HJS XY450U Service Manual

XY450U-A
SERVICE MANUAL
NOTICE
This manual was produced by the XINGYUN Group primarily for use by XINGYUN
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 XINGYUN 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.
XINGYUN Group is continually striving to improve all its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized
XINGYUN 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…………………………………….……….….…… ……Dynamic system
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 GENERAL INFORMATION SERVICE MANUAL
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 MOTOR SERIAL NUMBER
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 ①
and reinsert 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 MULTIPLIER IMP
**mm x 0. 3937 = **in
**cm x 0.03937 = **in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
m·kg 7.233 ft·lb
m·kg 86.794 In·lb
Torque
cm·kg 0.0723 ft·lb
cm·kg 0.8679 In·lb
kg 2.205 lb
Weight
g 0.03527 oz
km/h 0.6214 mph
km 0.6214 mi
m 3.281 ft
Distance
m 1.094 yd
cm 0.3927 in
mm 0.03927 in
cc(cm3) 0.03527 oz(IMP liq.)
Volume/ cc(cm3) 0.06102 cu·in
Capacity lit(liter) 0.8799 qt (IMP liq.)
lit(liter) 0.2199 gal(IMP liq.)
kg/mm 55.997 lb/in
Miscellaneous kg/cm 2
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 left side of the rear frame tube.
The engine serial number ② is stamped into left

side of engine crankcase.
The transmission serial number ③ is stamped

into back side of transmission case.

1.3 VEHICLE DIMENSIONS
Note.
The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA.

NOTES

CHAPTER 2 MAINTENANCE SERVICE MANUAL
CHAPTER 2 MAINTENANCE
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.
2.1 PERIODIC MAI NTENANCE
2.2 THROTTLE PEDAL INSPECTION
2.3 FUEL SYSTEM
2.4 TOE ALIGNMENT
2.5 BRAKING SYSTEM INSPECTION
2.6 SUSPENSION SPRING RPELOAD ADJUSTMENT
2.7 W HEELS
2.8 TIRE PRESSURE
2.9 FRAME, NUTS , BOLTS, FASTENERS
CHAPTER 2 MAINTENANCE PAGE. 2- 1

2.1 PERIODIC MAINTENANCE
CAUTION
Due to the nature of the adjustments marked with a D on the following chart, it is
recommended that service be performed by an authorized dealer.
 More often under severe use, such as dirty or wet conditions to purge water or dirt
contamination from grease fittings and other critical components.
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, ask for a qualified dealer perform these operations.
Item Hours When Remarks

 Brake System Pre-ride Pre-ride Pre-ride inspection item
Inspect –adjust, lubricate, replace if
Accelerator pedal Pre-ride Pre-ride
necessary; pre-ride inspection item
Check for leaks at tank cap, lines, fuel
Fuel System Pre-ride Pre-ride
valve, filter, and carburetor
 Tires Pre-ride Pre-ride Inspect daily, pre-ride inspection item
Front and Rear
 Pre-ride Pre-ride Pre-ride inspection item
Wheels/ Hubs
 Steering Pre-ride Pre-ride Inspect daily, lubricate
Check for looseness/ damage. Replace if
D Wheels Bearings 10 hrs Monthly
damaged
Frame Nuts, Bolts
Pre-ride Pre-ride Pre-ride inspection item
Fasteners
 Air Filter-Pre-Cleaner Daily Daily Inspect-Clean
Coolant/Level
Daily Daily Replace engine coolant every one year
Inspection
Air Box Sediment

 Daily Daily Drain deposits whenever visible
Tube
Check operation daily; apply dielectric
Headlamp Inspection Daily Daily
grease to connector when replaced
Tail / Indicator Lamp Check operation daily; apply dielectric
Daily Daily
Inspection grease to socket when replaced
Air Filter-Main
 Weekly Weekly Inspect –Replace if necessary
Element
Transmission Oil
 20 hrs Monthly Inspect monthly; change annually
Level
Battery 20 hrs Monthly Check/clean Terminals; check fluid level
D Brake Pad Wear 10 hrs Monthly Inspect periodically
Front/Rear axle Gear
 100 hrs Monthly Check yearly or every 100 hours
case Oil
Engine Cylinder Head
Inspect (re-torque required at first service
and Cylinder Base 25 hrs 3 months
only)
Fasteners
 General Lubrication 50 hrs 3 months Lubricate all fittings, pivots, cables, etc.
Check Level Daily; Break in Service at 1
Engine Oil-Level/
 30 hrs 3 months month. Change oil more often in cold
Change
weather use
 Dipstick 50 hrs 6 months Inspect - clean
Engine Breather Hose 100 hrs 6 months Inspect
Throttle Cable / Inspect – adjust, lubricate, replace if
D 20 hrs monthly
Accelerator Pedal necessary; pre-ride inspection item
Shift Linkage 50 hrs 6 months Inspect, adjust
D Drive Belt 50 hrs 6 months Inspect, replace if necessary
Check operation and for looseness, worn,
damage, binding feeling / Adjust, repair,
D Steering System 50 hrs 6 months
Replace if necessary.
Check toe alignment /Adjust if necessary.
Toe Alignment Periodic inspection, adjust when parts are
D As required As required
Adjustment replaced
D Shaft 50 hrs 6 months Check for looseness/ damage
 Axle 50 hrs 6 months Inspect bearings, Lube
Front Prop Shaft ＆
 50 hrs 6 months Check for looseness/ damage
Shaft Yoke
Rear Prop Shaft,
 50 hrs 6 months Check for/ boots/ looseness/ damage
Shaft Yoke ＆ Boots
 Front Suspension 50 hrs 6 months Inspect - lubricate, tighten fasteners
 Rear Suspension 50 hrs 6 months Inspect, tighten fasteners
Spark Plug 100 hrs 12 months Inspect - replace if necessary
D Ignition Timing 100 hrs 12 months Inspect and adjust as needed

Check for leaks at tank cap, lines, fuel

D Fuel System 50 hrs 6 months
filter. Replace lines every one year
D Fuel Filter 100 hrs 12 months Replace annually
Radiator 100 hrs 12 months Inspect/clean external surface
Clean out-replace if
Spark Arrestor 50 hrs 3 months
necessary
Clutches (drive and
D 25 hrs 3 months Inspect, clean
driven)
Engine Mounts 25 hrs 3 months Inspect
D Valve Clearance 100 hrs 12 months Inspect/adjust
D Brake Fluid 200 hrs 24 months Change every two years
Idle Speed As required As required Adjust
Headlight Aim As required As required Adjust if necessary
LUBRICANT AND FLUID

Item Lube Rec Method Frequency
Add to proper level on
 1. Engine Oil SAE 15W/40SG Check level daily
dipstick
As require; change
Maintain level between fill
2. Brake Fluid DOT 3 Only every two years or
lines
200 hours
Add to proper level on Change annually or
3. Transmission Oil SAE 80W/90GL5
dipstick 100 hours
4. Front / Rear Axle Gear Fill the bottom of the fill plug Change annually or
SAE 80W/90GL5
Case Oil threads 100 hours
Lubricate the pivoting and Every 3 months or
 5. Steering System Grease
sliding parts 50 hours
 6. Shift Linkages Grease Locate fittings and Grease Semi-annually
 7. Tie Rods Grease Grease Semi-annually
Inspect, Locate fittings and
 8. Ball Joints Grease Grease, or replace it if Semi-annually
necessary
9. Prop Shaft ＆ Shaft
 Grease Locate fitting and Grease Semi-annually
Yoke, Spline Joint
Maintain level between fill
 10. Cooling Liquid HEC-Ⅱ-35 Check level daily
lines
11. Front / Rear A-arm Locate fitting on pivot shaft Every 3 months or
 Grease
Pivot Shaft and grease with grease gun 50 hours
Grease, inspect and replace
 12. Throttle Cable Grease M Monthly or 20 hours
it if necessary
13. Accelerator Pedal
 Grease Grease, inspect Monthly or 20 hours
and brake 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, free play is
achieved pedal. NOTE: While adjusting free
play, it is important you flip the throttle lever
back and forth.
3. Tighten locknut.
2.3 FUEL SYSTEM
Gasoline is extremely flammable and explosive under certain conditions.

Always stop the engine and refuel outdoors or in a well ventilated 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 gasoline in your eyes or if you swallow gasoline, see your doctor
immediately.
If you spill gasoline 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. Gasoline 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 signs of
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 or
pinched.
Replace all fuel lines every two years.
FUEL FILTER
The fuel filter should be replaced in accordance
with the Periodic Maintenance Chart or
whenever sediment is visible in the filter.
1. Remove line connectors at both ends of fuel
filter.
2. Install new fuel filter onto fuel lines (the
direction of fuel flow should be IN → OUT).
3. Start engine and inspect for leaks.
2.4 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.
The recommended toe alignment is 0 to

13/64”(0 to 5mm) toe in.
1. Set the steering wheel in a straight ahead
position and hold them in this position.
2. Measure A and B, A minus B should be 0 to
6/64” (0 to 2.5mm).

Always pay attention to tie rods assembly, Both ends must screw in same and enough
threads length.
2.5 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 18%
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.

2.6 SUSPENSION SPRING RPELOAD ADJUSTMENT

Operator weight and vehicle loading affect suspension spring preload requirements. Adjust as
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 from strut cartridges for leakage. Shock spring preload can not be adjusted, replace
if necessary.
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
2.7 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. Install the wheel nuts and tighten them by hand.
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 M12X1.25 59Ft.Lbs 66Nm
Rear M12X1.25 59Ft.Lbs 66Nm
CAUTION:
If wheels are improperly installed it could affect Vehicle handling and tire wear.
2.8 TIRE PRESSURE

TIRE INSPECTION
CAUTION:
 Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the
vehicle.
 Improper tire inflation may affect UTV maneuverability.
 When replacing a tire always use original equipment
size and type and replace in pairs. Tire Pressure
 The use of non- standard size or type tires may affect front rear
UTV handling and cause machine damage. 48kPa/7SI 48kPa/7PSI
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.

2.9 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 CUV SERVICE MANUAL 09.0
CHAPTER 3 ENGINE
3.1 MAI NTEN ANCE SPECIFICATIONS

3.1.1 SPECIFICATIONS
3.1.2 TIGHTENING TORQUES
3.2 PARTS INSPECTION AND SERVICE

3.2.1 VALVE CLEARANCE ADJUSTMENT
3.2.2 IDLING SPEED ADJUSTMENT
3.2.3 SPARK PLUG INSPECTION
3.2.4 COMPRESSION PRESSURE
3.2.5 ENGINE OIL LEVEL INSPECTION
3.2.6 COOLANT LEVEL INSPECTION
3.3 CYLINDER HEAD
3.4 CAMSHAFT AND ROCKER ARMS
3.5 VALVES AND VALVE SPRINGS
3.6 CYLINDER AND PISTON
3.7 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE
3.8 A.C. MAGNETO AND STARTER CLUTCH
3.9 OIL PUMP
3.10 CRANKCASE AND CRANKSHAFT
3.11 COOLING SYSTEM

3.11.1 RADIATOR
3.11.2 WATER PUMP
3.11.3 THERMOSTAT
CHAPTER 3 ENGINE PAGE. 3- 1

3.1 MAINTENANCE SPECIFICATIONS
3.1.1SPECIFICATIONS
Item Standard Limit

Cylinder head :
Warp limit 0.03 mm
Cylinder:
Bore size 82.000- 82.014 mm 82.025 mm
Out of round limit 0.03 mm
Camshaft:
Cam dimensions
Intake "A" 36 .545-36 .645 mm 36 .45 mm
"B" 30.021-30.121 mm 29.92 mm
"C" 6.524 mm …
Exhaust "A" 36 .547- 36 .647 mm 36 .45 mm
"B" 30 .067- 30.167 mm 29 .97 mm
"C" 6.48 mm …
Camshaft runout limit ….. 0.03m m
Cam chain: …
Cam chain type/No. of links DID SC.A-0404A
SDH/108
Rocker arm /rocker arm shaft:
Rocker arm inside diameter 12.000- 12.018 mm 12 .03 mm
Rocker shaft outside diameter 11.981- 11.991 mm 11.95 mm
Rocker arm - to- rocker arm shaft
Clearance 0.009- 0.012 mm …
Valve, Valve seat, Valve guide:
Valve clearance (cold) IN 0.12-0.14 mm
EX 0.14-0.16 mm …
Valve dimensions …
"A" head diameter IN 37.4-37.6mm …

EX 33.5-33.6mm …
"B" face width IN 3.394-3.960mm …
EX 3.394-3.960 mm …
"C " seat width IN 0.9-1.1mm …
EX 0.9-1.1 mm …
"D" margin thickness IN 0.8-1.2 mm …
EX 0.8-1.2 mm
Stem outside diameter IN 5.973- 5.995 mm 5.94 mm
EX 5.960-5.977 mm 5.92 mm
Guide inside diameter IN 6.000- 6.012 mm 6.05 mm
EX 6.000- 6.012 mm 6.05 mm

I te m Standard Limit
Stem-to-guide clearance IN 0.010- 0.037 mm 0.08 mm
EX 0.025-0.052 mm 0.1 mm
Stem runout limit … 0.01 mm
Valve seat width IN 0.9-1.1 mm 1.6 mm
EX 0.9-1.1 mm 1.6 mm
Valve spring :
Free length (Inner) IN/EX 38mm 36.1 mm
(Outer) IN/EX 37.5mm 35.0 mm
Set length (valve closed) (Inner) IN/EX 30 mm …
(Outer) IN/EX 31.6 mm …
Com pressed pressure (Inner) IN/EX 7.8- 9.0 kg …
(Outer) IN/EX 37.22-42.83 kg …
Tilt limit (Inner) IN/EX … 2.5°/1.7mm
(Outer) IN/EX … 2.5°/1.7mm
Piston:
Piston to cylinder 0.02 - 0.049mm 0.15m m
Clearance
Piston size "D" 81.965-81.980 mm …
Measuring point "H" 5mm …
Piston pin bore 18.004-18.015 mm 18.045 mm
inside diameter
Piston pin outside diameter 17 .994-18 .005 mm 17 .975 mm
Piston rings :
Top ring :
Type Barrel …
End gap (installed) 0.2-0.35 mm 0.5 mm
Side clearance (installed ) 0.03-0.065 mm 0.1 mm
2nd ring :
Type Taper …
End gap (installed) 0.28-0.48 mm 0.73 mm
Side clearance 0.02-0.052 mm 0.1 mm
Oil ring :
End gap (installed) 0. 15-0.45 mm …
Crankshaft:
Crank width "A" 59.90-60.00 mm …

Runout limit "C " 0.03 mm …
Big end side clearance "D" 0.35- 0.85 mm …

I te m Standard Limit
Automatic centrifugal clutch:

Clutch shoe thickness 3.0 mm 2.0 mm
Clutch hosing inside diameter 160 mm 160.5 mm
Clutch shoe spring free length 28.1 mm …
Weight outside diameter 20 mm 19 .5 mm
Clutch operating speed 2 ,900- 3,000 r/m in …
V-belt:
V-belt width 22.6 mm 21.0 mm
Throttle:
Type No Adjustment
Oil pump:
Type Trochoid
Tip clearance 0.1- 0.34 mm 0 .4 mm
Side clearance 0.013- 0.036 mm 0.15 mm
Housing and rotor clearance 0 .04- 0.09 mm 0.15 mm
Radiator:
Type Cooling fin with electric fan
Width/height/thickness 360/246/68 mm
Radiator cap opening pressure 110-140kPa
Radiator capacity 2L
Reservoir tank capacity 0.35 L
Thermostatic valve:
Valve opening temperature 64-67℃
Valve full open temperature 83 ℃
Valve full open lift 7mm

3.1.2 TIGHTENING TORQUES

Tightening
Part to be tightened Part Thread Q’ty Torque Remarks
name size N.m m.kg
Magneto motor stator Bolt M6 3 10 1
Trigger Bolt M5 2 6 0.6
Oil pump Bolt M6 2 10 1
Drain cock — — 1 30 3
Magneto motor rotor Bolt M8 6 26 2.6
Compression plate Bolt M6 2 10 1
Peep hole Bolt M6 1 10 1
Spark plug — — 1 26 2.6
Water temperature sensor — — 1 18 1.8
Thermostat — — 1 15 1.5
Inlet pipe Bolt M6 2 10 1
Left box Bolt M6 8 10 1
Pull rod — — 1 6 0.6
Water pump gears Bolt M6 2 6 0.6
Starting motor Bolt M6 2 10 1
Magneto motor rotor Bolt M16 1 190 19
Right cover Bolt M6 10 10 0.1
Cylinder head cover Bolt M6 2 10 0.1
Cylinder head cover Nut M8 4 26 2.6
Timing sprocket Bolt M10 1 32 3.2
Inlet / exhaust valve cover Bolt M6 5 10 1
Respirator Bolt M6 2 10 1
Timing chain adjuster assy Bolt M6 2 10 1
Water pump Bolt M6 2 10 1
Water pump connection Bolt M6 2 10 1
pipe — — — — —
Peep cover — — 1 10 1
Transmission case Bolt M8 4 26 2.6
Transmission case Bolt M10 2 32 3.2
Connecting plate Bolt M10 3 32 3.2
Clutch Nut M14 2 120 12
Left cover Bolt M6 10 6 0.6
Injector Bolt M6 1 10 1
Air inlet temperature Bolt M6 1 10 1
pressure sensor — — — — —
Throttle body — — 1 6 0.6


3.2.1 VALVE CLEARANCE ADJUSTMENT
NOTE:
Valve clearance adjustment should be made
with the engine cool, at room temperature.
When the valve clearance is to be measured or

adjusted, the piston must be at Top Dead Center
(T.D.C.) on the compression.
1. Remove :
Right cover
2. Remove :
Spark plug
 Valve cover (intake side)
Valve cover (exhaust side)
3. Remove:
Timing check plug
4. Remove:
Left cover
5.Measure:
Valve clearance
Out of specification → Adjust.
Valve clearance (cold):
Intake valve 0.12- 0.14m m
Exhaust valve 0.14- 0.16mm
Measurement steps:
 Turn the impeller clockwise to align the mark ⓐ
on the rotor of the magneto machine with the mark
ⓑ on the right cover.
Measure the valve clearance by using a feeler

gauge.
6. Adjust
Valve clearance
Adjustment steps:
Loosen the locknut ①
Turn the adjuster ③ in or out with the valve
adjusting tool ② until specified clearance is
obtained .
Turning in → Valve clearance is decreased.
Turning out → Valve clearance is increased.
Hold the adjuster to prevent it from moving and
tighten the locknut.

Measure the valve clearance.
If the clearance is incorrect, repeat above
steps until specified clearance is obtained.
7. Install:
Valve cover (intake side) 

O-ring
8 . Install:
Valve cover(exhaust side)

O-ring
Spark plug
 Timing check plug
Right cover
9 . Install:
Left cover
3.2.2 IDLING SPEED ADJUSTMENT
CAUTION:
NO IDLING SPEED ADJUSTMENT
Barring abnormal conditions, the throttle idle
screws shall not be adjusted. Otherwise, replace
the throttle.
3.2.3 SPARK PLUG INSPECTION

1.Remove :
 Spark plug cap
 Spark plug
CAUTION:
Before removing the spark plug, use compressed
air to blow away any dirt accumulated in the spark
plug wells to prevent it from falling into the
cylinder.
1. Check:
Spark plug type
Incorrect Replace.

Standard spark plug:
DR8EA(NGK)
2.Inspect:
Electrode 
Wear/ damage Replace.
Insulator 
Abnormal color Replace.
Normal color is a medium - to- light tan color.
3.Clean:
Spark plug
(with spark plug cleaner or wire brush)
4.Measure:
Spark plug gap ③
(with a wire gauge)
Out of specification Adjust gap.
Spark plug gap :

0.6-0.7 mm
6. Install:
Spark plug
NO TE:
Before installing a spark plug, clean the Gasket
surface and plug surface.
3.2.4COMPRESSION PRESSURE
MEASUREMENT
NOTE :
Insufficient compression pressure will result in
performance loss.
1. Check:
Valve clearance
Out of specification Adjust.
Refer to “CALCE CLEARANCE ADJUSTMENT”

section.
2. Start the engine and let it warm up for several

minutes.
3. Turn off the engine.

4. Remove:
Spark plug
Before removing the spark plug, use compressed

air to blow away any dirt accumulated in the spark
plug well to prevent it from falling into the cylinder.
5. Attach:
Compression gauge
6. Measure:
Compression pressure
If it exceeds the maximum pressure allowed→
Inspect the cylinder head, valve surfaces and
piston crown for carbon deposits.
If it is below the minimum pressure → Squirt a few

drops of oil into the affected cylinder and measure
again.
Follow the table below.
Compression pressure
(With oil applied into cylinder)
Reading Diagnosis
Higher than
Worn or damaged pistons
without oil
Possible defective ring (s), valves,
Same as
cylinder head gasket or
without oil
Piston →Repair.
Compression pressure(at sea level):

Standard:
1,400 kPa (14Kg/cm2, 14 bar)
Minimum :
1,120 kPa (11.2 kg /cm 2, 11.2 bar)
Measurement steps : ①
Crank the engine with the throttle wide open until
reading on the compression gauge stabilizes.
WARNING :
②
Before cranking the engine, ground all spark plug
leads to prevent sparking.
8. Install:
 Spark plug

3.2.5 ENGINE OIL LEVEL INSPECTION
1. Start the engine and let it warm up for a few
minutes .
3. Inspect: (Do not thread dipstick in)
Engine oil level
Oil level should be between maximum  and
minimum marks .
Oil level is below the minimum mark. Add oil up to
the proper lever.
RECOMMENDED ENGINE OIL

Refer to the chart for selection of the oils suited to
the atmospheric temperature.
API STANDARD:API
API SE or higher grade
CAUTION:
Do not put in any chemical additives or use
oils with a grade of CD or higher.
Be sure not to use oils labeled "ENERGY

CONSERVING I" or higher.
Engine oil also lubricates the clutch and ad-
ditives could cause clutch slippage.
Be sure no foreign material enters the

crankcase.
4. Start the engine and let it warm up for a few

minutes.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
ENGINE OIL REPLACEMENT

minutes .
2. Turn off the engine and place an oil pan under
the engine.
3. Remove :
Drain plug 

Compression spring 
Oil strainer 
O-ring
Drain the crankcase of its oil.
4. Install:
O-ring  NEW
Compression spring 
Oil strainer 
Drain plug 
NOTE :
Check the drain plug O-ring. If damaged, replace it
with a new one.
5. Fill:
Crankcase
Oil quantity:
1.4L
6. Check:
Engine oil level
Refer to "ENGINE OIL LEVEL INSPECTION"
section.
ENGINE OIL PRESSURE INSPECTION

Inspection steps:
Slightly loosen the oil check bolt 
Start the engine and keep it idling until the oil

begins to seep from the oil check bolt. If no oil
comes out after one minute, turn the engine off so it
will not seize.
Check oil passages and oil pump for damage or

leakage.
Start the engine after solving the problem (s), and
recheck the oil pressure.
Tighten the oil check bolt to specification.
CAUTION:
Start the engine and check the oil pressure with
the oil check bolt loosened.
Do not apply at high speeds more than specified
when checking the pressure.
NOTE:

Wipe any spilled oil off the engine.
3.2.6 COOLANT LEVEL INSPECTION

Inspect:
Coolant level
Coolant level should be between the maximum○ a
and minimum○ b marks. ○

a
Coolant level is below the "LOWER " level line

○
b
Add soft water (tap water) up to the proper level.
CAUTION:
Hard water or salt water is harmful to engine parts.
Use only distilled water if soft water is not available.
If you use tap water, make sure it is soft water.

minutes.
2. Turn off the engine and inspect the coolant level
again.
NOTE:
Wait a few minutes until the coolant settles before
inspecting the coolant level.
COOLANT REPLACE MENT ①

1. Remove:
Front cover of UTV plastic body work.
Seat.
2. Remove:
Hose  (reservoir tank)
Drain the reservoir tank of its coolant.
3. Loosen:
 Engine inlet pipe
4.Remove:
Radiator cap
WARNING:
Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot fluid ①
and steam may be blown out under pressure,
which could cause serious injury. When the
engine has cooled, open the radiator cap as
follows:
Place a thick rag or a towel over the radiator
cap. Slowly rotate the cap counterclockwise
toward the detent. This allows any residual
pressure to escape. When the hissing sound

has stopped, press down on the cap while
turning counterclockwise and remove it.
NOTE:
 Remove the radiator cap after loosening engine
inlet pipe.
5.Clean:
Radiator
Fill soft water into the filer neck support
(reservoir tank)
①
6. Connect:
Hose (reservoir tank)
 Engine inlet pipe①
7. Fill:
Radiator
( to specified level )
Fill the coolant slowly, until the coolant
○
a
comes out from the head hose.
Reservoir tank ○
b
( to maximum level ○ a )
Recommended coolant:
High quality ethylene glycol anti-freeze
containing corrosion inhibitors for
aluminum engine.
Coolant  and water ③ (soft water) :

Mixed ratio: min50% /max50% follow the
instruction of the coolant
Total amount:
2L
Reservoir tank capacity:
0.35L
Handling notes for coolant:

Coolant is potentially harmful and should be
handled with special care.
WARNING:
Splashes in your eyes:
Thoroughly wash your eyes with water and consult
a doctor.
If coolant splashes on your clothes:
Quickly wash it away with water and then with
soap and water.
If coolant is swallowed:
Vomit immediately and see a physician.
CAUTION:
Hard water or salt water is harmful to engine
parts. Use only distilled water if soft water is not
available.
If you use tap water, make sure it is soft water.
Do not use water containing impurities or oil.
Take care that no coolant splashes onto painted
surfaces. If it does, wash them immediately with
water.
Do not mix different types of ethylene glycol
antifreeze containing corrosion inhibitors for
aluminum engines.
9. Tighten:
Hose
Fill the coolant slowly to the specified level.
10. Install:
Radiator cap
minutes.
12. Stop the engine and inspect the level.
NOTE:
Wait a few minutes until the coolant settles before
inspecting the coolant level.
13. Install: Remain parts.

3.3 CYLINDER HEAD AND CYLINDER COMPONENTS

Order Job name / Part name Q ’ty Remarks
Cylinder head removal Remove the parts in order.

1 Pin dowel 10X14 2
2 Cylinder gasket 1
3 Cylinder 1
4 Cylinder head gasket 1 Refer to " Throttle valve "
5 Pin dowel 14X16 2 section .
6 Cylinder head ASSY 1
7 Bolt socket head M6X20 7
8 Valve cover intake side 1
9 O-ring 57.5X2.3 2
10 Valve cover exhaust side 1
11 O-ring 95X3.3 1
12 Breather ASSY Ⅰ 1
13 Breather ASSY 1
14 Pipe joint 1
15 Clip 13MM 1
16 Pipe breather 1 1
17 Steel wire clamp 15 1
18 Bolt flange M6X130 2
19 Acorn nuts M8 4
20 Washer plate 8 4
21 Bolt M6X12 1
22 Gasket 6.5 1
23 Bolt stud M8X25 2
24 Plug spark 1

CYLINDER HEAD REMOVAL

1. Align:
"I" mark ○a on the rotor (with stationary
pointer ○b on the crankcase cover )
NOTE: If any special mark found, contact the

UTV manufacture via the agent for the parts and
special instruction.
NOTE:
Turn the primary sheave counterclockwise with a
wrench and align the "I" mark ○ c with the
cylinder head match mark ○
d when the piston is at
TDC on the compression.
2. Loosen:
Bolt 
3. Remove:
Timing chain tensioner assembly
Timing chain tensioner gasket
4. Remove:
Breather plate 
Cam sprocket ③
Timing chain④
NOTE:
Fasten a safety wire to the timing chain to prevent
it from falling into the crankcase.
Remove the bolt  while holding the rotor
mounting bolt with a wrench.
5. Remove:
 Cylinder head
NOTE:
Loosen the nuts in their proper loosening
sequence.
Start by loosening each nut 1/2 turn until all are
loose.
CYLINDER HEAD INSPECTION:

1. Eliminate:
Carbon deposits
(from combustion chambers)
Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid damaging
or scratching:
Spark plug threads
Valve seats
2. Inspect:
Cylinder head
Scratches/damage → Replace.
3. Measure:
Cylinder head warp age
Out of specification → Resurface .
Cylinder head warpage :

Less than 0.03 mm
Warpage measurement and resurface ment.
steps: Place a straight edge and a feeler

gauge across the cylinder head.
Measure the warpage.

If the warpage is out of specification,
resurface the cylinder head.
 Place a 400 ~ 600 grit wet abrasive pape
on the surface plate, and resurface the head.
NOTE:
Rotate the cylinder head several times for
an even resurface ment.。
CYINDER HEAD INSTALLATION

1. Install:
Gasket (cylinder head) (NEW)
Dowel pins
Cylinder head
NOTE:
Apply engine oil onto the nut threads.
Tighten the nuts in a crisscross pattern.
2. Tighten:
Nuts (cylinder head)
Bolts (cylinder)
3. Install:
Cam sprocket 
Timing chain 
Installing steps :
Turn the primary sheave counterclockwise
until the TDC mark ○ a matches the
stationary pointer ○b .
Align the "I" mark ○ c on the cam sprocket
with the stationary pointer ○

d on the

cylinder head.
NOTE: If any special mark found, contact the
UTV manufacture via the agent for the parts and
Fit the timing chain onto the cam sprocket and
install the cam sprocket on the camshaft.
NOTE:
When installing the cam sprocket, keep the
timing chain as tense as possible on the exhaust
side.
Align the match mark ○ c on the cam sprocket
with the stationary pointer ○

d on the cylinder
head.
Align the pin on the cam shaft with the slot in the
cam sprocket.
CAUTION:
Do not turn the crankshaft during installation of
the cam shaft. Dam age or improper valve timing
will result.
While holding the camshaft, temporarily tighten
the bolts .
Remove the safety wire from the timing chain.
4. Install:
Breather plate 
Plane washer 
5. Install:
Timing chain tensioner
①
Installing steps:
Rotate the hole in the timing chain tensioner
with "one letter" to make  indent, and hold
"one letter".
Install the tensioner with a new gasket 
onto the cylinder. ②
Tighten the bolt (with gasket) to the specified ③
torque .
Put O-ring into the bolt (the timing chain
tensioner ).
Tighten the bolt (the timing chain tensioner) to ④
the timing chain tensioner.
6. Tighten:
Bolt (cam sprocket)

7. Check:
Valve timing
Out of alignment → Adjust.
8. Check:
Valve clearance
Out of specification → Adjust.
Refer to the "VALVE CLEARANC ADJUSTMENT"
section.

3.4CAMSHAFT AND ROCKER ARMS

Cam shaft and rocker arms Remove the parts in order.
Removal Refer to "CYLINDER HEAD" section.
Cylinder head
1 Lock washer 1
2 Plate 1 Refer to "ROCKER ARM AND ROCKER
3 Rocker arm shaft (intake) 1 SHAFT REMOVAL AND INSTALLATION"
4 Rocker arm shaft (exhaust) 1 section.
5 Rocker arm 2
6 Camshaft 1 Refer to "CAMSHAFT INSTALLATION"
7 Locknut 2 section .
8 Adjuster 2
9 O-ring 1
Reverse the removal procedure for
Installation

ROCKER ARM AND ROCKER ARM

SHAFTRE MOVAL
1. Remove:
Rocker arm shaft (intake)
Rocker arm shaft (exhaust)
NOTE:
Attach a rocker arm shaft puller bolt  and
weight  to the rocker arm shaft and slide
out the shaft.
CAM SHAFT INSPECTION

1. Inspect:
Cam lobes
Pitting/Scratches/Blue discoloration →Replace .
2. Measure:
Cam lobes length ○ a and ○b
Out of specification → Replace.

Cam lobes length:
Intake:
○
a 36 .545- 36 .645 mm
<Limit: 36.45 mm>

○
b 30.021-30.121 mm
<Limit: 29.92 mm>

Exhaust:
○
a 36 .547- 36 .647 mm
<Limit: 36.45 mm>

○ 30.067- 30.167 mm
b
<Limit: 29.97 mm>
3. Inspect:
Cam shaft oil passage
Stuffed → Blow out oil passage with compressed
air.
ROCKER ARMS AND ROCKER ARM SHAFTS
INSPECTION
1. Inspect:
Cam lobe contact surface 
Adjuster surface 
Wear/Pitting/Scratches/Blue discoloration →
Replace.
Inspection steps:
Inspect the two contact areas on the rocker
arms for signs of unusual wear.
Rocker arm shaft hole.
Cam-lobe contact surface.
Excessive wear → Replace.
Inspect the surface condition of the rocker arm
shafts.
Pitting/scratches/blue discoloration → Replace
or check lubrication.
Measure the inside diameter A of the rocker arm
holes.
Inside diameter (rocker arm ):

12.000- 12.018mm
< Lim it: 12.030 mm >
 Measure the outside diameter B of the rocker
arm shafts.
Outside diameter(rocker arm shaft):
11.981-11.991 mm
<Lim it: 11.95 mm>
CAMSHAFT AND ROCKER ARM

INSTALLATION
1. Lubricate:
Cam shaft 
Camshaft:
Molybdenum disulfide oil
Camshaft bearing:
Engine oil
2. Install:
Plate
Lockwasher  NEW
Bolt 
NOTE:
Bend the lockwasher tabs along the bolt  faults.
3. Apply:
Molybdenum disulfide oil onto the rocker arm
and rocker arm shaft.
4. Install:
Rocker arm 
Rocker arm shaft  (exhaust)

NOTE:
Exhaust:
Install the rocker arm shaft (exhaust) completely
pushed in.
5. Install:
Rocker arm 
Rocker arm shaft  (intake)
NOTE:
Intake:
Insert the guide shaft (8 mm)  into the stud bolt
hole in the cylinder head to the rocker arm shaft
(intake).
CAUTION:
Do not confuse the installation direction of
rocker arm shaft. Be sure to install the
threaded part facing outward.

3.5VALVES AND VALVE SPRINGS

Valves and valve springs removal Remove the parts in order.
Cylinder head Refer to "CYLINDER HEAD " section .
Refer to "ROCKER ARM SHAFT AND
Rocker arm , rocker arm shaft ROCKER ARMS" section.
1 Valve cotters 4 Refer to "VALVES AND VALVE SPRINGS
2 Spring retainer 2 REMOVAL/INSTALLATION" section.
3 Valve spring (inner) 2 Refer to "VALVES AND VALVE SPRINGS
4 Valve spring (Outer) 2 INSTALLATION" section
5 Valve (intake) 1
6 Valve (exhaust) 1
7 Valve guide 2
8 Spring seat 2 Reverse the removal procedure for installation
9 Valve seal 2
VALVES AND VALVE SPRINGS REMOVAL

1. Remove:
 Valve cotters 
NOTE:
Attach a valve spring compressor and attachment
 between the valve spring retainer and cylinder
head to remove the valve cotters.
CAUTION:
Do not compress so much as to avoid damage to
the valve spring.
VALVE AND VALVE SPRINGS INSPECTION
1. Measure:
Valve stem diameter
Valve stem diameter:

Intake:
5.973-5.995mm
<Limit: 5.94mm>
Exhaust:
5.960-5.975mm
<Limit: 5.92mm>
2. Measure:
Runout (valve stem )）
Runout limit:
0.01 mm
3. Measure:
Free length (valve spring)
Valve spring free length:

Inner spring:
38 mm
<Limit: 36mm>
Outer spring:
37.5 mm
<Limit: 34.5mm>
4. Measure:

Spring tilt
Spring tilt limit:

1.7mm (2.5º)
5. Inspect:
 Spring contact face
Wear/Pitting/Scratches → Replace.
6. Measure:
Valve guide inside diameter
Valve guide inside diameter:

Intake:
6.000-6.012 mm
<Limit: 6.05mm>
Exhaust:
6.000-6.012 mm
<Limit: 6.05 mm>
7. Measure:
Stem-to guide clearance
Valve guide inside diameter
Valve stem diameter
Out of specification → Replace the valve
guide.
Stem-to-guide clearance limit:

Intake:
0.08 mm
Exhaust:
0.10 mm
VALVE SEATS INSPECTION

1. Eliminate:
Carbon deposits
(from the valve face and valve seat)
2. Inspect:
Valve seats
Pitting/wear → Reface the valve seat.
3. Measure:

Valve seat width ○
a
Out of specification → Reface the valve seat.
Valve seat width:

Intake:
0.9-1.1mm
<Limit:1.6mm>
Exhaust:
0.9-1.1mm
<Limit:1.6mm>
Measurement step:
Apply Mechanic’s bluing dye (Dykem) to the
valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide and

onto the valve seat to make a clear pattern.
Measure the valve seat width. Where the valve

seat and valve face made contact, bluing will
have been removed.
If the valve seat is too wide, too narrow, or the

seat is not centered, the valve seat must be
replaced.
4. Lap:
Valve face
Valve seat
NOTE:
After replacing the valve seat, valve and valve
guide, the valve seat and valve face should be
lapped.
Lapping steps:
Apply a coarse lapping com pound ○
a to the
valve face.
CAUTION:
Do not let compound enter the gap between the
valve stem and the guide.
Apply molybdenum disulfide oil to the valve

stem.
Turn the valve until the valve face and valve
seat are evenly polished, then clean off all com-
pound.

NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hand.
Apply a fine lapping compound to the valve
face and repeat the above steps.
NOTE:
Make sure to clean off all compound from the
valve face and valve seat after every lapping
operation.
Apply Mechanic’s bluing dye (Dykem) ○ b to
the valve face.

Press the valve through the valve guide and

onto the valve seat to make a clear pattern.
Measure the valve seat with ○ c again.
VALVES AND VALVE SPRINGS

INSTALLATION
1. Deburr:
Valve stem end
Use an oilstone to smooth the stem end.
2. Apply:
Molybdenum disulfide oil
(onto the valve stem and oil seal  )
3. Install:
Valve spring seat 
Valve stem seal(NEW)
Valve 
(into the cylinder head)
Valve spring (under) 
Valve spring (outer) 
Spring retainer 
NOTE:
Install the valve spring with the larger pitch ○
a
facing upwards.
○b Smaller pitch

4. Install:
Valve cotters 
NOTE:
Install the valve cotters while compressing the
valve spring with a valve spring compressor and
attachment .
5. Secure the valve cotters onto the valve stem

by tapping lightly with a piece of wood.
CAUTION:
Do not hit so much as to damage the valve.

3.6CYLINDER AND PISTON
Cylinder and piston removal Remove the parts in order.

Cylinder head Refer to " CYLINDER HEAD "
1 Joint 1 section .
2 O-ring 2
3 Timing chain guide (exhaust side) 1 Refer to " PISTON RINGS,
4 Cylinder 1 PISTON AND CYLINDER
5 Dowel pin 2 INSTALLATION" section.
6 Cylinder gasket 1
7 Piston pin circ lip 2 Refer to "PISTON AND
8 Piston pin 1 PISTON RINGS REMOVAL"
9 Piston 1 section .
10 Piston ring (top) 1 Refer to "PISTON RINGS,
11 Piston ring (2nd) 1 PISTON AND CYLINDER
12 Side rail/Spacer 2/1 INSTALLATION " section .
Reverse the removal
procedure for installation

PISTON AND PISTON RINGS REMOVAL

1. Remove:
Piston pin circ lip 
Piston pin 
Piston 
NOTE:
Before removing the piston pin circ lip, cover the
crankcase opening with a clean tow el or rag to
prevent the circ lip from falling into the
crankcase cavity.
2. Remove:
Top ring
2nd ring
Oil ring
NOTE:
When removing the piston ring, open the end
gap of the ring by fingers, and push up the other
side of the ring.
CYLINDER INSPECTION
1. Measure:
Cylinder bore
Out of specification → Rebore or replace.
NOTE:
Measure the cylinder bore with a cylinder bore
gauge.
Measure the cylinder bore in parallel to and a
right angle to the crankshaft. Then, find the
average of the measurements.
Cylinder bore:
82.000- 82.014mm
< Limit:82.025mm>
< Difference limit between A,B and
C :0.03m m >
2. Measure:
Warpage
Cylinder warpage limit:

0.03mm

PISTON AND PISTON PIN INSPECTION

1. Measure:
Piston skirt diameter
Out of specification → Replace .
○a 5.0mm from the piston bottom edge.
Valve skirt diameter:

81.965-81.980 mm
2. Calculate:
Piston-to-cylinder clearance
Piston-to-cylinder clearance
Cylinder bore-Piston skirt diameter
Refer to “CYLINDER” section for cylinder bore
measurement.
Out of specification → Replace the piston and
piston rings as a set.
Piston-to-cylinder clearance:
0.02-0.04mm
3. Measure:
Piston pin bore diameter
Piston pin bore diameter:
18.000-18.015mm
<Limit:18.045mm>
4. Measure:
Piston pin outside diameter
Piston pin bore diameter:
17.994-18.005mm
<Limit:17.975mm>
5. Inspect:
Piston pin
Blue discoloration/groove → Clean or replace.
PISTON RINGS INSPECTION

1. Measure:
Side clearance ○ 1
Out of specification → Replace the piston and

the piston rings as a set.
NOTE:
Eliminate the carbon deposits from the piston
ring grooves and rings before measuring the
side clearance.

Side clearance (piston ring):

Top ring:
0.04- 0.08m m
<Limit: 0.12mm>
2nd ring:
0.03 - 0.07mm
<Limit: 0.12mm>
2.Position:
Piston ring into the cylinder
NOTE :
Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
○
1 5.0mm
3. Measure:
End gap
Out of specification → Replace.
NOTE:
You cannot measure the end gap on the
expander spacer of the oil ring. If the oil ring rails
show excessive gap, replace all three rings.
End gap:
Top ring:
0.15-0.30mm
<Limit:0.45mm>
2nd ring:
0.30-0.45mm
<Limit:0.70m m>
Oil ring:
0.20-0.70mm
PISTON RINGS, PISTON AND

CYLINDER INSTALLATION
1. Install:
Top ring 
2nd ring 
Side rails (oil ring) 
Expander spacer (oil ring) 
NOTE:
Make sure to install the piston rings so that the
manufacturer’s m arks or numbers are located
on the upper side of the rings.
Lubricate the pistons and piston rings liberally
with engine oil.

3. Install:
 Piston 
 Piston pin 
Piston pin clip  NEW
NOTE:
Apply engine oil to the piston pins.
The " → " mark ○ a on the piston must face
the intake side of the cylinder.
4. Position:
Piston rings
NOTE: 注
Offset the piston ring end gaps as shown.
○a Top ring end
○b Oil ring end (lower)
○c Oil ring end (upper)
○d 2nd ring end
5. Lubricate:
Piston outer surface
Piston ring
Cylinder inner surface
Engine oil

6. Install:
Cylinder
NOTE:
Install the cylinder with one hand while com
pressing the piston rings with the other hand.
Pass the timing chain and timing chain guide 。

(exhaust side) through the timing chain cavity.
3.7V-BELT,CLUTCH AND SECONDARY/PRIMARY SHEAVE

CRANKCASE COVER (LEFT)
Left cover removal Remove the parts in order.

1 Left cover 1
2 Bolt 10 Reverse the removal
procedure for installation .

PRIMARY SHEAVE
*Apply molybdenum disulfide grease
V-belt, clutch and secondary/ Remove the parts in order

primary sheave removal
1 Nut/Plain washer 1/1 Refer to "PRIMARY SHEA VE
2 Primary fixed sheave 1 REMOVAL" section.
3 Nut 1 Refer to "SECONDARY SHEAVE
4 Clutch housing 1 AND V-BELT REMOVAL"
5 Clutch assembly 1 section.
6 V-belt 1 Refer to "SECONDARY SHEAVE
7 Primary sliding sheave 1 INSTALLATION" section.
8 Collar 1
9 Primary sheave cap 1 Refer to "PRIMARY SHEAVE

10 Cam 1 ASSEMBLY" section.
11 Weight 8
12 Slider 4 Refer to "PRIMARY SHEAVE

13 Spacer 4 ASSEMBLY" section.
14 Oil seal 1 Reverse the removal
Procedure for installation.

SECONDARY SHEAVE
**Apply lightweight lithium-soap base grease
Secondary sheave disassembly Disassemble the parts in order.

1 Nut 1
2 Clutch carrier 1 Refer to "SECONDARY SHEAVE
3 Clutch shoe spring 3 DISASSEMBLY" section.
4 Compression spring 1
5 Spring seat 1 Refer to "SECONDARY SHEAVE
6 Guide pin 4 INSTALLATION " section .
7 Secondary sliding sheave 1
8 O-ring 2 Refer to "SECONDARY SHEAVE
9 Oil seal 2 INSTALLATION" section.
10 Secondary fixed sheave 1
Reverse the disassembly
procedure for assembly.

PRIMARY SHEAVE REMOVAL
1. Remove:
Nut (primary sheave)
Plate washer
Primary fixed sheave
NOTE:
Loosen the nut (primary fixed sheave) while holding
the primary fixed sheave with the rotor holder.
SECONDARY SHEAVE AND V-BELT REMOVAL

1. Remove:
Nut  (secondary sheave)
Clutch housing 
NOTE:
Loosen the nut (secondary sheave) while holding
the clutch housing with the sheave holder.
2. Remove:
Nut  (clutch carrier)
CAUTION:
Do not remove the nut (clutch carrier) yet.
NOTE:
Loosen the nut (clutch carrier) one turn using the
locknut wrench  while holding the clutch carrier
with the rotor holder.
3. Remove:
Clutch assembly 
V-belt 
NOTE:
Remove the V-belt from the primary sheave side
with clutch assembly.
SECONDARY SHEAVE DISASSEMBLY

1. Remove:
 Nut  (secondary sheave)
NOTE:
Loosen the nut  while attaching the clutch
spring compressor  and clutch spring holder
arm  and release the compressed spring after
removing the nut.
CAUTION:
Use the spacer  (diameter: Φ30mm ;
thickness: 2-3mm).
CLUTCH INSPECTION
1.Measure:
Clutch shoe thickness
Scratches → Glaze using coarse sandpaper.
Wear /Damage → Replace
Clutch shoe thickness:

3.0mm
<Limit:2.0mm>
NOTE:
After using the sandpaper, clean off the
polished particles.
Inspect the other clutch shoes.
Replace all three as a set.
V-BELT INSPECTION
1.Inspect:
V-belt 
Cracks/Wear /Scaling /Chipping → Replace.
Oil/Grease → Check primary sheave and
secondary sheave.
2. Measure:
V-belt width 
Out of specification → Replace
V-belt width:
22.6mm
(Limit:21.0mm)
ROLLER INSPECTION
1. Inspect:
 Roller minimum outside diameter
Cracks/Wear /Scaling /Chipping → Replace.
Roller outside diameter:

20.0 mm
<Limit: 19.5mm>

SECOMDARY SHEAVE INSPECTION
1. Inspect:
Secondary fixed sheave smooth operation
Secondary sliding sheave smooth operation
2. Inspect:
Torque cam groove 
Wear /Damage → Replace.
3. Inspect:
Guide pin 
Wear /Damage → Replace.
PRIMARY SHEAVE ASSEMEBLY

1. Clean:
Primary fixed sheave face 
Collar 
Weight 
Primary sliding sheave cam face
NOTE:
Remove any excess grease.
2. Install:
Roller 
Collar 
NOTE:
Apply molybdenum disulfide grease to all of the
outside of the roller and install.
Apply lightweight lithium-soap base grease to

the inside of the collar.
3. Install:
Spacer 
Slider 
Cam 
Primary sliding sheave cap.
SECOMDARY SHEAVE INSTALLATION

1. Apply:
Lightweight lithium-soap base grease
(to the secondary sliding sheave  inner
surface, grease nipple groove, and oil seals)
 Lightweight lithium-soap base grease
(to the bearings, oil seals and inner surface of
the secondary fixed sheave  )
2. Install:
Secondary sliding sheave 
NOTE:
Install the secondary sliding sheave using
the oil seal guide  to the secondary fixed
sheave.
3. Install:
Guide pin
4. Apply:
 Lightweight lithium-soap base grease
(to the guide pin sliding groove , and oil seal 
(NEW)
5. Install:
Secondary sheave complete 
Compression spring
Clutch carrier 
NOTE:
Temporarily tighten the nut while attaching the
clutch spring holder  and clutch spring holder
arm  and compress the spring.
CAUTION:
Use the spacer  (30mm, thickness: 2-3mm).
6. Install:
V-belt 
Clutch assembly 

NOTE:
Install the V-bet with clutch assembly to the
primary sheave side.
CAUTION:
Never smear grease to the V-belt, secondary
sheave and clutch.
7. Install:
Nut  (clutch carrier)
NOTE:
Tighten the nut (clutch carrier), using the locknut
wrench  while holding the clutch carrier with
the rotor holder 。
8. Install:
Clutch housing 
Nut (clutch housing) 
NOTE:
Tighten the nut (clutch housing),using the
sheave holder ).
9. Set:
V- belt 
NOTE:
Move the V-belt to minimum diameter of the
primary sheave , maximum diameter of the
secondary sheave  and make the V-belt tense.

3.8A.C. MAGNETO AND STARTER CLUTCH
MAGNETO COVER AND STATOR COIL
Order Job name/ Part name Q'ty Remarks

Remove the parts in order.
Magneto cover and stator coil
Refer to "ENGINE OIL REPLACEMENT"
Removal
section.
Drain the engine oil.
1 Magneto cover 2
2 Couplers
Gasket (magneto
(A.C. magneto
cover) lead) 1
3 Dowel pins 1 Reverse the removal procedure for
4 Stator coil 1 installation.

A. C. MAGNETO AND STARTER CLUTCH

A.C. magneto and starter clutch Remove the parts in order.
Removal Refer to "A.C. MAGNETO ROTOR
1 Rotor 1 REMOVAL /INSTALLATION" section
2 Shaft (idle gear) 1 Refer to "ROTOR INSTALLATION"

3 Idler gear 1 section.
4 Starter one way clutch assembly 1 Reverse the removal procedure for
5 Woodruff key 1 installation.
6 Starter wheel gear 1

A.C. MAGNETO ROTOR REMOVAL
1. Remove:
Nut  (rotor)
Plain washer
NOTE:
Loosen the nut (rotor) while holding the rotor
with a sheave holder .
Do not allow sheave the holder touch to the
projection on the rotor.
2. Remove:
Rotor 
Woodruff key
NOTE:
Remove the rotor using the flywheel puller.
Center the flywheel puller over the rotor.
Make sure after installing the holding bolts that the

clearance between the flywheel puller and the
rotor is the same everywhere. If necessary, one
holding bolt may be turned out slightly to adjust
the flywheel puller's position.
CAUTION:
Cover the crankshaft end with the box wrench for
protection.
STARTER DRIVE GEAR INSPECTION

1. Inspect:
Starter idle gear teeth
Starter drive gear teeth
Starter wheel gear teeth
Burrs /chips /roughness /wear → Replace.
2. Check:
Starter clutch operation
Push the dowel pins to the arrow direction.
Unsmooth operation → Replace.
Checking steps:
When turning the starter wheel gear clockwise,
the starter clutch and the starter wheel gear
should be engaged.
If not, the starter clutch is faulty. Replace it.
When turning the starter wheel gear counter
clockwise, it should turn freely.
If not, the starter clutch is faulty. Replace it.
A.C. MAGNETO ROTOR INSTALLATION
1. Install:
Starter wheel gear .
Woodruff key 
NOTE:
Install the starter wheel gear, then install the
woodruff key.
2. Install:
Plain washer
Rotor 
NOTE:
Clean the tapered portion of the crankshaft
and the rotor hub.
When installing the magneto rotor, make sure
the woodruff key is properly seated in the key
way of the crankshaft.
3.Tighten:
Nut(rotor)
NOTE:
Tighten the nut (rotor) while holding the
magneto rotor with a sheave holder.

3.9 OIL PUMP
Oil pump removal Remove the parts in order.

A.C. magneto Refer to "A.C. MAGNETO AND STARTER
1 Cover 1 CLUTCH" section.
2 Pump driven gear 1
3 Dowel pin 1
4 Oil pump assembly 1
5 Gasket 1
6 Impeller shaft gear 1
7 Dowel Pin 1
8 Shaft 1
Reverse the removal procedure for

installation.

OIL PUMP INSPECTION

1. Inspect:
Drive gear (oil pump) 
Pump housing
Pump housing cover
Wear /cracks/ damage → Replace.
2. Measure:
 Tip clearance
(between the inner rotor  and the outer rotor)
Side clearance
(between the outer rotor  and the pump
housing  )
Housing and rotor clearance
(between the pump housing  and the rotors 
)
Out of specification → Replace the oil pump
assembly.
Tip clearance □
A :
0.10-0.34 mm <Limit: 0.40mm>
Side clearance □
B :
0.013-0.036mm <Limit:0.15mm>
Housing and rotor clearance □
C:
0.04-0.09 mm <Limit: 0.15mm>

3.10CRANKCASE AND CRANKSHAFT

Crankcase and crankshaft
Removal Remove the parts in the order.
Engine removal Refer to "ENGINE REMOVAL" section.
Cylinder head Refer to "CYLINDER HEAD" section.
Cylinder, and piston Refer to "CYLINDER AND PISTION"
V-belt, clutch, secondary/ primary section.
Sheave Refer to "V BELT, CLUTCH AND
A.C. magneto and starter clutch SECONDARY/PRIMARY SHEAVE" section.
1 Pull rod screw 1 Refer to "A.C. MAGNETO AND
2 O-ring 1 STARTER CLUTCH" section.
3 Guide plate(on) 1 Refer to "OIL PUMP" section.
4 Right box 1 Refer to "WATER PUMP" section.
5 Dowel pin 2 Refer to "REAR WHEEL AND REAR
6 Camshaft ASSY 1 BRAKE" section.
7 Timing chain 1 Refer to "CRANKSHAFT INSTALLATION"
8 Left box 1 section.
9 Bearing 2 Refer to "CRANKSHAFT REMOVAL/
10 Balance shaft ASSY 1 INSTALLATION" section.
11 Bolt 10 Reverse the removal procedure for
12 Guide plate(down) 1 installation.

CRANKSHAFT REMOVAL
1. Remove:
Crankshaft assembly
Timing chain
NOTE:
Before removing the crankshaft assembly,
remove the timing chain from the crankshaft
sprocket.
If the timing chain hooks to the crankshaft
sprocket, the crankshaft cannot be removed.
CRANKSHAFT INSPECTION
1. Measure:
Crankshaft runout
Out of specification → Replace crankshaft and
/ or bearing.
NOTE:
Measure the crankshaft runout with the
crankshaft assembly running slowly.
Runout limit:
0.03 mm
2. Measure:
Big end side clearance
big end bearing, crank pin and/or connecting
rod.
Big end side clearance:

0.35-0.85 mm
3. Measure:
Crank width
Out of specification → Replace crankshaft.
Crank width:
59.95-60.00 mm

4. Inspect:
Crankshaft sprocket 
Wear/ Damage → Replace crankshaft.
Bearing 
Wear/ Crack /Damage → Replace crankshaft.
Pump drive gear 
Wear/ Damage → Replace crankshaft.
5. Inspect:
Crankshaft journal
Clogged → Blow out the journal with
compressed air.
CRANKCASE INSTALLATION
1. Clean all the gasket mating surface and
crankcase mating surface thoroughly.
2. Apply:
Sealant
(onto the crankcase mating surfaces)
NOTE:
DO NOT ALLOW any sealant to come into
contact with the oil gallery.
3. Install:
Dowel pins
Timing chain 
NOTE:
Install the timing chain not to be seen through
the crankshaft hole○ a on the crankcase (left).
3.11COOLING SYSTEM
3.11.1RADIATOR

Radiator removal Remove the parts in order
Drain the coolant. Remove the parts in order.
1 Radiator ASSY 1 Refer to "COOLANT REPLACEMENT"
2 Blower ASSY 1 section.
3 Clamp 8 Reverse the removal procedure for
4 Water supply pipe 1 installation.
5 Return pipe 1
6 Clamp 9 2
7 RADIATOR CAP 1
8 Leaky pipe 1
9 Leaking kettle 1
10 Clamp 10 1
11 Feed hose 1
12 Fan fixing card 4
13 Flange Bolt 4
14 THERMOSTAT SWITCH ASSY 1
15 Return hose
1
16 connecting pipe
17 Water pipe fixing card 2
18 Flange Bolt 4
4

19 Return hose, cylinder 1
20 Feed hose, valve 1
21 Water tank rubber cushion 1
22 Temperature control switch gasket 1
INSPECTION
1. Inspect:
Radiator 
Obstruction → Blow out with compressed air
through the rear of the radiator.
Flattened fins → Repair or replace.
If flattened over the 20% of radiator fin, repair or
replace the radiator.
CAUTION:
Use only specified adhesive to repair the
radiator.
2. Inspect:
Radiator hoses
Radiator pipes
Cracks/damage → Replace.
3. Measure:
Radiator cap opening pressure
Radiator cap opens at a pressure below the
specified pressure → Replace.
Radiator cap opening pressure:

110-140kPa
(1.1-1.4kg/cm2 , 1.1-1.4 bar)
Measurement steps:
Attach the radiator cap tester and adapter 
to the radiator cap .
Apply the specified pressure for 10 seconds,
and make sure there is no pressure drop.
4. Inspect:
Fan motor assembly
Damage → Replace.
Malfunction → Check and repair.
Refer to "COOLING SYSTEM " section.
5. Inspect:
Pipes
Cracks/damage → Replace.

3.11.2WATER PUMP
Water pump removal Remove the parts in order.

Drain the coolant. Refer to "COOLANT REPLACEMENT"
section.
A.C. magneto Refer to "A.C. MAGNETO AND STARTER
CLUTCH" section.
1 lmpeller shaft gear 1
2 Dowel pin/plain washer 1/1
3 Shaft 1 Refer to "WATER PUMP INSTALLATION"
4 Outlet hose (radiator) 1 section.
5 Housing cover 1
6 Housing cover gasket 1 Refer to “WATER PUMPINSTALLATION”
7 Water pump housing 1 section.
Impeller shaft 1 Reverse the removal procedure for
installation.
O-ring
1
O-ring

NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant temperature and/
or level, discoloration of coolant, or milky
transmission oil.
If necessary, replace water pump as an
assembly.
INSPECTION
1. Inspect:
Impeller shaft
Wear/damage → Replace.
Fur deposits → Clean.
2. Inspect:
Impeller shaft gear
Wear/damage → Replace.
3. Inspect:
Oil seal 
Damage/worn/wear → Replace.
WATER PUMP INSTALLATION
1. Install:
Oil seal  NEW
Installation steps:
Apply the bond to the outside of the oil seal.
Install the oil seal by using the oil seal installer
 and middle shaft bearing driver 
2. Install:
Oil seal  NEW
Apply coolant to the outside of the oil seal
before installing.
NOTE:
Do not smear any oils or grease on the ring side
of the oil seal.
3. Inspect:
Mechanical sea , slip ring side 
Inspect the slip ring side of the oil seal and the
impeller  for level installation.
Incorrect level → Reinstall.
4. Install:
Impeller shaft
Circ lip  NEW
Installation steps:
Apply a small amount of grease to the impeller
shaft tip.
Install the impeller shaft while turning it. Use
care so that the oil seal is not damaged or the
spring does not slip off its position.
NOTE:
After installing the impeller shaft, check it for
smooth rotation.
5.Install:
O-ring(NEW )
6. Install:
Water pump housing
Housing cover
7. Install:
Shaft
Align the slot on the impeller shaft with the
projection on the shaft when installing.

3.11.3THERMOSTAT
Thermostat removal Remove the parts in order.

Drain the coolant Refer to "COOLANT REPLACEMENT"
section.
1 Bolt 2 Refer to "THERMOSTAT INSTALLATION"
2 Thermostatic cover 1 section.
3 Thermostatic valve 1 Reverse the removal procedure for
installation.
INSTALLATION
1. Inspect:
Thermostatic valve
Valve does not open at 70-74℃→Replace.
Inspection steps:
Suspend the thermostatic valve in a vessel.
Place a reliable thermometer in water.
CHAPTER 3 ENGINE 450UTV SERVICE MANUAL 2016/ version number
1601
 Observe the thermometer, while continually
stirring the water.
Thermostatic valve
Vessel
Thermometer
Water
A CLOSE
B OPEN
NOTE:
The thermostatic valve is sealed and its setting
requires specialized work. If its accuracy is in
doubt, replace. A faulty unit could cause serious
over-heating or over cooling.
2.Inspect:
Thermostatic cover
Cracks /damage → Replace.
INSTALLATION
1. Install:
Thermostatic valve
Thermostatic cover

1601
3.12 Transmission assemly（Independent）
Failure analysis and repair of the transmission assemly refer to the table：
Possible causes of Measures Maintenance
Fault type
failure Reference
Shift shaft O-ring damage replace Remove the gearshift
leakage mechanism
V-belt with Spindle oil seal is replace Remove the left cover of the
leaka slip damaged gearbox
ge Front output The front output shaft oil replace Remove the front cover of
shaft leakageseal is damaged the gearbox
The front output shaft is replace Remove the front output
damaged shaft
Rear output The rear output shaft oil replace Removal
shaft leakage seal is damaged
The rear output shaft is replace Remove the rear output shaft
damaged assembly
gear unclear The shifter fork is replace Remove the gear control
damaged
The shifting cam is replace
damaged
The shift stop lever is replace
damaged
Damage of shift drum replace Refer to "Removing the main
shaft and auxiliary shaft
assemblies"
Difficulty in shifting or The shifter fork is replace
unable to shift gears damaged
Shift drum wear / replace
damage
The shift disc is replace
damaged
The shift shaft is replace
damaged
Defective shift cable replace Refer to the vehicle section
to replace the shift cable

1601
3.12.1The transmission is connected to the engine
order Process Name / Part Name Qua Remarks

ntity
Remove the transmission
assembly Refer to "V type belt, clutch and driven /
Remove the transmission active pulley"
assembly from the engine
1 Bolt M6X40 10
2 Left cover 1
3 Nut M14X1 1
4 Follower clutch assembly 1
5 Drive belt 1
6 Bolt M8 4
7 Bolt M10 2
8 Bolt M10 3
9 Connection plate 1
Examination
1、leakage
Shift Shaft (O-ring)
Shift drum (O-ring, at the inside of transfer indicator)
Transmission left cover
Transmission (rear output shaft oil seal)
Transmission front cover (front output shaft oil seal)

1601
3.12.2Shifting mechanism
orde Process Name / Part Name Qua Remarks

r ntity
Remove the shifting When necessary
mechanism
Remove the gearbox from the
engine
1 Loosen the M6 bolts 1
2 Shift cable tray 1
3 Shaft Collar 9 1
4 Shift switch 1
5 Bolt M6 5
6 Shift small cover 1
7 O-ring 1
8 Shift positioning spring 1
9 Shift stop lever 1
10 Shift shaft 1
11 O-ring 1
12 Shift cam 1
13 Shift drive gear 1
14 Shift driven gear 1

1601
1、Inspect
The spline of the shift cable tray
Wear / damage → replacement.
Shaft collar 9 → Replace with new one.
Shift positioning spring Limit height:
Fail / Out of Standard → Replace. 28 mm
Shift stop lever

Wear / Out of Standard → Replace.
Standard value h: 15 ± 0.5mm
Limit value: 14mm
Spline of the shift shaft

Wear / damage → replacement
Shift drive gear
Shift cam
Shift driven gear
with the two gear teeth marked by the shifting

2、 Installation
driving gear . Otherwise, it will cause the shift is
Shift drive gear not accurate, must be re-adjusted. When the
Note: teeth, you can turn the shift drum to ensure that
The side of the shift driven gear with the the mark is aligned.
marked side facing up.
Shift driven gear
Note:
The gears of the shift driving gear and the
shifting driven gear are in a one-to-one
correspondence, and when the shift driving
gear is mounted, it is ensured that the shift
driven gear has a marked one tooth meshed
Shift shaft
Shift cam
Shift stop lever
Shift positioning spring
O-ring 13.8X1.8 (shift shaft)
O-ring 9X1.8 (shift drum)

1601
Note: O-ring to prevent the O-ring from being cut
Apply a small amount of grease to the when installing the small shift cover.
Shift small cover
Sealant (applied to the transmission cover surface)
Note:
Do not apply too much sealant on the bonding surface to prevent excessive
of the sealant into the gearbox interior, blocking the oil path and airway.
Do not apply the sealant to the threaded hole to prevent plugging of the threaded hole.
Bolt M6
Use a rag to wipe out at the junction of excess sealant.

1601
3.12.3 A spindle assembly and a countershaft assembly
order Process Name / Part Name Qua Remarks

ntity
Remove the spindle Refer to "Disconnecting the Transmission
assembly and the from the Engine"
countershaft assembly Refer to "Removing the Shift Mechanism"
Remove the gearbox
assembly
Drain the oil (remove drain The whole removed
screw and gasket)
Remove the gearshift
mechanism If necessary, decomposition
Bolt M8
Left cover of transmission If there is
1 Locating Pins 9 If there is
2 Spindle assembly, vice 1
shaft assembly, shift drum
3 and fork, fork shaft 2
4 Shift drum
Shifter fork assembly
Shaft Collar
Fork spring cover
5 Low-speed fork spring 1
Fork
6 Fork shaft 2
1601
7 Bolt M6 1
8 Parking seat 1
9 2
10 1
11 3
12 1
1、Examination
Oil seal
Damage / wear / failure of inner spring → Replacement.
Shift drum
Spline damage / wear → Replacement. Standard values: 8.0-8.2mm
Drum 2 groove width Limit value: 8.75mm (except low gear)
Substandard → replacement.
Shifter fork
Symmetr Standard value:
Damage / wear → replacement.
y with 0.1mm
respect Limit value: 0.175mm
Shifter fork substandard →
to the pin
replacement.
Standard value:
thickness 4.9-5.1mm
Limit value: 4.75mm
Note:
Check, if found fork burns, discoloration, please check
Check whether the corresponding shift plate burns, discoloration or damage If so ,
please also replace.
To remove the shift disc, refer to "Disassembling the Main and Secondary Shaft
Assemblies".
Low-speed fork spring

Failure → replacement
Shifter fork shaft

Wear / damage / substandard → replacement Diameter 11.66—11.84mm
standard
value
1601
Diameter 11.41mm
limit value
2、Installation
Parking gear
Bolt M6
Shifter fork and shifter fork shaft assembly disc
Disassembly shifter fork and shifter fork shaft
⑤ components
Install shaft collar 12 ①
Install the shifter fork spring cover ②
Install low-speed shifter fork spring ③
2 shifter forks installed ④ (with pin a side
up)
Shifter forks were installed on the vice shaft
on the shift
Shift drum
Note:
The pin a of the shifter fork is attached to the guide groove of the shift drum,
The small end of the shift drum faces toward the spring.
The overall installation of the main and vice-axis components and fork components, shift drum
Locating Pins
Sealant (applied to the transmission cover surface)
Note:
Do not apply too much sealant on the bonding surface to prevent excessive
of the sealant into the gearbox interior, blocking the oil path and airway.
Do not apply the sealant to the threaded hole to prevent plugging of the threaded
hole.
Bolt M8
Use a cloth to wipe away any excess sealant from the bond surface.
3、The main and auxiliary shaft components are disassembled

1601
order Process Name / Part Name Quant Remarks

ity
1 Bearing 6004 1
2 Washer 21X30X2 1
3 Low speed driving gear 1
4 Drive sprocket 1
5 Toothed chain 1
6 Bearing 6204 1
7 Transition gear 1 1
8 Shaft Collar 25 1
9 Washer 25X38X1.2 1
10 Needle roller bearings 1
25X29X10
11 High speed driven gear 1
12 Washer 25X38X1.2 1
13 Shaft Collar 25 1
14 Reverse high speed shift 1
16 Washer 32X39.2X1.8 1
17 Driven sprocket (reverse gear) 1
Needle Roller Bearings
18 32X37X13 1
1601
Washer 32X39.2X1.8
19 Bearing 6004 1
20 Low-speed parking shift 1
22 Washer 25X38X1.2 1
23 Low speed driven gear 1
24 Needle roller bearings 1
25 25X29X10 1
Washer 25X38X1.2
26 Bearing 6205 1
27 1
Examination
Reverse high speed shift
Worn / damaged / broken → replaced
Low-speed parking shift

Reverse high speed gear

Low speed parking gear

Spindle
Thread damage / teeth → replacement
Gear wear / damage / fracture → replacement
Shaft Collars
Deformation / distortion / damage → replacement
Assembly:
Refer to "Decomposition of Main and Secondary Shaft Components". in reverse
order of decomposition.
3.12.4Output shaft assembly

1601
order Process Name / Part Name Quan Remarks

tity
1 Remove the output shaft Refer to "Disconnecting the Transmission
assembly from the Engine"
Remove the gearbox
assembly
2 Drain the oil (remove drain when necessary
screw and gasket) 1/1 when necessary
3 Bolt M8 7
4 Transmission front cover 1
5 Oil seal 1 when necessary
6 Limit pin 2
7 Locating Pins 1
8 Front output shaft assembly 1
Rear output shaft assembly
9 Transmission chain 1
Remove the shaft sleeve
10 1
11 1
Examination
Oil seal
Damage / wear / failure of inner spring → Replacement.
Front output shaft
Spline damage / distortion / break / crack → replacement
1601
Bearings
Wear / Gap / Crack → Replace
Rear output shaft
Spline damage / distortion / break / crack → replacement
Bearings
Wear / Gap / Crack → Replace
Large bevel gear
Tooth surface damage / distortion / fracture / crack → replacement
Note:
If you replace the output shaft, while complete sets of replacement, with the assembly of large
bevel gear, drive sprocket, both ends of the bearing and paired with small bevel teeth.
Chain
Damage / distortion / fracture / crack / elongation → replacement
h Standard value:
0.2-0.96mm
Limit value: 2.9mm
Note: When measuring, measure the
chain by pressing
forward.
Shaft sleeve
Damage / wear → replacement.
standard value：
19-19.021mm
limits：19.039mm
Note:
When removing damaged bushings, be careful not to damage the bores.
Assembly:

1601
Refer to disassembly in reverse order.

Shaft sleeve
In the sleeve hole is coated with a little grease.
Rear output shaft assembly and chain
Apply a small amount of grease to the lip of the oil seal.
Driven sprocket
Output shaft assembly
Locating Pins
Apply a small amount of sealant to the lid
Transmission front cover
Note:
Install the stop pin on the front cover of the gearbox. Before installing the limit pin, apply a
small amount of grease to the stop pin hole on the front cover of the gearbox to prevent dropping
during assembly. If you fall into the gearbox, but not found in time, the gearbox is very dangerous,
there may be serious accidents.
Bolt M8
Drain bolts and gaskets

1601
NOTES

CHAPTER 4 CHASSIS SERVICE MANUAL
CHAPTER 4 CHASSIS
WARNING
have almost same appearance. Always refer to Parts Manual of each CUV model for spare
4.1 FRONT A-ARM REPLACEMENT
4.2 REAR A-ARM REPLACEMENT
4.3 REAR STABILIZER BAR REMOVA L/INSTALLATION
4.4 FRONT STRUT REPLACEMENT
4.5 FRONT STRUT BALL JOINT REPLACEMENT
4.6 BOX REMOVAL/INSTALLATION
4.7 STEERING ASSEMBLY REMOVAL/INSTALLATION
CHAPTER 4 CHASSIS PAGE. 4- 1

4.1 FRONT A-ARM REPLACEMENT
1. Elevate and safely support vehicle with weight removed from front wheel(s).
2. Remove cotter pin from ball joint stud at wheel end of A- arm and loosen nut until it is flush
with end of stud.
3. Using a soft face hammer, tap nut to loosen A- arm from bolt. Remove nut and A-arm from
hub strut assembly.
4. Loosen and remove two bolts on A-arm, and remove A-arm.
5. Examine A-arm bushing. Replace if worn or tore. Discard hardware.
6. 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.
7. 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.
8. Install hubs, calipers and wheels, lower the vehicle to the ground. Apply Loctite™ 242 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. 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 hub cap, cotter pin, spindle bolt,

and washer.
4. 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.

5. Loosen two bolts that secure the rear knuckle to

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

absorber to the lower A-arm.
7. Remove the bolts that secure the upper A-arm to
frame.
8. Remove the bottom stabilizer bar nut.

9. Remove the bolts that secure the lower A-arm to frame.
10. Examine all the A-arm bushings and A-arm shafts. Replace if worn. Discard hardware.
11. Insert new A-arm bushings and new A-arm shafts 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 absorber and tighten shock bolt to 32 ft.lbs. (44 Nm).
15. Install the stabilizer and tighten nut to 40 ft.lbs. (56 Nm).
16. Re-install wheel and caliper.
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 23 ft.lbs (32 Nm).
4.4 FRONT STRUT REPLACEMENT

1. Hold strut rod with wrench and remove top nut.

2. Compress spring.
3. Remove all strut pivot assembly.
4. Remove coil spring and collapse strut body.
5. Remove two pinch bolts from strut body.
6. Remove strut body.
7. Install front shock cartridge until bottomed in strut casting.
8. Install pinch bolts with clamp(s). Torque pinch bolts to 18ft.lbs.(25Nm).
9. Reassemble spring and top pivot assembly. Be sure all parts are installed properly and
seated fully.
10. Torque strut rod nut to specification. Do not over torque nut.
Strut Rod Nut Torque :15 ft. lbs. (21 Nm)
4.5 FRONT STRUT BALL JOINT REPLACEMENT

1. Loosen front wheel nuts.
2. Elevate and safely support CUV under footrest /
frame area. .
CAUTION: Serious injury may result if CUV tips or
falls. Be sure CUV is secure before beginning this
service procedure.
3. Remove wheel nuts and wheels.
4. Remove cotter pin from ball joint
5. Remove castle nut and separate A-arm from ball
joint stud.
6. Remove screws and ball joint mounting bracket.
7. Using ball joint cup removal/installation toolkit,
remove ball joint cup from strut housing. Refer to
photos at right.
Install puller guide (1) .
Thread bolt (2) with nut (3) onto ball joint stud
as shown .
Hold bolt (2) and turn nut (3) clockwise until ball
joint is removed from strut housing.
8. To install new ball joint cup.
Insert new ball joint into driver (installation
toolkit).
Drive new ball joint cup into strut housing until
fully seated.
9. Apply Loctite 242 (blue) to threads of mounting
bracket new screws.
Torque screw s to 8 ft.lbs. (11 Nm).

10. Install A-arm on ball joint cup and torque castle
nut to 25 ft. lbs. (35 Nm ).
11. Reinstall cotter pin with open ends toward rear of
machine.
4.6 BOX REMOVAL/INSTALLATION

Box Removal
1. Disconnect the taillight coupler.
2. Lift the box into the dump position.
3. Remove the box shock pin from the frame (both
sides).
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 (both sides).
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 may be 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 (both sides).
3. Secure the box hinges with the cotter pins (both
sides).
4. With the hinges installed, decompress the box
shocks and place them into the shock brackets
on the frame (both sides).
5. Secure the box shocks with the shock pin (both
sides).
6. Lower the box and secure the latch.
7. Connect the taillight coupler.
4.7 STEERING ASSEMBLY REMOVAL/INSTALLATION
1. Remove the bolt and nuts that fixed the plastic sleeve.
2. With the steering wheel cover bolts removed, remove the steering wheel cover and steering
wheel and horn switch.
3. With the steering wheel holder nut / spring washer / flat washer removed, remove the
steering wheel holder and plastic sleeve.
4. With the steering column bolts removed, 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 SERVICE MANUAL
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 REAR HUB EXPLODED VIEW
5.7 REAR HUB AND KNUCKLE RE MOVAL/ INSPECTION
5.8 REAR HUB AND KNUCKLE INSTALLAT ION
5.9 REAR DRIVE SHAFT REMOVAL
5.10 REAR DRIVE SHAFT INSTALLATION
CHAPTER 5 FINAL DRIVE. 5- 1

5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE
Item Specification
Front W heel Nuts 59 Ft.Lbs 66 N.m
Rear Wheel Nuts 59 Ft.Lbs 66 N.m
Front Hub Nut on Spindle/ outer CV joint 101 Ft.Lbs 137 N.m
Rear Hub Retaining Nut 101 Ft.Lbs 137 N.m

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 hub cap, cotter pin, front spindle nut,

and washer, separate hub from front driveshaft.
7. Rotate break disc 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 rotate bearing surface for wear or
damage.
2. Install the hub into the bearing.
3. Apply grease to the spline of front driveshaft.

Install driveshaft through the backside of the
HUB.
4. Install washer and spindle nut and tighten to 101

ft.lbs (137 N.m).
5. Install a new cotter pin. Tighten nut slightly if

necessary to align cotter pin holes. bend both
ends of cotter pin around end of spindle in
different directions. Install hub cap.

6. Rotate hub. It should rotate smoothly without

binding or rough spots or side play.
7. Install brake caliper using new bolts. (Apply

Loctite™ 242 to threads) Tighten bolts to 18 ft.lbs
(25 N.m)
CAUTION: New bolts have a pre-applied locking
agent which is destroyed bolts upon removal. Always
use new brake caliper mounting bolts upon
assembly.
8. 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 housing if damaged.

5.6 REAR HUB EXPLODED VIEW
5.7 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 hub cap, cotter pin, 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
shaft.
8. Inspect the rear hub and knuckle assembly by

hand for smoothness and side to side movement,
replace as needed.
5.8 RE AR HUB AND KNUCKLE INSTALL ATION

1. Install 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. Tighten upper and lower bolts to 45 ft.lbs (60
N.m).
5. Install the washer and the spindle retainer nut,
tighten bolts to 101 ft.lbs (137 N.m), install a new
cotter key and hub cap.
(25 N.m).
7. Install the wheel and wheel nuts. Torque wheel
nuts to 59 ft.lbs. (66 N.m).
5.9 RE AR DRIVE SHAFT REM OVAL

1. Repeat of the steps in the “REAR HUB AND
KNUCKLE REMOVAL” section.
2. Pull the rear drive shaft straight out of the frame.

Use short sharp jerks to free the circlip from the
gearcase. (The circlip holds the shaft in the
gearcase)

3. Inspect the shaft splines and cv boots for any

damage.
5.10 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 shaft into the knuckle.
4. Lift knuckle into place and install bolt to upper

and lower control arm. Torque bolt to 45 ft.lbs (60
N.m).
5. Install the washer and the spindle retainer nut,

tighten bolts to 101 ft.lbs (137 N.m), install a new
cotter key and hub cap.

(25 N.m).
7. Install the wheel and wheel nuts. Torque wheel

nuts to 59 ft.lbs. (66 N.m).

NOTES

CHAPTER 6 BRAKES SERVICE MANUAL
CHAPTER 6 BRAKES
WARNING
have almost same appearance. Always refer to Parts Manual of each ATV 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 REAR PADS REMOVAL/INSTALL
6.9 FRONT PADS INSPECTION / REMOVAL / REPLACEMENT
6.10 FRONT DISC INSPECTION / REMOVAL / REPLACEMENT
6.11 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION
6.12 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION
6.13 REAR BRAKE DISC INSPECTION / REMOVAL / REPLACEMENT
CHAPTER 6 BRAKES PAGE. 7- 1

6.1 SPECIFICATIONS
Front Brake Caliper
Item Standard Service Limit
Brake Pad Friction material
0.157"/ 4mm 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"/ 4mm
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*) (N.m )
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
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 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 th e 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 between the MIN line and MAX
line of reservoir.
DOT 3 Brake Fluid
5. Begin bleeding procedure with the caliper that is
Reservoir
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 w ear or abrasion is found.

6.6 PARKING BRAKE AND BRAKE LINE INSPECTION
1. Inspect the spring on the parking brake lever

assembly. Brake Line
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 7 to 9 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 on the rear caliper
adjustment bolt.
4. Tighten the adjustment bolt until the rear tire will
not rotate.
5. Back off the adjustment bolt 1/4 turn.
6. Tighten the jam nut while holding the adjustment
nut in place.
6.8 REAR PADS REMOVAL / INSTALL

NOTE: The brake pads should be replaced as a set.
1. Elevate and support rear of CUV safely.
CAUTION:
Be care when supporting vehicle so that it does not
tip or fall. Severe injury may occur if machine tips or
falls.
2. Remove the rear wheels.
3. Remove the two caliper bolts and caliper from

mounting bracket.

4. Measure the thickness of the caliper parking

brake pads. Replace pads if worn beyond the
service limit.
Service Limit 3/64"(1 mm)
The Procedure of Pads Replacement

1. 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.
2. Push mounting bracket inward and slip outer

brake pad past edge. Remove inner pad.
3. Lubricate mounting bracket pins with a light film

of All Season Grease, and install rubber dust
boots.
Installation
4. Compress mounting bracket and make sure dust

boots are fully seated. Install pads with friction
material facing each other.
NOTE: Do not get oil, grease or fluid on the park
brake pads. Damage to the pads may cause the
pads to function improperly.
Rear Brake Caliper Installation

1. Install the park brake assembly into place.
Tighten the two bolts for proper installation.
2. Torque the two bolts to 18 ft.lbs. (25 N.m).
3. Test the park brake for proper function.

6.9 FRONT PADS REMOVAL / INSPECTION / INSTALLATION

NOTE: The brake pads should be replaced as a set.
REMOVAL
1. Elevate and support front of CUV safely.
CAUTION:
Be 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 wheels.
3. Remove the two caliper bolts and caliper from

mounting bracket.
INSPECTION
Measure the thickness of the pads friction material.
Replace pads if worn beyond the service limit.
Service Limit 3/64"(1 mm)
The procedure of pads replacement

1. Repeat of the Replacement Steps in the “REAR PADS REMOVAL / INSTALL” section.
Front Caliper Installation

1. Install caliper on hub strut, and torque mounting bolts.
Front Caliper Mounting Bolts Torque 18 ft. lbs. (25 N.m )
NOTE: The Following Procedure Should Be Done After Front / Rear Brake Pads Replacement.
1. 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.
2. Turn the adjustment bolt clockwise until stationary pad contacts disc, then back off 1/4 turn
(counter clockwise), then lock the jam nut.
3. Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.
4. Install wheels and torque wheel nuts.
5. 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.
2. Remove bolts and disc.
3. Clean mating surface of disc and hub.
4. Install new disc on hub and tighten to specified.

Front Brake Disc Mounting Bolt Torque
18 ft. lbs (25 N.m )
CAUTION:
Always use new brake disc mounting bolts.

6.11 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION
CAUTION:
The caliper is a non-serviceable Component, it must
be replaced as an assembly. Brake Hose
NOTE: If any special service needed, contact the

CUV manufacture via the agent for the parts and
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™ 242 to screw threads and Install new bolts.
Front Caliper Mounting Bolt Torque: 18 ft. lbs (25 N.m )
2. Install brake hose and tighten to specified torque.
Bolt Torque: 15 ft. lbs (21 N.m)
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 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 Brake Hose
CUV manufacture via the agent for the parts and
1. Safely support the rear of the machine.

2. Remove the brake hose and park brake line.
Place a container to catch brake fluid draining

from brake hose.

3. After the fluid has drained into the container, remove the caliper mounting bolts and remove
caliper.
4. Remove brake pads 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 N.m).
8. Install park brake line, brake hose and tighten to specified torque.
Bolt Torque: 15 ft. lbs(21 N.m)
9. 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.
10. 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.
6.13 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 0.150-0.164" (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 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.
Rear Brake Disc Mounting Bolt Torque : 18 ft. lbs (25 N.m )
CAUTION:
Always use new brake disc mounting bolts.

NOTES

CHAPTER 7 ELECTRICAL CUV SERVICE MANUAL 09.0
CHAPTER 7 ELECTRICAL
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 REVERSE LIMIT SYSTEM
7.9 GEAR POSITION INDICATOR SWITCH TEST
7.10 SPEEDOMETER SYSTEM
7.11 MAIN SWITCH AND HANDLE SWITCH
7.12 FUEL GAUGE/ FUEL LEVEL SENSOR
7.13 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT
7.14 WIRING DIAGRAM

A HEADLIGHT ADJUSTMENT
1. Use bulb 12V 35W/35W.
2. Remove the black sheath, turning the socket counterclockwise and take it out.
Turning the bulb counterclockwise and Remove it from the socket.
3. Change the bulb.
HEADLIGHT ADJUSTMENT
1. The headlight beam can be adjusted vertically.
2. Place the vehicle on a level surface with the headlight approximately 33in(10m) 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 86mm to
129mm 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.
To turn the two adjusting screws backward is to lower the beam. To turn the two adjusting screws
forward is to heighten the beam.

TAILLIGHT / BRAKELIGHT LAMP REPLACEMENT

1. From the rear of the taillight remove two screws holding lens cover in place and remove
lens cover.
2. Remove lamp and replace it with recommended lamp.
3. Reinstall the lens cover removed in step 1.
4. Test the taillight / brake light.

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
INSTERUCTIONS FOR SEALED TYPE DRY CHARGED STOR AGE BATTERY

This battery is dry and charged , which means that it starts operating when being filled with the
electrolyte and sealed with the sealing plugs.
To fill the electrolyte proceed as follows:
(1)Place the battery on a level place, and tear down the sealed tape on even place.
(2)Softly inlay the filling funnel on the ports the storage battery.
(3)Take out the electrolyte container. Put it down straightly. Then pour through the funnel to the
ports.
CAUTION: Unless the electrolyte container is pushed in straightly, the battery may fall down, from
which spillages may cause loss of eyesight and/or burns.
(4)Be sure that bubbles are generating in all 6 cells of the electrolyte container and the level of
electrolyte should be down.
CAUTION: If there is any cell which does not produce bubbles, tap it softly with finger and filling will
start.
Removing the electrolyte container from the battery is not necessary.
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 multimeter
NOTE: Lead acid batteries should be kept at or near a full digital multitester. Readings of 12.6 or
less require further battery testing and charging. 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
Emergency 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)
Faulty ECU module
Faulty Electric relay

CIRCUIT DIAGRAM

IF THE IGNITION SYSTEM FAILS TO OPERATE
Procedure
Check:
1. Fuse (Main) 7. Main switch
2. Battery 8. Emergency stop switch
3. Spark plug 9. Wiring connection
4. lgnition spark gap (entire ignition system)
5. Spark plug cap resistance
6. Ignition coil
1.Fuse INCONTINUITY
Check switches
Replace the fuse.
CONTINUITY
2. Battery INCORRECT
 Check the battery condition.  Clean battery terminals.

Refer to "BATTERY TESTING"  Recharge or replace the battery.
CORRECT
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 ±

0.1mm

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
starter switch, and increase the spark
gap until a misfire occurs.
MEETS SPECIFICATION
Minimum spark gap:
6mm (0.24 in) The ignition system is not faulty.
OUT OF
SPECIFICATION
OR
NO SPARK
Tester (+) lead →
Spark plug side
5.Spark plug cap resistance Tester (—) lead→
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
5KΩ(20 ℃)
CORRECT

* Tester (+) lead
Pink Terminal
Tester ( ) lead B/Y
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:

0.8Ω (20 ℃)
Tester (+) lead

Connect the pocket tester to the Spark plug lead
ignition coil. Tester (— ) lead
Check the secondary has the Pink Terminal
specified resistance
Secondary coil resistance: OUT OF SPECIFICATION

6.8KΩ(20℃)
BOTH MEET
SPECIFICATION
* Replace the ignition coil.
NO CONTINUITY
7.Main switch
CHECK SWITCHES
Replace the main switch

CONTINIUTY
8.Emergency stop switch

NO CONTINUITY
CHECK SWITCHES
Replace the emergency stop switch
CONTINIUTY
9.Wiring connection
Check the connection of the POOR CONNECTIONS
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
CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 12

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.
Connect the pocket tester
(DC20V) to the battery
Test (+) lead→
Battery (+) terminal 
Test (-) lead→
Battery (-) terminal 
Measure the battery terminal
voltage.
start the engine and accelerate to
about 5,000rpm
check the terminal voltage
Measured voltage-terminal OUT OF SPECITICATION
Voltage:
0.2-2.5V up
NOTE: Use a fully changed battery.
The charging circuit is not faulty

Replace the battery
MEETS 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
IF THE STARTER MOTOR FAILS TO OPERATE
Procedure
Check:
1. Fuse (Main) 6. Engine stop switch
2. Battery 7. front/rear brake switch
3. starter motor 8. Starter switch
4. starter relay 9. wiring connection (entire starting system)
5. main switch
1. fuse
refer to ―CHECKING SWITCHES‖ NO CONTINUITY
section
Replace the fuse
2. Battery
Refer to "BATTERY INSPECTION" section
in CHAPTER 3

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
5.Main switch
CHECK SWITCHES NO CONTINUITY

6. Emergency stop switch
NO CONTINUITY
Replace emergency stop switch
7. Front /rear brake switch

NO CONTINUITY
CHECKING SWITCHES
Replace the brake switch

8. Starter switch
NO CONTINUITY
CHECKING SWITCHES
Replace the handlebar switch
9. 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
Refer to "BATTERY INSPECTION" section


3 Main switch
4. Fan motor(inspection 1)
Connect the battery to the fan motor.
Battery (+) lead→Green/Blue terminal DOES NOT MOVE

Battery (-) lead→Green ground 
Check the fan motor operation
Replace fan motor
5. Fan motor (inspection 2)

Turn the main switch to off.
Remove the thermo switch lead from DOES NOT MOVE
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
6. 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
7.Starter relay
A wire used as a jumper lead
must have the equivalent
Disconnect the relay unit coupler from capacity as that of the battery
the wire harness. lead or more, otherwise it may
Connect the pocket tester (Ωx1) and burn.
battery (12V) to the relay unit coupler This check is likely to produce
terminals. sparks, so be sure that no
flammable gas or fluid is in the
vicinity.
Battery (+) lead→

Dark Gray terminal 
Battery (-) lead→
Green terminal 
Check the relay for continuity.
Test (+) lead →  terminal
Test (-) lead →  terminal
Replace the relay
8.Wring connection UPPER CONNECTION

Check the connection of the entire
cooling system.
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 75±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℃ with the buzzer sounding 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. Relay
7. Wiring connection (entire cooling system)
1. fuse
CHECKING SWITCHES NO CONTINUITY
Replace the fuse

2. Battery
Refer to "BATTERY INSPECTION"

3.Main switch
CHECKING SWITCHES NO CONTINUITY

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
5.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. OUT OF SPECIFICATION
Check for voltage (12V) on the
temperature gauge lead.
The wiring circuit from main

switch to temperature gauge
is faulty. Repair.
6.Relay NOT CONDUCTION

Measure the relay.
Replace the relay

7.Wiring connection check the POOR CONNECTION

connections of the entire cooling
system.
CORRECT
Replace the temperature gauge

7.7 LIGHTING SYSTEM
FOR USA MODEL
FOR EUROPE MODEL

TROUBLESHOOTING

Procedure
Check:
1. Fuse (Main) 4.Lights switch
2. Battery 5.Diatance light switch
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
in CHAPTER 3

3. Main switch
NO CONTINUITY
CHECK SWITCHES
4. Light switch
NO CONTINUITY
CHECK SWITCHES
Replace the light switch
5. Distance light switch

NO CONTINUITY
CHECK SWITCHES
Replace the distance light

switch
POOR CONNECTIONS
6.Wiring connection

Check the connection of the entire

lighting system
correct
7.check the condition of each of the

lighting system’s circuits
Refer to ―LIGHTING SYSTEM CHECK‖
LIGHT SYSTEM CHECK

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

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

beam.
B When dimmer switch is on high
beam
Headlight::
Tester (+) lead →White or Blue lead
Tester negative (-) lead →Green lead
Turn the main switch to on.

Turn the light switch to on position.
Turn the dimmer switch to low beam or
high beam.
Check for voltage (12V) on the lead at
bulb socket connectors OUT OF SPECIFICATION
The wiring circuit from the main

switch to
This circuit is not faulty bulb socket connector is faulty.
Repair

2. the taillight fails to come on
1. Bulb and bulb socket NO CONTINUITY
CHECK SWITCHES
Replace the bulb and /or bulb

socket
CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to
the bulb
socket connector.
Tester (+) lead→
Brown terminal 
Tester (-) lead→
Green terminal 
Turn the main switch to on. OUT OF SPECIFICATION
Turn the lights switch to on pilot position.
Check the voltage (12V) on the bulb
socket connector
The wiring circuit from main

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

7.8 REVERSE LIMIT SYSTEM
Speed is controlled by the ECU factory Settings In the 15 km/h,

which can be reset in accordance with the user’s practice.

7.9 GEAR POSITION INDICATOR SWITCH TEST
Switch table

Low range
The LCD screen show ―L‖ below
the middle position.
High range
The LCD screen show ―H‖ below
Neutral
The LCD screen show ―N‖ below
Neutral light is lit.
Reverse
The LCD screen show ―R‖ below
Parking
The LCD screen show ―P‖ below

Switch schematic

7.10 SPEEDMETER SYSTEM
OPERATION OF SPPED SENSOR

Speed Sensor is on the rear axle
Operation Instructions of Electric Dial Meter and Speed Sensor/ Operation Instructions of LCD Meter
and Speed Sensor
A. Hall Sensor is a new type sensor used to measure speed, angle, revolution and length, etc by
means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear
rack.
B. Main Technical Parameter for sensor：
Item Code Vol value Unit
Operating voltage Vcc 5-20 V
Operating current Icc ≤15 mA
Low voltage output Vol ≤ 0.4 V
Hight voltage output Voh ≥ (Vcc-1) V
Operating distance D 1mm ≤ D ≤ 2.5mm mm
C. The following is the graphic illustration for sensor installation, Wire 1 (red) is positive and wire 2
(black) negative, Wire 3 (yellow) works as the one to output signals.
Note: Always screw in the sensor by hand when installation or adjustment.

1, Align one tooth of the splines to the centre of the hole of the sensor by turning the rear axle.
2. Screw the senor in (CW) by hand slightly until resistance is felt.
3. Turn the sensor CCW by 1 to 2 turn(s).
4. Tighten the jam nut.

Operation Instructions of the Meter assembly
1. Left turn signal lamp 7. The odometer

2. High beam indicator light 8.Trip/ Total selector
3. Safe belt indicator 9.Battery alarm indicator
4.LCD show 10. Oil position show
5. Km/h/ mile/h selector 11. Engine rpm meter
6.Fuction button 12.Reverse indicator light
13.Electric fuel injection failure alarm indicator 16. 4WD indicator

14. Lamp switch indicator 17. Differential lock indicator
15. Water temperature alarm indicator

7.11 MAIN SWITCH AND HANDLE SWITCH

7.12 FUEL GAUGE/ FUEL LEVEL SENSOR
Removal
Turn the ignition switch to“OFF”.
Remove two connecting pipe of oil pump.
Remove the terminal of oil pump.
Remove the oil pump cover.
Retain plate and fuel level sensor from the fuel
tank.
Installation
Install rubber oil seal to the oil pump.
Install oil pump to the fuel tank, location to align .
Install the oil pump cover.
Install two connecting pipe of oil pump.
Install the terminal of oil pump.
Fuel Gauge / Fuel level Sensor Inspection

Move the float to the bottom (RESERVE)
position, turn the ignition switch to“ON”and
check the fuel gauge.
When shows that there are only two

segments,segments should blink.
With the fuel level sensor float at the top

(FULL)position, turn the main switch to“ON”
and check the fuel gauge. All segments up to
segment“F”should come on.
If all of the six segments blink, check the wiring

connection of fuel level system.
Refer to " Circuit of the fuel level"
If the fuel gauge does not function properly,

check the fuel level sensor
If the fuel level sensor is OK, replace the LCD
Meter.
Fuel level Sensor Inspection

Disconnect the fuel level sensor 2p Green
connector and connect the ohmmeter to the RESISTANCE(20℃/
FLOAT POSITION
sensor side connector terminals. 68°F)
Measure the fuel level sensor resistance with the TOP(FULL) 0-12Ω(±2Ω)
float at the top (FULL) BOTTOM(RESERVE) 94-128Ω(±2Ω)
And bottom (RESERVE) positions.

CUV SERVICE MANUAL 09.0
39
CHAPTER 7 ELECTRICAL CTRICAL PAGE 7-
WIRING DIAGRAM FOR XY45OU-A UTV EURDPE MODEL
Note Colour
R Red
Y Yellow
Br Brown
L G Light Green
W White
G/R Green/Red
W/R White/Red
P Pink
G Green
G/B Green/Black
G/Y Green/Yellow
Y/W Yellow/White
Or Orange
Bl/W Blue/White
R/Bl Red/Blue
B/Y Black/Yellow
Bl Blue
L Bl Light Blue
D G Dark Green
Br/R Brown/Red
B/R Black/Red
Bl/Y Blue/Yellow
Bl/B Blue/Black
Pu/W Purple/White
Pu Purple
Y/R Yellow/Red
R/W Red/White
Gr/R Gray/Red
Br/G Brown/Green
G/W Green/White
B/G Black/Green
Gr/G Gray/Green
B/W BLACK/White
Gr Gray
Gr/W Gray/White
Br/R
8.13 WIRING DIAGR
Brown/Red
CUV SERVICE MANUAL 09.0
40
CHAPTER 7 ELECTRICAL CTRICAL PAGE 7-
WIRING DIAGRAM FOR XY45OU-A UTV U.S.A MODEL
Note Colour
R Red
Y Yellow
Br Brown
L G Light Green
W White
G/R Green/Red
W/R White/Red
P Pink
G Green
G/B Green/Black
G/Y Green/Yellow
Y/W Yellow/White
Or Orange
Bl/W Blue/White
R/Bl Red/Blue
B/Y Black/Yellow
Bl Blue
L Bl Light Blue
D G Dark Green
Br/R Brown/Red
B/R Black/Red
Bl/Y Blue/Yellow
Bl/B Blue/Black
Pu/W Purple/White
Pu Purple
Y/R Yellow/Red
R/W Red/White
Gr/R Gray/Red
Br/G Brown/Green
G/W Green/White
B/G Black/Green
Gr/G Gray/Green
B/W BLACK/White
Gr Gray
Gr/W Gray/White
Br/R Brown/Red
NOTES

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XY450U-A

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

CHAPTER3…………………………………….……….….…… ……Dynamic system

CHAPTER 1 GENERAL INFORMATION

1.1 IMPORTANT INFORMATION

1.2 V.I.N AND MOTOR SERIAL NUMBER

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 pins

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

The vehicle identification number ① is stamped

The engine serial number ② is stamped into left

The transmission serial number ③ 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 NTENANCE

2.2 THROTTLE PEDAL INSPECTION

2.3 FUEL SYSTEM

2.4 TOE ALIGNMENT

2.5 BRAKING SYSTEM INSPECTION

2.6 SUSPENSION SPRING RPELOAD ADJUSTMENT

2.8 TIRE PRESSURE

2.9 FRAME, NUTS , BOLTS, FASTENERS

CHAPTER 2 MAINTENANCE PAGE. 2- 1

2.1 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE：

Item Hours When Remarks

Air Box Sediment

CHAPTER 2 MAINTENANCE PAGE. 2- 3

Check for leaks at tank cap, lines, fuel

LUBRICANT AND FLUID

2.2 THROTTLE PEDAL INSPECTION

THROTTLE FREEPLAY INSPECTION

2.3 FUEL SYSTEM

Gasoline is extremely flammable and explosive under certain conditions.

2.4 TOE ALIGNMENT

The recommended toe alignment is 0 to

CHAPTER 2 MAINTENANCE PAGE. 2- 7

2.5 BRAKING SYSTEM INSPECTION

BRAKE PAD INSPECTION

CHAPTER 2 MAINTENANCE PAGE. 2- 8

ADJUSTING THE BRAKE PEDAL

ADJUSTING THE PARKING BRAKE

CHAPTER 2 MAINTENANCE PAGE. 2- 9

2.6 SUSPENSION SPRING RPELOAD ADJUSTMENT