left light(LED)

Tester (+) lead →Orange lead
Check for voltage (12V) on the lead at

bulb socket connectors
This circuit is not faulty

Replace the bulb.
If the light is LED,replace the light directly
2. the taillight fails to come on
1. Voltage
Connect the pocket tester (DC20V) to
the taillight couplers
Tester (+) lead→
Green/Yellow terminal
Tester (-) lead→
Green terminal
Turn the main switch to on.
Step on brake. OUT OF SPECIFICATION
Check the voltage (12V) on the taillight
couplers
The wiring circuit from main

switch to light connector of
faulty. Repair
This circuit is not faulty

Replace the light.

7.8 GEAR SHIFT SWITCH TEST

DI AG R AM

Switch table

7.9 SPEEDMETER SYSTEM
OPERATION OF SPPED SENSOR

Speed Sensor is on the gearbox
This sensor is used to detect the rotating speed of the engine output shaft and provide
the signal for ECU and speedometer to determine the vehicle speed. It belongs to Hall
effect sensor,that varies its output voltage in response to a magnetic f ield.
1. Ground
2. Output voltage signal
3. Power DC 12V(+)
The following figure refers to speed sensor wiring

Speed Sensor Test:

 Ground pin 1and connect pin 3 with +12V power;
 Fix a gear 2.5mm away from a speed sensor as the right figure illustrates;
 Turn multimeter to DCV range;
 Slowly turn the gear and measure the voltage between pin 2 and pin 3 to determine that if
the reading varies from 0V-12V;
 If the reading doesn’t vary, that indicates the sensor is defective and needs to be replaced

1. Turn Left Indicator Light 10. Dome Lamp Indicator

2. Position Lamp Indicator 11. Coolant Temperature Meter
3. High Beam Indicator Light 12. 2WD/4WD/DIFF Lock Indicator
4. Parking Brake Indicate Lamp 13. Gear Position Indicator
5. Safety Belt Lamp 14. The Odometer and Engine Working Hour Counter
6. Turn Right Indicator Light 15. EPS Fault Indicator
7. Engine RPM Meter 16. MIL Indicator
8. Fuel Gauge Indicator A.ODO/TRIP/HOUR Selector
9. Speedometer B.km/h、mph and km、miles Selector

7.10 SWITCHES
Optional

7.11 FUEL GAUGE/ FUEL LEVEL SENSOR
EFI
Remove seat, and then remove fuel

sensor attached to fuel tank
Hold fuel sensor in an upright position

after removing it. It is normal if indicator
shows “ E ” , otherwise, circuitry
connection, fuel sensor or instrument
should be inspected
Turn fuel sensor upside down. It is

normal if indicator shows “ F ” ,
otherwise, circuitry connection, fuel
sensor or instrument should be
inspected

RESISTANCE(20℃/
FLOAT POSITION
68°F)
Fuel sensor resistance range TOP(FULL) ＜16Ω
BOTTOM(RESERVE) ＞100Ω

7.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT
1, The rider shifts 2WD to 4WD by the Switch on panel.

2. When shift 2WD/ 4WD or Diff Lock, the mechanics in the front gear box maybe still engaged/
disengaged, the mechanics would finally disengaged/ engaged when rides on a hard surface or
rides in reverse.
3. Always shift as the vehicle stop.

7.13 WIRING DIAGR

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SERVICE MANUAL

Failure to follow WARNING instructions could result in severe

CAUTION: A CAUTION indicates special precautions that must be taken to

NOTE: A NOTE provides key information to make procedures easier or

CHAPTER1 ……………………………………………………….General Information

CHAPTER 1 GENERAL INFORMATION

1.1 IMPORTANT INFORMATION

1.2 V.I.N AND ENG INE SERIAL NUMB ER

1.3 VEHICLE DIMENSIONS

CHAPTER 1 GENERAL PAGE. 1- 1

1.1 IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES

GASKETS,OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER PINS

Replace all lock washers/plates and cotter

BEARINGS AND OIL SEALS

CHAPTER 1 GENERAL PAGE. 1- 2

7. Check for continuity with a tester.

CHAPTER 1 GENERAL PAGE. 1- 3

How to use the CONVERSION TABLE

CHAPTER 1 GENERAL PAGE. 1- 4

1.2 V.I.N AND ENGINE SERIAL NUMBER

The engine serial number ② is stamped

CHAPTER 1 GENERAL PAGE. 1- 5

1.3 VEHICLE DIMENSIONS

CHAPTER 1 GENERAL PAGE. 1- 6

CHAPTER 1 GENERAL PAGE. 1- 7

2.1 PERIODIC MAI NTE NANCE

2.2 THROTTLE PEDAL INSPECTION

2.3 CHOKE ADJUS TMETN

2.4 FUEL SYSTEM

2.5 TOE ALIGNMENT

2.6 BRAKING SYSTEM INSPECTION

2.7 SUSPENSION SPRING RPELOAD ADJUSTMENT

2.9 TIRE PRESSURE

3.0 FRAME, NUTS , BOLTS, FASTENERS

CHAPTER 2 MAINTENANCE PAGE. 2- 1

2.1 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Item Hours When Remarks

Parking Brake / Pre-ride I

Frame nuts, bolts fasteners / Pre-ride I

▲ Air Filter-Pre-Cleaner / Daily I C

Coolant 150 Annually R

Coolant strength 25 3 months I Inspect strength seasonally

▲ Air Box Sediment Tube / Daily D

CHAPTER 2 MAINTENANCE PAGE. 2- 2

Headlamp Inspection / Daily apply dielectric grease to connector

Tail lamp inspection / Daily apply dielectric grease to socket when

Battery Terminals 10 Monthly I C

DL Brake pad wear 10 Monthly I

Engine Cylinder Head and I

Engine Oil-Level / Daily I

Engine Oil Change 30 3 months Break-in Service at 1 month. Change oil

more often in cold weather use.

▲ Oil Filter 50 6 months I C

▲ Engine breather hose 100 6 months I

Throttle Cable / Pre-ride I

DL Throttle Cable/Throttle pedal 50 6 months A L (Grease M) R if necessary

Shift linkage 50 6 months I A R if necessary