1992-2006 Argo Conquest 8×8 Utv Service Repair Manual Download

Service Manual Models:

S, SN, BF, RB, C, CB,V A, B, N & R

Ontario Drive & Gear Limited Part # 673-04-1 PH.(519)- 662-2840 FAX (519)- 662-2421

05/06

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General Information

Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

Argo Service Manual

GI-28

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Argo Service Manual

How to use this manual This manual is divided into general sections which are identified by a 2 letter designation. Find the section you want in the guide on this page, and then turn to the Table of Contents on page 1of that section. Each section begins with general information for servicing the assemblies listed in that section. The rest of the section outlines detailed servicing procedures and are accompanied by photographs & diagrams for easier use.

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Service Guide General Information............. GI Engine.....................................EN Electrical System................... ES Brake System......................... BR Clutch System........................ CS Wheels,Axles&Chains...........WA Fuel System............................ FS Vehicle Bodies........................ VB Ducting & Exhaust............... DE Transmission.......................... TR

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Argo Service Manual

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Argo Service Manual

General Information

SECTION GI General Information Table of Contents Forward....................................................................................... GI-2 General Instructions................................................................... GI-3 Available Service Instruction..................................................... GI-4 Argo Vehicle Capacity................................................................ GI-5 Model Identification (early models only)..................................GI- 6, 7 Identification and Location of Controls................................... GI-8, 9 Argo Model Specifications......................................................... GI-10, 11 Information Labels..................................................................... GI-12 Argo Torque Specifications........................................................ GI-13, 14 Maintenance Chart..................................................................... GI-15 Trouble Shooting Charts............................................................ GI-16, 17 Flat Rate Schedule (Service)...................................................... GI-18, 19, 20 Flat Rate Schedule (Accessories)............................................... GI-21, 22 Tool List.......................................................................................GI-23, 24, 25 Special Tools................................................................................ GI-26, 27

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GI-1

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Argo Service Manual Foreward

ODG has prepared this Argo Service Manual to assist qualified technicians of authorized ARGO dealers and distributors in providing fast and effective service and maintenance of the following ARGO vehicles produced from 1992. First CONQUEST from CB10847 First RESPONSE from RB12075 First BIGFOOT from BF9212 First 6x6 CONQUEST from V6016200000C12747 First VANGUARD 2 from SN7841 First VANGUARD from S6999 First AVENGER from 2DGSS0BT54NV20905

August 16, 1993 June 23, 1995 July 2, 1997 October 17, 2001 March 7, 1995 February 6, 1992 January 29, 2004

Proper and regular maintenance is essential to prolonging the life of the ARGO and will result in satisfied ARGO customers. Please refer to this Service Manual before performing any servicing procedure on any of the above vehicles. This ARGO Service Manual provides information on maintenance procedures, service operations, and on the removal, disassembly, reassembly, and installation of components, parts, and assemblies. Illustrated Parts Manuals on vehicles manufactured since 1977 are available on a separate CD (Part # 673-05CD), available from your distributor or local ARGO dealer. All information contained in this service manual is based on the product specification records of Ontario Drive & Gear Ltd. If the ARGO that you are servicing differs from the specifications contained in this manual, contact Ontario Drive & Gear for information. ODG reserves the right to alter servicing procedures at any time without obligation or prior notification. Liability for any personal injury, or damage to property or an ARGO vehicle which is occasioned by the use of this 673-04 Argo Service Manual, is in no way assumed by Ontario Drive & Gear Ltd.

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Read your owner/operators manual before you operate your ARGO. It contains safe operating instructions and warns the user about potential hazards that can result in personal injury. Warnings are identified in the text by the following symbol:

Warning text warns the user about potential hazards that can result in personal injury or death.

Cautions are identified in the text by the following symbol:

Caution text contains cautions that can prevent damage to the vehicle.

This manual is based on the latest product information available at the time of printing. Ontario Drive & Gear Limited reserves the right to make changes at any time and without obligation. Reproduction of any part of this publication is prohibited without prior written permission. Une version francaise du manuel d’operation est disponsible sous le numero suivant 67104FR. Les plaquettes d’avertissement et d’instructions qui apparaissent sur l’Argo sont aussi disponsibles en francais sous le numero suivant 126-73. © Ontario Drive & Gear Limited, 2000

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Argo Service Manual

673-25 Argo Service Video Ontario Drive & Gear has produced a video which provides the Argo service technician with step-by-step instructions on how to perform service procedures to the vehicle. Everything from removal and replacement of brake pads to rebuilding the transmission. Itâ&#x20AC;&#x2122;s all there. Removal and replacement of engines is included, however, engine overhaul is not. A separate overhaul manual is available for each engine from your Argo dealer. Order the Service Video from your selling dealer or from Ontario Drive & Gear directly (have your VISA card information ready). Cost of the 4 hour video is $33.00. Available Service Manuals

Part number Part Number Part Number Part Number Part Number Part Number

670-00 ------- Service Manual for Models prior to 1977. 673-00-------- Service Manual for Models to 1986 673-01-------- Service Manual for 1987 Models 673-02-------- Service Manual Supplement for NKB Models (1988) 673-04CD ----Service Manual for Models from 1992 - 2002 673-04-1------Service Manual for Models from 1992 including 673-06 Avenger Service Manual Supplements Part Number 673-06 Avenger Service Manual Supplements This edition of the ARGO Service Manual contains information and servicing procedures for models produced from 1992, when the 16H.P and then in 1995 the 18 H.P " V" Twin Briggs & Stratton Vanguard engines were introduced to our vehicle line up. Also covered, is the 8x8 Conquest model powered by the 20 H.P Kawasaki FD620D Liquid cooled engine which was introduced in 1993 & The Avenger Argo model, introduced in January of 2004. Although many parts and service procedures outlined in the 673-04 Service Manual also pertain to Avenger, additional supplement sections have been created in order to cover parts and procedures unique to Avenger (See supplement part number above). The service manuals 673-00, 673-01 and 673-02 Supplement, can be used for Magnum models prior to 1995. Although the 673-02 supplement indicates coverage up until 1988 only for V888 & V688 models, the servicing procedures in both earlier manuals are still applicable to the Magnum models produced from 1988 to 1994. However, attention should be payed to the appropriate Magnum parts manual for these later years of vehicle production to identify any changes that may have been made to components until the Response was introduced in 1995. Refer to the Vehicle Parts Manual CD (Part # 67305CD) Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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A MESSAGE FROM THE PEOPLE WHO BUILD THE ARGO

Ontario Drive & Gear Limited has been building ARGO vehicles since 1967. By listening carefully to our customers and responding to their needs, we have been constantly improving the ARGO and will continue to do so. Argo Vehicle Capacity Vehicle capacity includes occupants, cargo, fuel, and all accessories. Capacity for occupants and cargo is reduced by the weight of accessories as shown in the chart below. Available vehicle capacity must be reduced if your vehicle is equipped with any accessories. Reduce the available capacity by the total weight of accessories fitted to your vehicle Reduce By Accessory On On Vehicle Land Regular Tracks 6x6 135 lbs. (60 kg) Regular Tracks 8x8 175 (80) Supertracks 6x6 145 (65) Supertracks 8x8 210 (95) Rubber Track Kit 240 (110) Winch Kit 50 (23) Brush Guard 11 (5) 11 Windshield 33 (15) Roll Bar 6x6 50 (23) ROPS 6x6 130 (60) ROPS 8x8 140 (64) ROPS Avenger 155 (70) Half Top 16 (7) Full Top 8x8 27 (12) Full Top 6x6 22 (10) Snow Plow 190 (85) Dump Box 100 (45) Rear Bench Seat 34 (15)

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On Water 85 lbs. (40 kg) 110 (50) 90 (40) 135 (60) (150) (68) 50 (23) (5) 33 (15) 50 (23) SEE WARNING 140 (64) 155 (70) 16 (7) 27 (12) 22 (10) SEE WARNING 500 (225) 34 (15)

Do NOT use an Argo on water when equipped with a snow plow. Do NOT use an Argo 6x6 in water when equipped with a ROPS. The increased weight of the snow plow out front or the top-heavy weight of the ROPS on the 6x6 will make the Argo unstable and could cause the vehicle to capsize, causing injury or drowning to the driver and passengers.

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Argo Service Manual

Model Identification & Description

List of Earlier Models Tecumseh

V688-20 V888-20 V888-21

Conquest (Mid 1999)

V894-37 V894-38

Briggs& Stratton Twin

V888-22 V688-22 V891-22 V691-22 V892-22 V692-22

Vanguard

V693-22 V693-36 V694-36 V697-51 V699-51

Magnum

V888-23 V688-23 V890-23 V690-23

Vanguard2

V696-55 V697-55 V699-55

Bigfoot

V698-58

Magnum Magnum

V891-23 V691-23

Magnum

V891-27

Magnum

V894-23 V894-27

Response

V896-55

Response

V896-65

Conquest

V899-37

- MU Transmission

Conquest

V899-38

- GU Transmission

Conquest

V899-37A

- Alternator, MU Transmission

Conquest

V899-45

- Alternator, Horn & Parking Brake, MU

Conquest

V899-46

- 22" Rawhide III Tires, MU

Conquest

V899-47

- 22" Rawhide III Tires, GU

Response

V899-64

- GU Transmission

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Model Identification & Description (continued)

List of Earlier Models Response

V899-65

- MU Transmission

Response

V899-65E

- Bearing Extensions, MU

Response

V899-66

- Skidplate, MU

Response

V899-67

- Horn & Parking Brake, MU

Response

V899-68

- 22" Rawhide lll Tires, MU

Response

V899-69

- Skidplate & GU Transmission

Vanguard

V699-51

- HU Transmission

Vanguard 2

V699-55

- HU Transmission

Vanguard 2

V699-55E

- Bearing Extensions, HU

Vanguard 2

V699-56

- MU Transmission

Vanguard 2

V699-57

- Horn & Parking Brake, HU

Bigfoot

V698-58

- HU Transmission

Bigfoot

V698-59

- MU Transmission

Bigfoot

V698-60

- Horn & Parking Brake, HU

Bigfoot

V698-61

- Runamuck Tires, HU

Conquest 6x6

V601-62

- Rollbar, HU

Conquest 6x6

V601-63

- without Rollbar, HU

Conquest 6x6

V601-64

- Rollbar & MU Transmission

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GI-7

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Argo Service Manual

Identfication and Location of Controls

Prior to serial # N14708, B14700, R22452

Prior to serial # C22453 & A14743

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From serial # N14708, B14700, R22452

From serial # C22453 & A14743 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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GI-9

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Argo Service Manual

ARGO Model Specifications AVENGER (V)

ARGO CONQUEST (CB)(C)

Engine:

Kohler 685 cc (25 h.p.) or Kohler 690cc (26 h.p) V-twin 4 cycle, liquid cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converter Fuel Capacity: 29 Litre (6.3 Imp. Ga., 7.6 U.S Gal.) Steering/Brakes: Hydraulic Caliper, 10.25" with holding brake system Drive Chains: Double RC-50 roller chains & Single RC 60 Roller chain Electrical: 12 volt D.C. battery, 495 cranking amps at 0 F; 25 Amp charging system, electronic ignition Speed: Land - 32 km/hr (20mph) Water - 3 km/h (2 mph) Load Capacity: Land - 6 persons or 522kg (1150lbs) SEE SECT.1.4.1 Water - 4 adults or 317kg (700lbs) Tires: 25x11.5-9NHS, 2 ply Dry Weight: 542kg (1195lbs)

Serial Number: Engine:

ARGO 8 x 8 RESPONSE (RB)(R)

ARGO 6 x 6 CONQUEST (C)(A)

Serial Number: Engine:

Serial Number: Engine: Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains: Electrical:

Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains: Electrical:

Speed: Load Capacity: Tires: Dry Weight:

RB-12075 Briggs & Stratton Vanguard, 570 cc (18 h.p.) V-Twin, 4 cycle, air cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic, 9" disc with holding brake system Double RC-50 roller chain & Single RC 60 Roller chain 12 volt D.C. battery, 495 cranking amps at 0 F; 20 Amp magneto type charging system, electronic ignition Land - 30 km/h (20 mph) Water - 3 km/h (2 mph) Land - 6 persons or 454 kg (1000 lbs.) Water - 4 adults or 317 kg (700 lbs.) 22x10.00-8NHS, 2 ply 436 kg (960 lbs.)

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CB-10847 Kawasaki 620 cc (20 h.p.) V-twin 4 cycle, liquid cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Hydraulic Caliper, 9" disc with holding brake system Drive Chains: Double RC-50 roller chains & Single RC 60 Roller chain Electrical: 12 volt D.C. battery, 495 cranking amps at 0 F; 20 Amp charging system, battery ignition Speed: Land - 30 km/h (20 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 6 persons or 454 kg (1000 lbs.)

Speed: Load Capacity: Tires: Dry Weight:

GI-10

C-12747 Kawasaki 620 cc (20 h.p.) V-twin 4 cycle, liquid cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic, 9" disc with holding brake system Double RC-50 roller chain and single RC-60 roller chain 12 volt D.C. battery, 495 cranking amps at 0 F; 20 Amp charging system, battery ignition Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Land - 2 persons or 317 kg (700 lbs.) Water - 2 adults or 158 kg (350 lbs.) 25x12.00-9NHS, 2 ply 450 kg (990 lbs.)

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ARGO Model Specifications ARGO 6 x 6 BIGFOOT (BF)(B)

ARGO FRONTIER (F)

Serial Number: Engine:

ARGO FRONTIER (F)

BF-9212 Briggs & Stratton Vanguard, 570 cc (18h.p.) V-Twin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Hydraulic, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain and single RC-60 roller chain Electrical: 12 volt D.C. battery, 495 cranking amps at 0 F; 20 Amp or 20/50 amp magneto type charging system, electronic ignition Speed: Land - 39 km/h (24 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) Water - 2 adults or 158 kg (350 lbs.) Tires: 25x12.00-9NHS, 2 ply Dry Weight: 414 kg (910 lbs.)

Engine:

Briggs & Stratton Vanguard, 627 cc cooler cleaner running (18 h.p.) V-Twin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converter Fuel Capacity: 29 Litre (6.3 Imp. Ga., 7.6 U.S Gal.) Steering/Brakes: Hydraulic Caliper, 10.25" with holding brake system Drive Chains: Single RC-60 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 20/50 Amp magneto type charging system, electronic ignition Speed: Land - 39 km/h (24 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) SEE SECT.1.4.1 Water - 2 adults or 158 kg (350 lbs.) Tires: 24x10.00-8NHS, 8 ply Dry Weight: 414 kg (910 lbs.)

ARGO 6 x 6 VANGUARD2 (SN) Serial Number: Engine: Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains: Electrical: Speed: Load Capacity: Maximum Rear Capacity: Tires: Dry Weight:

SN-7888 Briggs & Stratton Vanguard, 480 cc (16 h.p.) V-Twin, 4 cycle, air cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic, 9" disc with holding brake system Double RC-50 roller chain and single RC-60 roller chain 12 volt D.C. battery, 495 cranking amps at 0 F; 16 Amp magneto type charging system, electronic ignition Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Land - 4 persons or 317 kg (700 lbs.) Water - 2 adults or 158 kg (350 lbs.) Land and Water - 63 kg (140 lbs.) 22x10.00-8NHS, 2 ply 348 kg (765 lbs.)

ARGO 6 x 6 VANGUARD (S) Serial Number: Engine:

S-6999 Briggs & Stratton Vanguard, 480 cc (16 h.p.) V-Twin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Mechanical, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain and single RC-60 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 16 Amp magneto type charging system, electronic ignition Speed: Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) Water - 2 adults or 158 kg (350 lbs.) Maximum Rear Capacity: Land and Water - 63 kg (140 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 348 kg (765 lbs.)

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GI-11

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Argo Service Manual

INFORMATION LABELS There are labels on all models which indicate operating hazards and provide special operating instructions. Information about the use of the holding brake system, the use of the vehicle in water, correct fueling procedures and placement of the floorpans has been provided on distinctive coloured labels fastened to the various locations on the Argo.

Figure 1-1 Location of Information Labels - All Models

The label shown below is located behind the seat in the rear compartment of all 6-wheel models.

Figure 1-2 Rear Compartment Capacity Label - All 6x6 Models

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ARGO Torque Specifications Transmission Side Cover Bolts............................................................. 216 IN. LBS. Differential Bolts.............................................................35 FT. LBS. Shifter Plate Bolts (Avenger)..........................................75 IN. LBS

24.3Nm 47.5Nm 8.5Nm

Intake & Exhaust Kawasaki Exhaust Manifold to Engine...........................204 IN. LBS. Kawasaki Muffler to Engine........................................... 204 IN. LBS Briggs Muffler to Engine................................................ 204 IN. LBS Briggs Exhaust Man. to Engine...................................... 204 IN. LBS. Kohler Exhaust Man. to Engine (Avenger).....................204 IN. LBS

23.2Nm 23.2Nm 23.2Nm 23.2Nm 23.2Nm

Clutch System Driver Clutch Nut on Clutch.......................... ................100 FT. LBS. Driver Clutch Bolt to Briggs Engine.............................. 50 FT. LBS. Driver Clutch Bolt to Kohler Engine (Avenger)..............40 FT. LBS Driver Clutch Bolt to Kaw. Engine ............... ................50 FT. LBS. Driven Clutch Bolt to Input Shaft................................... 15 FT. LBS. Spring Cover Cap Screws............................................... 85in. lbs.

135.6Nm 67.8Nm 54.3Nm 67.8Nm 20.3Nm 9.6Nm

Powerpak Assembly Engine to Powerpak Frame (Kaw)..................................30 FT. LBS. Engine to Powerpak Frame (Briggs................................ 24 FT. LBS. Engine to Powerpak Frame (Kohler)...............................35 FT. LBS Transmission to Powerpak Frame................................... 75 FT. LBS. Brake Cooling Air Duct to Frame.................. ................35 in.lbs. Master Cylinder Mounting Bolts.................... ................96 IN. LBS. Belt Guard to Transmission........................... ................30 FT. LBS. Brake Bracket Mounting Bolts....................................... 240 IN. LBS. Power Pack Bolts to Main Vehicle Frame.......................80 FT. LBS.

40.7Nm 32.6Nm 47.5Nm 101.7Nm 4.0Nm 10.7Nm 40.7Nm 27.1Nm 108.2Nm

Brake System - Hydraulic Brake Caliper to Transmission........................................45 FT. LBS. Brake Caliper Assembly Bolts (M10) (Gremica)........... 33 FT. LBS. Brake Caliper Assembly Bolts (M8) (Gremica)............. 17 FT. LBS. Hydraulic Hose Bolts...................................................... 180 IN. LBS. Avenger Brake Caliper Assembly Bolts .........................218 IN. LBS

61.0Nm 44.8Nm 23.2Nm 20.3Nm 24.6Nm

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Argo Service Manual

Argo Torque Specifications Brake Disc to Output Shaft.............................................30FT.LBS 40.7 Nm Brake Sprocket to Disc (Avenger)...................................15 FT. LBS 20.3Nm Master Cylinder Lid Screws........................................... Snug By Hand Upper Handle Bar Clamp Bolts (Avenger).....................12 Ft. LBS 16.3Nm Steering Shaft Nut................ .......................................Tighten snug. Back off until lower washer can be turned by hand. Ensure shaft can be turned with minimal end play Vehicle Body and Firewall Hood Hinge Mounting Bolts...........................................Snug By Hand Rear Seat Mounting Bolts............................................... Snug By Hand Trailer Hitch Mounting Bolts..........................................35 FT. LBS. Trailer Hitch Ball............................................................ 100 FT. LBS.

47.5Nm 135.6Nm

Frame and Drive System Wheel Nuts......................................................................45 FT. LBS. Bearing Extensions ........................................................ 30 FT. LBS. Bearing Extension Bolts................................................. 240 IN. LBS. Bearing Extension Flange Nuts (Avenger).....................30 FT. LBS Axle Flange Bolts........................................................... 30 FT. LBS. Battery Bracket to Frame................................................ 30 FT. LBS. Axle Sprocket Retaining Screws................................... 144 IN. LBS Axle Bearing Set Screws................................................ 10-15 IN. LBS Axle Retaining Bolt........................................................ 35 FT. LBS Wheel Stud Extensions................................................... 45 FT. LBS

61.0Nm 40.7Nm 27.1Nm 40.7Nm 40.7Nm 40.7Nm 16.4Nm 1.1-1.6Nm 47.5Nm 61.0Nm

Fuel System and Seat Assembly Handrail Assembly to UpperbodyHand Tight Approx... 48 IN. LBS Backpad to Handrail Assembly....................................... 72 IN.LBS Angle Bracket to Seat Assembly..................................... 72 IN.LBS Seat Frame Assembly to Frame..................... ................72 IN.LBS Seat Frame Assembly to Body........................................ Snug By Hand

5.4Nm 8.1Nm 8.1Nm 8.1Nm

Electrical System Battery Retaining Bracket...............................................Snug By Hand Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

GI-14

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General Information BEFORE EACH USE

COOLANT LEVEL (CONQUEST & AVENGER) FAN BELT TENSION (CONQUEST & AVENGER) CHECK FUEL LEVEL CHECK TIRE INFLATION CHECK TWIST GRIP THROTTLE OPER. CHECK STEERING LEVER TRAVEL CHECK ENGINE INTAKE/EXH. FOR OBSTR. CHECK THAT DRAIN PLUGS ARE IN PLACE CHECK ENGINE OIL LEVEL CHANGE ENGINE OIL & OIL FILTER - KAWASAKI & KOHLER - BRIGGS & STRATTON CHECK TRANSMISSION OIL LEVEL CHANGE TRANSMISSION OIL CLEAN AIR PRE-CLEANER (Briggs & Kaw. only) CHECK CLEAN/REPLACE AIR FILTER REPLACE FUEL FILTER LUBRICATE DRIVEN CLUTCH SERVICE DRIVER & DRIVEN CLUTCH LUBRICATE DRIVE CHAINS REMOVE, CLEAN & LUBE. DRIVE CHAINS LUBRICATE IDLER CHAINS REMOVE, CLEAN & LUBE. IDLER CHAINS LUBRICATE AXLE FLANGE - OUTER CAVITY LUBRICATE AXLE FLANGE - INNER CAVITY LUBRICATE INNER AXLE BEARINGS LUBRICATE IDLER BEARINGS LUBRICATE STEERING LEVERS CHECK BATTERY FLUID LEVEL & CAPS CLEAN BATTERY TERMINALS & CONNEC. CLEAN BATTERY CLEAN, ADJUST/REPLACE SPARK PLUGS CHECK THE DRIVE BELT CHECK NYLON SLIDERS - DRIVEN CLUTCH CHECK SLIDERS - CHAIN TAKE-UP SYSTEM CHECK & ADJUST IDLER CHAINS SERVICE THE CLUTCH UNITS INSPECT BRAKE PADS ADJUST HOLDING BRAKE CHECK HYD. BRAKE FLUID LEVEL/COND. CHECK FUEL TANK CONNECTIONS/LINES INSPECT WIRING HARNESS TIGHTEN BEARING EXT. BOLTS CLEAN OUT SPARK ARRESTER

AFTER INITIAL 2hrs.

8hrs.

EVERY

20hrs. 10hrs. 25hrs. 50hrs. 100hrs. 250hrs.

X X X X X X X X X

SECTION REF.

2.2 7.2.6 2.2 2.2 2.2 5.6 6.1.1 X

X X X

X X X X X X X X X X X X X X

6.1.3 6.1.3 6.2.1 6.2.2 6.3.1 6.3.1 6.3.2 6.4.2 6.4.2 6.4.3 6.4.3 6.4.4 6.4.4 6.4.5 6.4.5 6.4.7 6.4.6

X X X X X X X X

X X X

X X X X X X X

X X

7.1.2 7.1.2 7.1.2 7.1.4 7.2.1 7.2.2 7.2.4 7.2.5 6.4.2 7.3.1 7.3.5 7.4.2

7.2.8 7.1.5

The intervals shown on the schedule are based on average operating conditions. Vehicles which are subjected to severe use and wet or dusty conditions will require more frequent servicing. Use only Argo replacement parts to ensure safe operation of the vehicle and to comply with the warranty coverage. We strongly recommend that an Argo Dealer perform a complete check-over of your vehicle after the initial 20 hours of operation, then once each year. This will reduce maintenance costs over the life of your vehicle.

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Argo Service Manual

MALFUNCTION (SYMPTOM)

PROBABLE CAUSE

CORRECTIVE ACTION

Electric starter inoperative

1. Loose electrical connections

1. Clean and re-tighten electrical connections 2. Recharge battery or replace as necessary 3. Remove and replace or repair the starter motor.

2. Battery charge low or dead 3. Faulty starter motor

Engine turns over but will not start

1. Engine is cold and choke is not pulled out 2. Fuel tank is empty 3. Blocked fuel or air filter 4. Carburetor adjustment too lean 5. Spark plugs defective or fouled 6. Ignition system inoperative 7. Insufficient compression 8. Improperly operating electric fuel pump or fuel shut off solenoid. KAWASAKI ENGINE ONLY.

Engine will not run Vehicle will not move or turn

1. Refer to engine manual 1. Transmission in neutral or not properly engaged in gear 2. Drive belt worn (see Section 7.2.1) 3. Clutch not engaging 4. Transmission failure 5. Brakes not functioning 6. Idler chain broken 7. Idler sprocket weld broken

Vehicle pulls to right

1. Right tire pressure too low 2. Left tire pressure too high 3. Right brake engaged

4. Right side drive chain broken Vehicle pulls to left

1. Pull out the choke and try to start again 2. Refill tank 3. Remove obstruction or replace filter as necessary 4. Adjust as detailed in the engine manufacturer’s manual 5. Clean and re-gap or replace 6. Refer to the Briggs & Stratton engine service manual 7. Take the vehicle to a factory authorized engine repair outlet 8. Check that electric fuel pump is operating. Make sure fuel shut off solenoid is activated to allow fuel into carburetor.

1. Place gear shift properly in gear 2. Replace belt if worn excessively 3. Service clutches 4. Same as 3. above 5. Adjust caliper or replace brake pads 6. Repair or replace 7. Replace idler sprocket 1. Inflate all tires to the correct pressure 2. Same as above 3. Make sure the steering lever is held forward against the dash. Adjust brake assembly if required. 4. Repair or replace

1. See “Vehicle pulls to right” substitute right with left

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General Information

MALFUNCTION (SYMPTOM)

PROBABLE CAUSE

CORRECTIVE ACTION

Severe vibration when vehicle service.

1. Engine loose on mounts

1. Secure engine mounts

2. Driver or driven clutch or engine defective 3. Axle bent 4. Wheel rim bent 5. Worn or damaged drive belt

2. Same as above.

1. Leak has developed at the axle bearing flange 2. Bearing flange seal has been damaged 3. Water is leaking in around the outer bearing flange bolts 4. Lower body is cut or punctured 5. Drain plugs not in place

1. Replace the bearing flange gaskets.

Water leaks into lower body

Tire leaks air

1. Tire is punctured

2. Tire is not properly seated on bead

3. Position of air leak is not obvious

4. Defective valve Hydraulic brakes are spongy, or there is excessive steering lever travel

1. Air in hydraulic system

3. Remove and straighten or replace. 4. Replace. 5. Replace. Clutch service may be required.

2. Replace the bearing flange seal. 3. Caulk under 103-81 bolt heads with silicone sealer. 4. Repair or replace vehicle lower body 5. Secure drain plugs. 1. Remove tire from rim and repair the hole with a radial tire patch or install a tube in the tire. 2. Deflate tire and carefully push tire bead off the rim. Clean the rim bead area to remove dirt and foreign matter. Re-inflate tire. 3. Submerge tire and rim in a water tank. Air may be escaping through the rim halves or the valve stem. Repair as required. 4. Replace defective valve.

3. Loose brakes

1. Bleed the brake system and add fluid. 2. Check all fittings, hoses, calipers and seals for loose connections or leakage. Refill as needed. 3. Adjust or tighten.

Brakes ineffective

1. Pads have overheated and glazed 2. Pads worn beyond 0.10" 3. Pads are contaminated with lubricant

1. Replace or clean pads 2. Replace. 3. Clean or replace pads

There is a loud bang when the vehicle is turned right or left

1. Idler chains worn/loose

1. Adjust/replace idler chains as required 2. Adjust/replace drive chains as required

2. Leak in system

2. Drive chains worn/loose

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General Information

Argo Service Manual

FLAT RATE SCHEDULE ARGO SERVICE Job Description Number

Maximum TIme (Hours) Conq Resp Bigf Van2 Van Aveng

Transmission 1000 1500 1750

Transmission Re & Re Transmission Re & Re & Overhaul Transmission Shift Lever Re & Re

2.0 5.0 .1

2100 2200 2300 2600 2700 2800

Intake & Exhaust System Muffler Re & Re Tailpipe & Spark Arrestor Re & Re Muffler Shield Assembly Intake Duct Assembly Re & Re Radiator Seal Assembly Re & Re Engine Duct Re & Re

.5 .3 1.6 1.7 .3 none

.5 .3 .8 .1 none .6

.5 .3 .8

.6 1.4 .3 .8

4.8 5.0 .4 .3 .3 .3 .5 .8 .5

2.5 3.1 .4 .3 .3 .3 .5 .8 .5

2.5 2.5 3.1 .4 .3 .3 .3 none .8 .5

2.5

Clutch System 3000 3200 3500 3700

Driver Clutch Re & Re Driver Clutch Re & Re & Overhaul Driven Clutch Re & Re Driven Clutch Re & Re & Overhaul Powerpack Assembly

4000 4100 4200 4300 4400 4600 4700 4800 4900

Engine Re & Re Powerpack Frame Re & Re Throttle Cable Re & Re Choke Cable Re & Re Twist Grip Assembly Re & Re Steering Lever Re & Re Steering Bracket Assembly Re & Re Brake Disc Re & Re Guard - Belt Protect Brake System

5000 -------5200 5500

Caliper Re & Re Both Calipers Caliper Re & Re & Overhaul Master Cylinder Re & Re

0.5 0.7 1.0 .6

0.5 0.5 0.7 0.5 .8 1.0 none .6

5300

Master Cylinder Re & Re & Overhaul

none

5700

Blower Fan Re & Re

none

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FLAT RATE SCHEDULE ARGO SERVICE Number Job Description Maximum TIme (Hours) Conq Resp Bigf Van2 Van Aveng 5800 Intake Hose Re & Re .3 .3 .3 none none 5900 Brake Cooling Air Duct Re & Re 1.8 .6 .6 none none Vehicle Body & Firewall 6000 6100 6150 6200 6250 6300 6350 6400 6500

Firewall Re & Re Front Floorpan Re & Re Rear Floorpan Re & Re Intake Screen Re & Re Exhaust Screen Re & Re Rear Seats Re & Re & Reassemble Vinyl Bumper Re & Re Hood Frame Assembly Re & Re Upper Body Re & Re

.1 .1 .1 .5 .5 .3 .3 .9 6.4

.1 .1 .1 none .5 .3 .3 .8 5.5

.1 .1 .1 none .5 .1 .3 .8 5.5

.1 .1 .1 none .5 .1 .3 .8 4.8

.2 .1 .1 none .5 .1 .3 .8 4.8

.1 .1 .1

6550 6600

Upper Body Sub-Assembly Skidplate Re & Re

1.8 5.0

1.4 5.0

1.4 4.0

1.1 4.0

6700 ------6800

Trailer Hitch Re & Re Hood Lower body Re & Re

.2 .2 .2 0.5 0.5 0.5 25.6 20.6 22.6

none 0.5 18.2

none .2 0.5 0.5 18.2 30.0

.3 .3

Frame & Drive System 7000 7100 7200 7250 7300 7350 7400 7500

Front Axle Re & Re Rear Axle Re & Re Middle Axle Re & Re Chain Tensioner Re & Re Idler Shaft (LH) Re & Re Idler Shaft (RH) Re & Re Idler Shaft Alignment Only Battery Frame Re & Re

1.5 1.5 1.5 .3 2.5 2.6 .3 .3

1.5 1.5 1.5 .3 2.5 2.6 1.4 .3

1.5 1.5 1.5 .3

7600 7650

Tire Re & Re Rim Re & Re

.3 .3

.2 .1 .2 0.3 1.4

.2 .1 .2 .3 1.4

.2 .1 .2

.3 N/A

Fuel System & Seat Assembly 8000 8100 8200 8300 8400

Handrail Re & Re Backpad Re & Re Bench Seat Re & Re & Subassemble Tool Box Re & Re Fuel Tank Re & Re

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GI-19

General Information Number Job Description 8500 8600 8700

Argo Service Manual

FLAT RATE SCHEDULE ARGO SERVICE Maximum TIme (Hours) Conq Resp Bigf Van2 Van Aveng

Seat Frame Assembly Re & Re Filler Hose Re & Re Vent Hose Re & Re

1.5 .8 .9

Electrical System 9000 9100 9200 9300 9400 9500 9550 9600 9700 9800 -------9900

Hourmeter Re & Re (Includes Testing) Voltmeter Re & Re (Includes Testing) Coolant Gauge Re & Re (Includes Testing) Battery Re & Re & Service Wiring Harness Re & Re Headlight Re & Re Headlight Bulb Re & Re Light Switch Warning Light Ignition Switch Winch Solenoid Starter Relay

.2 .5 .5 .4 2.5 .2 .2 .2 .3 .2 0.5 0.3

.2 none none .4 1.3 .2 .2 .2 .3 .2 0.5 0.3

.2 .3 none .4 1.3 .2 .2 .2 none .2 0.5 0.3

.2 none none .4 1.3 .2 .2 .2 none .2 0.5 0.3

.2 none none .4 1.3 .2 .2 .2 none .2 0.5

------

Starter Motor

1.0

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GI-20

.2 .5 .5 .3

.2 .3 .2

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FLAT RATE SCHEDULE ARGO ACCESSORY INSTALLATION Part No. 614-06 615-42K

615-37K

615-10 617-00 617-10 618-00 618-10 621-30 622-21 622-40 622-70 622-78 622-80 622-96 624-00 624-10 625-42K

625-37K

625-20 626-10 632-15 633-10 634-08 634-11 638-25 638-30 639-20 642-00 642-20 648-15 648-75 648-40 649-31

Description

No.of Hours

Cargo Tie-Down Kit 6 Wheel Track Set - Assembly - Installation - Removal Bigfoot Track Set - Assembly - Installation - Removal Tire Chain Kit Outboard Motor Bracket Outboard Motor Bracket (Avenger) Outboard Motor Support Outboard Motor Bracket - Side Mount Utility Pouch Winch Bracket Kit Winch & Bracket Assembly Winch Kit - Vanguard2/Response Winch Bracket Kit - Vanguard2/Response Winch Kit - Avenger Receiver Winch Kit Dual Tail Light Kit Brake/Tailight Kit 6 Wheel Super Track Set - Assembly - Installation - Removal Bigfoot Super Track Set - Assembly - Installation - Removal Ice Cleat Kit - Installation Trailer Hitch Hourmeter Voltmeter Engine Oil Pressure Light Oil Temperature Gauge Bilge Pump Kit Bilge Pump 6x6 Hand Rail Kit Tow Hook Kit Brush Guard - Avenger Roll Bar Kit Fold Down Windshield - Installation - Removal ROPS Kit - 6x6 Convertible Top, Front - Installation - Removal

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.8 2.0 .5 .5 3.0 .5 .5 .2 .3 .5 .1 1.0 .2 1.0 3.0 3.0 1.0 3.0 1.0 .5 1.5 2.0 1.0 .5 3.0 1.0 .5 1.0 .3 .5 .5 1.0 .5 1.5 1.5 1.2 .2 1.5 2.0 1.0 .5 4.0 1.0 .5 www.odg.com

GI-21

General Information

Argo Service Manual

FLAT RATE SCHEDULE ARGO ACCESSORY INSTALLATION Part No. 649-50 650-60 657-00 663-10 663-11K 668-02 695-75 815-42K

825-42K

825-20 825-50

825-55 839-20 839-30 848-10 848-32 848-40-2 848-40-4 849-50 849-60 849-80 850-40 849-90-2 849-90-4 850-60 863-10 NPN 642-05 648-50 835-00 835-01

Description

No.of Hours

Convertible Top ASM - Installation 1.0 - Removal .5 Alternator Kit - Vanguard2 2.5 Snow Plow Kit (Seasonal Availability) 2.0 Full Length Skid Plate - 6x6 2.0 Full Length Skid Plate - 6x6 (V699-51/V699-55) 2.0 Brake Cooling Fan - Vanguard 2.0 Amphibious Trailer ASM 3.0 8 Wheel Track Set - Assembly 2.5 - Installation .5 - Removal .5 8 Wheel Super Track Set - Assembly 2.5 - Installation 1.3 - Removal .5 Ice Cleat Kit - Installation 1.2 Rubber Track Kit - assembly 4.0 -installation without hinge kit 2.0 -with hinge kit 1.0 Hinge Kit 2.0 Hand Rail Kit - 8x8 1.2 Hand Rail Kit 8x8 Avenger 1.2 Heater Kit - Conquest 3.5 Heater Kit - Avenger 7.0 ROPS Kit - 8x8 c/w 2 Seat belts 4.0 ROPS Kit + Rear Bench Seat 5.5 Convertible Top ASM - Installation 1.5 - Removal .5 Rear Bench Seat 2.5 Rear Bench Seat 1.0 Alternator Kit - Conquest 2.5 ROPS Kit 8x8 c/w 2 seat belts 4.0 ROPS Kit 8x8 + Rear Bench Seat 5.5 Alternator Kit - Response 2.5 Full Length Skid Plate - 8x8 2.5 Installation of front/rear bearing extensions on: Vanguard/Vanguard2/Response 4.0 Brush Guard Kit 1.5 Roll Bar Lights 1.5 Powered Dump Box 4.0 Manual Dump Box 3.5 Pre-service 2.0 Pre-service ( 6x6 Conquest C/W Roll Bar) 4.0

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GI-22

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ARGO Tool List 1/2" Impact 5/8" Socket Nylon Mallet [large] x2 Torque Wrench Air Gun Pry Bars 9/16" Wrench 1/2" Air Ratchet 9/16" Socket 3/8" Ratchet 3/4" Socket 5/8" Wrench 90 Degree Drill 9/16" Wrench 7/8" Drill Bit Urethane Mallet 5/8" Drill Bit Flat Head Screw Driver [med] Deburring Tool Air Rivet Gun Needle Nose Pliers 1/8" Allen Wrench 5/32" T Allen Wrench C-Clamps 11R Air Silicone Gun Modified C-Clamps (See Special Tools) Center Square Clamps Nylon and Rubber Mallet 15/16" Socket 7/16" Socket 3/8 Air Ratchet Flat Head Screw Driver Impact Wrench ( ½” Drive) Impact Wrench (3/8" Drive) 15/16" Pivot Socket Air Gun Med. Ball Peen Hammer 15/16" Socket Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

Ext. Retaining Ring Plyers 4R Ext. Retaining Ring Plyers 490R Side Cutters Channel Lock Plyers Flat Head Screw Driver(long] Star Head Screw Driver [short] Star Head Screw Driver [medium] 9/16" to ½” Wrench 9/16" Modified Combination Wrench ½” Hand Ratchet Stapler Needle Nose Plyers [small, notched] 1 1/16" Socket ½” Die 13 NC 7/16" Combination Wrench 7/16" Socket 1/6" to 3/8" Drill 1/2" Socket 1/4" Socket Gaping Tool Angled Needle Nose Plyers 12mm Combination Socket-Wrench Angle Drill 3/8" Socket Angled Side Cutters #3 Phillips 1/2" Combination Wrench 7/16" Combination Wrench Magnet Extension 1/4" Drive Air Ratchet 1/4" Extension 5/16" Socket Wire Strippers Jig Saw 1/4" Extension Star Screw Driver [short] 3/16" ‘T’ Allen Hex Key 9/16" Combination Wrench www.odg.com

GI-23

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Argo Service Manual

ARGO Tool List #2 Star Screw Driver [ long ] 11/32" Nut Driver 1/8" Hex Key 5mm Hex Key 4mm Hex Key 3mm Hex Key 3/4" Combination Wrench 8mm Combination Wrench 10mm Angled Combination Wrench 1/4" Nut Driver Hand Die N-32NF Vise Grips 7WR Needle Nosed Vise Grips Light Tester Electric Screwdriver [ Star Head ] ½” Extension (6 Inch) 1/2" Torque Wrench Heat Gun Flat Head Screw Driver [medium] 0-5/6" Drill Chuck Butterfly Ratchet 1/4" Square Head Socket 21mm Socket Exacto Knife C-Clamps 11R Claw Hammer Die Grinder Metal File Disk Grinder Small Hammer Small Exacto Knife 5/16" Nut Driver Flat Head Screw Driver [ small ] Deburrer Router With Drill Bit Valve Stem Remover Calking Gun 3/32" Hex Key [long ] Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

10mm Nut Driver 8mm Combination Wrench 6mm Hex Socket [short] 10mm Socket 13mm Combination Wrench & Socket Switch Knife 8" - 200mm Click stop 12mm Combination Wrench 1/2" Hand Ratchet [ long ] 17mm Socket Hand Crimping Tool File [small] 3/4" Combination Wrench 12mm Socket 6mm Hex Key #2 Star Screw Driver [short] 6mm Hex Socket [long] 3/8"-1/4" Socket Adapter 3/8" Torque Wrench [small ] 3/8" Palm Impact Wrench Rubber and Nylon Mallet 10mm Nut Driver 8mm Combination Wrench 6mm Hex Socket 13mm Combination Wrench & Socket Switch Knife 8" - 200mm Click stop 17mm Combination Wrench 12mm Combination Wrench 1/2" Hand Ratchet [ long ] 17mm Socket Hand Crimping Tool File [small] 6mm Hex Key #2 Star Screw Driver [green] 6mm Hex Socket [long] 3/8"-1/4" Socket Adapter

GI-24

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ARGO Tool List 3/8" Torque Wrench [small ] 3/8" Palm Impact Wrench 3/8" Torque Wrench [small] 1/4" Nut Driver Retaining Ring Plyers 2R Angled Air Ratchet 3/8" Box End Air Ratchet Wrench 1/4" - 1/2" Tapping Socket #21 Drill Bit 13/64" Drill Bit 29/64" Drill Bit 3/32" Drill Bit 3/4" Drill Bit 9/16" Drill Bit 21/64" Drill Bit 2 1/8" Hole Drill Bit 2 3/8" Hole Drill 3/8"Drill Bit 7/8" Drill Bit Rivet Gun Reciprocating Saw 1/4" Driving Air Ratchet Wrench Small Side Cutters

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GI-25

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Argo Service Manual

7R VICE GRIP MODIFICATION A pair of modified 7R Vice Grips is required to hold the ends of the drive chain together while inserting the connecting link. This tool can also be used to hold the ends of the idler chain together while inserting the connecting link. Grind the undercut and sides of the vice grip jaw to fit over 2 chain rollers. The undercut is approximately 1/4" radius as shown.

658-20 Tool, Driven Clutch Service

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GI-26

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Starter Removal

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GI-27

General Information

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GI-28

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Argo Service Manual

Engine System

SECTION EN Engine System Table of Contents Briggs V Twin, Kawasaki L/C & Kohler Engine Photographs....... EN-2 General Instructions............................................................................. EN-3 Checking the Engine Oil....................................................................... EN-4 Recommended Engine Oil.................................................................... EN-4 Changing the Engine Oil...................................................................... EN-5 Draining the Engine Oil........................................................................EN-5 Oil Filter Replacement..........................................................................EN-6 Refilling the Engine...............................................................................EN-7 Air Filter................................................................................................. EN-7 Spark Plugs............................................................................................ EN-7 Removing the Engine(Kawasaki FD620D L/C)..................................EN-8 Assembling the Engine to the Power Pack Frame (Kawasaki)......... EN-13 Installing the Engine............................................................................. EN-14 Removing the Engine(Briggs Models)................................................. EN-18 Installing the Engine (Briggs Models)................................................. EN-20 Removing the Engine (Kohler Aegis) Supplement Pages................ EN-20A Installing the Engine (Kohler Aegis) Supplement Pages.................. EN-25A

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EN-1

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Engine System

Argo Service Manual

Briggs& Stratton V Twin OHV 16, 18 & 23 H.P

Kawasaki FD620D Liquid Cooled 20 H.P OHV Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

Kohler Aegis 26H.P Carburated & 31H.P EFI EN-2

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Argo Service Manual

Engine System

General Instructions

Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual. Before performing a servicing operation, an individual must have determined to his/her satisfaction that personal injury or vehicle damage will not result from the servicing procedure or tools selected.

All engine service work should be performed by a qualified mechanic. Severe damage and/or reduced performance can result from an improperly serviced engine.

Basic engine servicing information is provided in this section of the manual. For more detailed servicing operations please refer to the proper engine service manual listed in the chart below.

Models

Engine

Engine Service Manual

S, SN, BF, F Briggs & Stratton Briggs & Stratton Repair RB, R, B, N V Twin OHV 16,18 & 23H.P Manual V Twin OHVN

C, CB, A

NV, NH

670-33 670-40-1 (23H.P)

Kawasaki Service Manual Four Stroke Liquid Cooled 99924-2030-03

Kawasaki FD620D

Kohler Aegis 26 & 31H.P

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Part Number

EN-3

Kohler Service Manual

TP-2527-A

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Engine System

Argo Service Manual

Engine Oil Information Checking the Engine Oil Level To check the oil during an operating period, shut the engine off, let it cool down and allow the oil time to drain into the sump before checking the oil level. Position the vehicle so the engine is level. Check the engine oil level each day before operating the engine. The BRIGGS & STRATTON VANGUARD (Figure EN-1) and KAWASAKI engines (Photo EN-2) are equipped with a dipstick and a separate oil filler tube. To check the oil level, clean the area around the dipstick before removing. Remove the dipstick and wipe it with a clean cloth. Re-insert the dipstick and push it all the way into the tube. Remove the dipstick and check the oil level. The oil level should be between the marks. If the level has dropped, add oil to bring the level up to the FULL mark. DO NOT OVERFILL. Do not run the engine if the oil level is above the FULL mark or below the ADD mark. Premature engine damage or total engine failure can occur when the oil level is not properly maintained.

EN-2

EN-1 Recommended Engine Oil Use a high quality detergent oil of API (American Petroleum Institute) service class as listed below. Choose the correct viscosity of oil for seasonal driving conditions. See chart following page. Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-4

EN-2a www.odg.com

Argo Service Manual

Engine System

Briggs & Stratton API Service Class SE, SF or SG

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EN-5

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Engine System

Argo Service Manual

Changing Engine Oil During the initial engine break-in period, change the oil after the first 8 hours of operation for Briggs & Stratton and 20 hours of operation for the Kawasaki. After the break-in period, change the engine oil every 50 operating hours, or more frequently if the vehicle is operated in dusty or dirty conditions. Draining the Engine Oil Each engine is equipped with a drain plug for draining the oil. The drain plug location for the Kawasaki FD620D and Kohler Aegis engines is beneath the driver clutch. Photo EN2a Remove the drive belt for easier access to the drain plug. The oil drain plug on the Briggs and Stratton engine is located at both the front and rear of the engine block. The rear plug on the Briggs & Stratton engine is the recommended choice for draining the oil (same side as the oil filter). See IMPORTANT on the following page. 1.

Start and warm up the engine so the oil will drain easily.

Level the vehicle so the oil will drain completely.

Place a suitable container under oil drain of engine and remove drain plug with a wrench: an 8 point 7/16" square socket for Briggs & Stratton engines or a 21mm socket for Kawasaki engines.

IMPORTANT When draining the oil on the Briggs 18h.p or 16 h.p V Twin engines, it is advisable to remove it from the drain plug located between the engine and transmission (same side as the oil filter). To provide a good view of the draining area and avoid any spills into the lower body, it is best to remove the driven clutch and drive belt as well. Remove the clamp securing the brake cooling duct to its mounting bracket and tilt it up and out of the line of view of the drain plug area. Position the container beneath the drain plug and remove the plug. Refer to Removing the Drive Belt and Removing the Driven Clutch in section CS of this service guide if necessary.

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EN-6

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Argo Service Manual

Engine System

When all the oil has been drained from the engine, clean and replace the drain plug. MAKE SURE it is properly tightened before refilling the engine.

See Oil Filter Replacement Below.

Oil Filter Replacement During the initial engine break-in period, change the oil filter (Part No. 126-95 for Briggs & Stratton engines and Part No. 127-68 for Kawasaki engines) when the oil is changed. After that, change the oil filter every 50 hours. Before installing the new filter, lubricate the rubber filter gasket with fresh engine oil. Screw the filter on by hand until the gasket contacts the filter adapter. Tighten 1/2 to 3/4 turn more. Add the specified oil. See previous page for oil capacities based on the engine powering your vehicle. Start and run engine to check for oil leaks. Stop engine and recheck oil level. Add oil if required.

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EN-7

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Engine System

Argo Service Manual

Refilling the Engine Refill the engine through the oil fill port with the correct amount of oil (Photo EN-1 & 2 on page EN-4). Make sure the appropriate grade of oil is used (page EN-5). As you add oil, frequently check the level with the dipstick. Do not overfill. Start engine. Check for leaks. Stop the engine. Check the oil level. Add oil only to the “Full” or “H” mark on the dipstick. Air Filter All ARGO engines are equipped with a foam precleaner and dry paper air filter element housed in an air cleaner assembly attached to the carburetor. Wash and oil the precleaner after every 25 hours of operation or more often under extremely dusty or dirty conditions. Check the paper air filter element every 100 hours of operation or more often under extremely dusty or dirty conditions. For instructions to remove, clean and replace the air filter components, refer to the air cleaner section of the engine owner’s manual. Spark Plugs Remove and inspect the spark plugs after every 100 hours of operation. Clean the plugs and reset the gap as detailed in the engine owner’s manual. Replace the spark plugs if the electrodes are corroded or damaged or if the insulator is cracked. Use the correct plug for the engine as detailed in the engine owner’s manual. Re-install the spark plugs carefully, taking care to start the threads properly. Torque the plugs to 10 - 15 ft. lbs (14 to 20 N·m). Do not over tighten.

When replacing spark plugs on the Kawasaki FD620D Liquid Cooled OHV Engine, it is extremely important to pay strict attention to the specification number of the engine being serviced. All Conquest vehicles manufactured prior to vehicle serial number CB17857 require spark plug part number 92070-2072. Vehicles produced from CB17857 with a specification number of HS12 or later require spark plug number 92070-2112. Kawasaki has made changes to the Cylinder Heads, Head composition, & spark plugs of the FD620D. The newer spark plugs are longer and will cause damage if used in an older spec. engine. Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-8

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Argo Service Manual

Engine System

Removing the Engine (FD620D Kawasaki Liquid Cooled OHV)

Accessing the 4 mounting bolts that secure the engine to the power pack frame requires the power pack frame to be removed from the vehicle. Both engine and transmission can be removed through the engine access opening using an overhead hoist. You may prefer to remove the transmission first before lifting engine and frame through the hood area.. 1.

Perform the servicing procedure, Removing the Battery in section ES of this service guide.

Locate and remove the engine access cover. Photo EN-3

Separate the main wire harness from the nylon clips securing it at the back of the engine. Photo EN-4

EN-3

EN-4

Disconnect the main engine wire harness plug located between engine and transmission. Photo EN-5

Remove the starter cable at the electric starter. Photo EN-6

EN-5 Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

EN-6 EN-9

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Argo Service Manual

Disconnect the ground wire (leading from the battery ground terminal post), at the engine.

Remove the radiator overflow bottle at the front of the engine.

Conquests manufactured prior to CB14963 have an O.D.G overflow bottle and holder to remove. Conquests manufactured from CB14963 utilize a Kawasaki bottle secured directly to the upper radiator bracket. 8.

Unclip the fuel line from the nylon clips at the front of the engine.

Remove the engine air filter cover and air element. Photo EN-7

10. Remove the 7 fasteners securing the plastic base of the air filter housing. Photo EN-8

When removing the 3 fasteners securing the base closest to the mouth of the carburetor, be aware of the 3 metal inserts in each mounting hole. These may pull out when removing the fastener. Caution is advised to ensure that they do not fall into the throat of the carburetor undetected. Severe engine damage will occur if this has not been observed.

EN-7

EN-8

11. Remove the 2 nuts securing the lower metal base of the air filter system to the carburetor, and remove. Once the metal base has been removed, temporarily reinstall the 2 nuts to secure the carburetor lid. Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-10

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12. Disconnect the fuel line at the carburetor. Photo EN-9

IMPORTANT Before proceeding any further, be sure to cover the mouth of the carburetor with a rag, or other option. This will prevent anything from entering the carburetor unintentionally. 13. Disconnect the choke at the dash.

On Conquests manufactured prior to CB14606, remove the molded panel nut at the dash and slip the assembly back through the body into the engine compartment. Conquests manufactured from CB14606, require that the choke be disconnected at the throttle/choke control panel. Photo EN-10 The choke knob is molded to the end of the cable and does not thread off.

EN-9

EN-10

14. Perform the servicing procedure, Removing the Muffler and Shroud (Conquest), steps 1-6 on page DE-3 (models prior to C19672) or steps 1-2 on page DE-7 (models from C19672). 15. Disconnect the intake hose at the brake cooling duct. Photo EN-11 16. Remove the front pivot mounting bolt securing the power pack frame to the lower main frame. Photo EN-12

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EN-11

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Argo Service Manual EN-12

EN-11 17. Perform the servicing procedure, Removing the Drive Belt in section CS of this service guide. 18. Perform the servicing procedure, Removing the Driven Clutch, in section CS of this service guide. 19. Perform the servicing procedure, Removing the Brake Pads ( Hydraulic ) steps 14, in section BR of this service guide. 20. Locate the (3) mounting bolts that secure the steering and master cylinder assembly to the transmission and remove them. Photo EN-13 21. Disconnect the wiring at the igniter box which is mounted to the steering assembly. Photo EN-14

EN-13

EN-14

22. Unfasten the twist grip assembly from the steering handle and remove it. Photo EN-15 23. Remove the entire hydraulic brake system from the vehicle. The calipers, master cylinders and brake lines can all remain attached without the loss of any brake fluid. Photo EN-16 Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-12

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EN-15

EN-16

24. Perform the servicing procedure, Idler Chain Removal, in section WA of this service guide. 25. Loosen off the 2 power pack mounting bolts that run through the power pack frame and connect it with the lower main frame. One is located in front of the idler shaft, the other behind. Photo EN-17 26. Loosen off the dash support and turn it 90 degrees. Photo EN-18

EN-17

EN-18

27. Remove the driven clutch guard from the transmission. It is secured with (2) bolts and (2) flatwashers. Photo EN-19 28. Attach an overhead hoist to the front engine hook only. This hook is located on the exhaust manifold. Photo EN-20

EN-19 Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

EN-13

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EN-20

EN-21

29. Gradually and gently begin to raise the power pack assembly out of the engine access opening. Photo EN-21 You may have to pry the transmission from the driverâ&#x20AC;&#x2122;s compartment to free it from the lower main frame. 30. Set the power pack on a clean work bench and remove the 4 bolts that secure the engine to the frame. These bolts are threaded into the engine block from below. Photo EN-22 31. Using the overhead hoist, remove the engine from the power pack frame. Photo EN-23

EN-23

EN-22

If the engine is being replaced, you will need to remove all Argo components that are not available with the new engine. These will need to be reassembled to the new engine. Components include, throttle cable, choke cable, exhaust manifold, driver clutch, etc. Assembling the Engine to the Power Pack Frame (Kawasaki) 1.

Position the engine on to the power pack frame and align the holes in the block with the holes of the frame. Photo EN-24

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Argo Service Manual 2.

Engine System

Apply blue 242 LOCTITE to the threads of each mounting bolt and install. Torque to specifications.

Installing the Engine (Kawasaki FD620D L/C) 3.

Attach the overhead hoist to the front engine hook and lower the power pack into the vehicle through the engine access opening. The power pack assembly will go in vertically with the transmission entering the vehicle first. Photo EN-25

EN-24

EN-25

IMPORTANT As the power pack is lowered into the vehicle, position yourself inside the drivers compartment. Lift up on the transmission and align the power pack frame with the vehicle main frame. 4.

Position the power pack frame on to the lower main frame and install the front mounting pivot bolt. Be sure to install the square lockwasher to the mountng bolt head. Photo EN-26. The bolt is installed from left to right when standing at the front of the vehicle.

Assemble the rear power pack mounting bolt, complete with spacers and square washers, through the power pack frame. Photo EN-27

EN-26 Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

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Lower the rear of the power pack frame aligning the mounting bolt with the main frame. Photo EN-28

Install the 3rd mid mounting bolt paying close attention to the hardware that is required along with it. See your illustrated parts manual. Photo EN-29

EN-28

EN-29

On vehicles manufactured prior to serial number CB17117, ensure that the air intake duct seal at the radiator, is properly seated back up against the face of the radiator assembly. Photo EN-30. 8.

Reconnect the hose at the brake cooling duct.

Perform the servicing procedure, Installing the Muffler and Shroud (Conquest Models), in section DE of this service guide.

Â&#x2039;

On Conquests manufactured prior to CB14963:

Reattach the radiator overflow bottle holder at the front of the engine.

ii.

Slip the over flow bottle back into the holder and connect the hose.

Â&#x2039;

On Conquests manufactured from CB14963:

Attach the radiator over flow bottle directly to the upper rad bracket installing the 2 required spacers at each mounting bolt. re-insert the overflow hose.

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EN-30

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10. Reconnect the fuel line at the carburetor and secure with the hose clamp. 11. Secure the fuel line to the nylon clips at the front of the vehicle. 12. Assemble the lower metal air filter plate to the top of the carburetor. Photo EN-31 13. Assemble the plastic air filter base to the top of the previously installed metal backing plate, Photo EN-32, being sure to reconnect the tube from the base to the air breather assembly on top of the engine.

EN-31

EN-32

14. Reinstall the air filter element with foam precleaner, and assemble the cover to the top of the engine. 15. Reconnect the main engine wire harness located between the engine and transmission. 16. Reconnect the starter cable at the electric starter and cover with the rubber boot. 17. Secure the main engine harness to the nylon clips between the engine and transmission. 18. Reconnect the ground wire from the negative battery post terminal to the engine. 19. Reconnect the choke cable assembly.

On Conquests manufactured prior to CB14606, slip the assembly back through the body at the dash and secure with the molded panel nut. It was not required that the choke was disconnected at the throttle/choke control panel for engine removal, but if it was, you will need to reattach it at the linkage as well. On Conquests manufactured from CB14606, reconnect the cable to the throttle/choke control panel. It was not required that the choke knob was removed at the dash when the engine was prepared for removal.. Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

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20. Reposition the adjustable dash support back down to the top of the transmission and secure the carriage bolt. Photo EN-33 21. Perform the servicing procedure, Idler Chain Installation and Idler Chain Adjustment in section WA of this service guide.

EN-33

22. Reinstall the steering assembly to the transmission securing it with 3 bolts and lockwashers. Photo EN-34 23. Reattach the hydraulic brake calipers. Apply blue 242 Loctite to the threads of the mounting bolts and torque to specifications. See step 2 of Installing the Brake Pads (Hydraulic), if necessary. 24. Reconnect the ignition system at the igniter box. 25. Reinstall the clutch guard. Apply blue 242 LOCTITE to the threads of the 2 bolts that secure it to the transmission. Install each bolt with 2 flat washers Torque to specifications. 26. Perform the servicing procedure, Installing the Driven Clutch, In section CS of this service guide.

EN-34

27. Perform the servicing procedure, Installing the Drive Belt, In section CS of this service guide. 28

Perform the servicing procedure, Hydraulic Brake Plunger Adjustment, in section BR of this service guide.

29. Perform the servicing procedure, Installing the Battery, in section ES of this service guide and reconnect the wiring. 30. Perform the servicing procedure, Installing the Firewall, in section VB of this service guide. See IMPORTANT on following page.

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Argo Service Manual

Engine System

IMPORTANT Ensure that all levels of fluid (oil and antifreeze), in engine are correct before starting the vehicle. Run the engine for 5 minutes and recheck all levels. Add or remove as necessary. Removing the Engine (Briggs & Stratton 16 h.p & 18h.p) Unlike the Kawasaki FD620D L/C OHV engine, the Briggs & Stratton 16h.p and 18h.p engines may be detached from the power pack frame without having to remove the frame from the vehicle to access the mounting bolts. The engine may then be lifted independently through the engine access opening using an overhead hoist. However, initial preparations and disassemblies must be followed first. 1.

Perform the servicing procedure, Removing the Firewall, in section CS of this service guide.

Remove the hood.

Disconnect and remove the battery.

Perform the servicing procedure, Removing the Air Intake Shroud (Briggs Models), in section DE of this service guide.

Perform the servicing procedure, Removing the Drive Belt, in section CS. Perform the servicing procedure, Driven Clutch Removal, in section CS of this service guide.

Remove the driven clutch guard.

Disconnect the hose at the brake cooling duct.

EN-35

Remove the gear clamp that secures the brake cooling duct to its mounting EN-36 bracket, located between engine and transmission. Remove the duct. 10. Perform the servicing procedure, Removing the Muffler(Briggs models) on page DE-11 (Bigfoot models) or DE-8 all other Briggs models. 11. Unplug the charging wire at the front of the vehicle. Photo EN-35 12. Disconnect the isolated ground wire at the front of the engine. Photo EN-36 Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

EN-19

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Argo Service Manual

13. Disconnect the throttle cable at the engine. 14. Disconnect the choke at the engine. 15. Locate the fuel filter at the front of the vehicle and disconnect the fuel line. Be sure to clamp the fuel line with fuel line crimpers to prevent any fuel from leaking from the tank into the lower body.

IMPORTANT

Never stick anything into the fuel line to plug it. This could damage the fuel line leading to stray pieces of fuel line rubber being introduced into the fuel system when the fuel line is reconnected. 16. Disconnect the ground cable at the engine. Photo EN-37 17. Disconnect the power cable for the electric start. Â&#x2039;

On vehicles manufactured prior to BF12097, RB17665, S12222 & SN12227:

Disconnect the starter cable at the starter motor.

Â&#x2039;

On vehicles manufactured from BF12097, RB17665, S12222 & SN12227:

Disconnect the power cable at the starter relay. The starter relay is attached to the front of the engine close to the regulator.

18. Remove all 4 mounting bolts at the lower frame. The engine is secured with 4 nylon locknuts. 19. Lift the engine out of the vehicle using an overhead hoist. Photo EN-38

EN-37

EN-38

If the engine is being replaced, all Argo components must be removed first and reinstalled on the new engine. These include driver clutch, muffler, exhaust manifold and any return springs. Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-20

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Argo Service Manual

Engine System

Installing the Engine (Briggs Models) 1.

Attach the overhead hoist to both engine hooks and lower the engine into the vehicle. Photo EN-39

Secure the engine to the power pack frame with 4 bolts, 8 flat washers and 4 nylon locknuts. Refer to the illustrated parts manual for correct hardware orientation. Torque to specifications.

EN-39

IMPORTANT You will notice 8 mounting holes in the block of the engine. It is important that the correct set of holes is used for clutch offset and belt alignment. Use the holes as illustrated in Photo EN-40 & 41 below.

EN-40

EN-41

Reconnect the power to the electric starter.

Â&#x2039;

On vehicles manufactured prior to BF12097, RB17665, S12222 & SN12227:

Connect the starter cable at the starter motor.

Reattach the clip that secures the starter cable at the front of the engine. Â&#x2039;

On vehicles manufactured from BF12097, RB17665, S12222 & SN12227:

Connect the power cable at the starter relay.

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EN-21

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Reattach the ground wire to the isolated ground at the front of the engine, and plug the charging wire from the main wire harness back into the engine wire harness.

Reconnect the fuel line at the fuel filter.

Place the brake cooling duct to the top of the mounting bracket and secure with the gear clamp.

Reattach the brake cooling hose to the brake cooling duct and secure with another gear clamp.

Assemble the choke cable to the carburetor linkage. Photo EN-42

Assemble the throttle cable to the carburetor linkage. Photo EN-43

EN-42

EN-43

10. Reattach the ground wire running from the battery terminal, back to the engine. Photo EN-44 11. Perform the servicing procedure, Installing the Muffler (BriggsModels),on page DE-11 (Bigfoot)or DE-10 (others). 12. Mount the driven clutch guard at the transmission. Apply blue 242 LOCTITE to the threads of both mounting bolts and install with 2 flat washers. Torque to specifications.

EN-44

13. Perform the servicing procedure, Installing the Driven Clutch in section CS of this service guide. 14. Perform the servicing procedure, Installing the Drive Belt, in section CS of this service guide. Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-22

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Argo Service Manual

Engine System

15. Perform the servicing procedure, Installing the Intake Duct (Briggs Models), in section DE of this service guide. 16. Install the battery and reconnect battery terminals. 17. Perform the servicing procedure, Installing the Firewall, in section VB of this service guide.

IMPORTANT Before starting the engine check the engine oil level and re-check all electrical connections.

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EN-23

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SECTION EN

Supplement Pages

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Removing the Engine (Kohler Aegis N.A) 1.

Locate the tailpipe assembly and detach the connecting springs between the tailpipe assembly and muffler. Photo 1 & 2 Pull the assembly out through the hood area.

Remove the heat deflector shield covering the muffler. Photo 3

Disconnect the fuel line from the fuel filter at the carburetor. Photo 4

Disconnect All Wiring 4. Disconnect the ground cable at the engine. Photo 5 & 6

5 Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

EN-20A

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Disconnect the ground wire attached at the front of the engine to the valve cover fastener. Photo 7

Locate the main wire harness plug-ins at the front of the engine compartment and disconnect all wires. Photo 8

Locate the starter at the front of the engine compartment and disconnect both red and black power wires from the starter solenoid. Photo 9 These wires are enclosed within a red rubber boot.

Remove the drive belt between engine and transmission. Photo 10

9 9.

Remove the driven clutch from the transmission input shaft. Photo 11 & 12

12 Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-21A

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10. Disconnect the brake cooling hose at the brake duct. Photo 13 11 Disconnect the choke & throttle cables from the control panel on the Kohler engine. Photo 14 & 15 Make note of which hole the throttle cable is inserted.

Removing The (4) Engine Mount Fasteners 12. To effectively and efficiently remove the nylon locknuts that are securing the engine to the power pack frame studs, a flat ratcheting style wrench is the recommended tool of choice. Photo 16

This type of wrench is preferred for removing 3 of the 4 nylon locknut fasteners. The exception is the fastener located at the rear left corner of the engine block (as viewed by the operator in the drivers seat). This fastener requires the use of a regular opened end style wrench. 13. Remove each nylon locking nut and flat washer. Photo 17

16 Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

EN-22A

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Engine System

Argo Service Manual

Lifting the Engine From the Vehicle

This procedure requires the use of an overhead hoist. Do NOT attempt to lift out by hand. Ensure all components attached to the engine have been detached. Lift out slowly and carefully. If you wish to remove the muffler from the engine before raising it out, you may do so as an optional procedure. You may find it easier to maneuver the engine up and out with the muffler removed, but it is not necessary.

Ensure all hoist chains or belts are secure, and hooks are locked into place. Keep all fingers and hands clear of the area from which the engine is being lifted. 14. Attach the overhead hoist to the engine. There is a hook provided on the engine Photo 18, (located near the yellow oil fill plug on earlier spec. engines and beside the rear cylinder head cover on later spec. engines),for connecting one side of the hoist chain. Connect the other side to the rad bracket. Photo 19

15. Slowly and gently raise the engine through the hood area. Some manuevering is required as the engine does not necessarily come straight up and out. Avoid damage to any other components as well as the upper body. Photo 20 & 21

20 Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

21 EN-23A

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16. Remove the engine to a clean workbench for further disassembly. 17. Remove the muffler if it was not previously removed. (EFI models will have an O2 sensor threaded into the muffler that will need to be removed as well. Photo 22 18. Remove the hex head fastener securing the driver clutch to the PTO and slide the clutch from the shaft. The PTO is a keyed shaft. Photo 23 & 24 19. Remove the (5) shims that are installed to the PTO. Photo 25

IMPORTANT These shims MUST be reinstalled before the driver clutch.

20. Remove all fluids.

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EN-24A

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Argo Service Manual

Installing The Engine (Kohler Avenger Model) 1.

Install the (5) shims to the PTO of the engine. Photo 1

Apply anti-seize compound to the PTO. Photo 2

Install the key to the keyway of the PTO. Photo 3

Slide the driver clutch on and up to the shoulder of the PTO. Photo 4

3 5.

Secure the driver with the hex head fastener. Apply blue LOCTITE and Torque to specifications. Photo 5

IMPORTANT

For part number and descriptions of all components and hardware, always refer to your illustrated Argo parts manual. 6.

Install the muffler assembly to the engine manifold. Photo 6

IMPORTANT Always use new manifold gaskets Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-25A

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IMPORTANT If you have removed the Kohler Aegis radiator assembly from the engine for any reason (repair, replacement etc.), ensure, when reinstalling it, that you tie-wrap the bottom of it securely to the lower bracket as in photo 7 & 8. This will prevent the lower radiator locating pins from dislodging from the rubber gromments under heavy vehicle application. Damage can occur to both fan and shroud if this is not done. Please note that later spec. engines have retaining clips installed to the locating pins and do not require the tie-wraps to secure the rad in place.

7 7.

Attach the hoist hooks to the engine location as described in 14 of Removing The Engine.

Swing the engine assembly over the open hood area of the Avenger vehicle. Locate the (4) mounting studs on the power pack frame. Photo 9

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EN-26A

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Engine System 9.

Argo Service Manual

Slowly and gently lower the engine through the hood area. Some manuevering is required as the engine does not necessarily drop in straight on. Avoid damage to any vehicle components as well as the upper body. Photo 10 & 11

IMPORTANT Align the mounting holes of the engine block with the powerpack frame studs. Once aligned properly, the engine should just drop into place. Do not force or hammer in any way. Damage may occur to the threads of the mounting studs.

IMPORTANT Once the engine is seated into place, ensure that the rubber rad seal is properly sealing at the face of the radiator. Photo 12

10. Locate the flat washer and nylon locknut used to secure the engine to the power pack frame studs. Photo 13 Refer to your illustrated parts manual. Install all four fasteners and Torque to specifications. Refer to step 12 of Removing The Engine, for preferred wrenches used to retighten the nylon locknuts. Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-27A

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11. Reconnect the brake cooling hose at the brake duct. Photo 14 12 Reconnect the choke & throttle cables to the control panel on the Kohler engine. Photo 15 Insert the throttle cable into the correct hole. Photo 16

13. Assemble the key to the keyway of the transmission input shaft. Apply antiseize compound to the length of the shaft. Photo 17 14. Install the driven clutch. Apply blue LOCTITE to the threads of the fastener and Torque to specifications. Photo 18

15. Reinstall the drive belt between engine and transmission.

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EN-28A

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16. Locate the starter at the front of the engine compartment and reconnect both red and black power wires to the starter solenoid. Photo 19 These wires are enclosed within a red rubber boot. 17. Reconnect the ground wire attached at the front of the engine to the valve cover fastener. Photo 20

18. Locate the main wire harness plug-ins at the front of the engine compartment and reconnect the main black plug. Reconnect both blue and orange wires (oil pressure and coolant temperature sensors). Photo 21

19. Reconnect the ground cable at the engine. Photo 22 & 23

22 20. Reconnect the fuel line to the carburator. Photo 24 21. Reinstall the heat deflector shield over the muffler. Photo 25 Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-29A

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22. Locate and install the tailpipe assembly. Attach the connecting springs between tailpipe assembly and muffler. Photo26 & 27 Feed the tailpipe assembly in through the hood area.

23. Replenish all fluid levels.

EN-30A Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

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Electrical System

SECTION ES Electrical System Table of Contents General Instructions............................................................................. ES-5 Battery.................................................................................................... ES-6 Checking Battery Fluid Level.............................................................. ES-6 Charging the Battery.............................................................................ES-6 Cleaning the Battery Terminals & Cable Connections......................ES-6 Cleaning the Battery..............................................................................ES-7 Battery Removal.................................................................................... ES-7 Battery Inspection................................................................................. ES-7 Battery Installation............................................................................... ES-8 Changing a Headlamp Bulb (Earlier Conquest Models)...................ES-8 Installing the Headlamp Bulb (Earlier Conquest Models)................ES-9 Removing a Headlamp Bulb................................................................ES-9 Installing a Headlamp Bulb..................................................................ES-10 Removing the Headlamp Lens Assembly (Conquest Models From CB12580).................................................... ES-10 Installing the Headlamp Lens Assembly (Conquest Models From CB12580)......................................................ES-11 Headlamp Removal (Earlier Vanguard2 & Vanguard 6x6)..............ES-11 Headlamp Installation (Earlier Vanguard2 & Vanguard 6x6)......... ES-11 Headlamp Removal (Response, Bigfoot & Later Vanguard2 and Vanguard 6x6)............ ES-12 Headlamp Installation (Response, Bigfoot & Later Vanguard2 and Vanguard 6x6)............ ES-12

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ES-1

Electrical System

Argo Service Manual

SECTION ES Electrical System Table of Contents Removing the Starter (Conquest Models).......................................... ES-13 Installing the Starter (Conquest Models)............................................ES-14 Removing the Starter (Response, Bigfoot, Vanguard2 & Vanuard Models)......................... ES-14 Installing the Starter (Response, Bigfoot, Vanguard2 & Vanguard Models)....................... ES-16 Removing the Brake Cooling Fan (Response & Bigfoot).................. ES-17 Installing the Brake Cooling Fan (Response & Bigfoot).................. ES-18 Removing the Brake Cooling Fan (Conquest)....................................ES-19 Installing the Brake Cooling Fan (Conquest).....................................ES-20 Calibrating the Digital Gauge Package............................Supl. Page ES-52

Wiring Diagrams and Schematics Models T, TB, HT, HTB From 1977; KB From 1981-86; K From 1983 S From 1986; SB From 1987;..........................................ES-22, 23 Argo Standard & Heavy Duty (Models V688-20,V888-20, V888-21; After T6460, TB8446, HTB8592 11/88).................................ES-23 Argo Twin (Model V888-22, V688-22 From SB8355, S6308).............ES-24 Argo Vanguard Model V891/892-22, V691/692-22 From S6834, SB9691..............................................................................ES-25 Argo Model NKB From 1987 1/87......................................................ES-26 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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ES-2

Argo Service Manual

Electrical System

Argo I/C Model V888-23, V688-23 From NKB 8187, NK 6192 11/88...........................................................ES-27 Argo Magnum Model V890-23, V690-23 12/89...................................ES-28 Argo Magnum Model V890-23, V690-23 From NKB9466, NK 6812 10/90............................................................ES-29 Argo Magnum Model V891-23 From NKB 10785; Models V891-27, V691-27 06/93...........................ES-30 Argo Magnum Model V894-23, V894-27 From NKB 10973 03/94....ES-31 Response Model V896-65 From RB 12075 08/95.................................ES-32 Response Model V896-65 From RB 12702 11/96.................................ES-33 Response Model V896-65 From RB 14121 10/97................................ES-34 Reponse Model V899-65 From RB 16104 06/99..................................ES-35 Response Model V899-65 From RB 17665 12/00.................................ES-36 Conquest V894-37, V894-38 From CB 10847 01/94............................ES-37 Conquest Model V894-37, V894-38 From CB 12580 03/96................ES-38 Conquest Model V899-37, V899-38 From CB 16049 05/99................ES-39 Conquest Model V899-37, V899-38 From CB 17857 02/01................ES-40 Argo Vanguard Model 693-22 From S6999 02/92..............................ES-41 Argo Vanguard Model V693-36 From S7304 06/93............................ES-42 Argo Vanguard Model V697-51 From S8131 09/97............................ES-43 Argo Vanguard Parts Manual Model V699-51 From S12222 03/02................................................................................ES-44 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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ES-3

Electrical System

Argo Service Manual

Argo Vanguard2 Model V696-55 From SN7841 04/95..................... ES-45 Argo Vanguard2 Model V697-55 From SN8138 11/95......................ES-46 Argo Vanguard2 Model V697-55 From SN8138 11/95......................ES-47 Argo Vanguard2 Model V699-55 From SN12227 02/01................... ES-48 Bigfoot Model V698-58 From BF9212 08/97......................................ES-49 Bigfoot Model V698-58 From BF12097 12/00...................................ES-50 Conquest 6x6 Model V601-62 From C12747 11/01........................... ES-51

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ES-4

Argo Service Manual

Electrical System

General Instructions

Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual. Before performing a servicing operation, an individual must have determined to his/her satisfaction that a personal injury or vehicle damage will not result from the servicing procedure or tools selected.

To prevent damage to the electrical system: •

Always disconnect the battery when servicing any electrical component.

•

Never weld on the vehicle without first disconnecting both positive and negative battery cables. Make sure the part you are welding is properly grounded.

•

Connecting booster cables to start your vehicle is not a recommended practice. Damage to engine electrical components could occur.

•

Connect switch terminals properly, especially the ground wire.

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Electrical System

Argo Service Manual

Battery All models are equipped with a 12 volt, wet cell type battery. The battery is located in the engine compartment, on the right side in front of the driverâ&#x20AC;&#x2122;s position. Checking the Fluid Level Check the fluid level every 50 hours of operation. Remove the pod vents and make sure each cell is filled to the fluid level as shown in Fig ES-1. If the fluid has dropped below the fill well, add distilled water until the cell is filled to correct level. DO NOT OVERFILL. Charging the Battery Fill all new dry charged batteries with electrolyte battery acid and let stand (off cement floor) for 6 hours. Slow charge for at least another 6 hours.

ES-1

If the battery loses its electrical charge, remove the battery from the ARGO and recharge it with a 12 volt battery charger at the rate of 1012 amps maximum. The battery should remain on charge until the specific gravity reaches 1.265 on a hydrometer. Re-install the battery in the vehicle and try to start the engine. If the battery fails to perform properly, have it tested by a battery service dealer. Replace a defective battery immediately.

Ventilate area when charging. Keep away from spark, heat, cigarettes or open flame. Cleaning the Battery Terminals and Cable Connections Clean the battery terminals and cable connections every 100 hours. Remove the black NEGATIVE (-) cables first. Make sure you reconnect the NEGATIVE (-) cables to the NEGATIVE (-) post and the red POSITIVE (+) cables to the POSITIVE (+) posts. Damage to the electrical system will occur if the cables are reversed.

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Argo Service Manual

Electrical System

Cleaning the Battery Clean the top of the battery every 250 hours with a mixture of baking soda and water. Before cleaning the battery, remove it from the vehicle and make sure the pod vents are in place. Soak a cloth in the soda/water mixture and scrub the top of the battery. After the foaming has stopped, flush with clean water and dry with a clean cloth. Battery Removal 1.

Perform the servicing procedure, Removing the Firewall, in section VB of this service guide.

Locate the battery on the right hand side of the vehicle.

Remove the negative battery cable first.

Accessing the negative ground cable terminal on Conquest models may require removing the battery retaining bracket first, then sliding the battery partially out to loosen the terminal hardware. 4.

Slide the battery out through the firewall area.

Battery Inspection 1.

Inspect the battery for:

•

cracks in the battery casing

•

cracked or broken terminals

•

exposed or corroded cells

•

weak cells

Inspect the Battery for:

•

corroded terminals

•

low water level

If any of these conditions are noted, service the battery immediately. Adjust battery fluid level with distilled water, and clean and grease the battery terminals.

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Electrical System

Argo Service Manual

Battery fluid contains sulphuric acid. If it comes into contact with your skin or eyes, serious personal injury will occur. Always wear rubber gloves and safety goggles when servicing the battery.

Batteries produce explosive gas. Keep sparks, flames and cigarettes away from the battery. Re-charge the battery only in a well ventilated area.

Keep the battery charged. Never allow the battery to become drained by unnecessary use of the headlights or overcranking of the engine. If the battery is dead or the electrical charge is low, re-charge it with a 12 volt battery charger. Slow charge for at least 6 hrs. If persistant problems with battery charge occur, before replacing the battery, ensure that the engine charging system is functioning properly. Refer to the appropriate engine service manual given in section GI of this service guide. Battery Installation 1.

Place the battery on to the battery frame. Install the battery retaining bracket and fasten securely.

Fasten the main power cable to the positive battery terminal.

Reattach the ground cable to the negative terminal side of the battery.

Reinstall the firewall.

Changing a Headlamp Bulb (Earlier Conquest Models) Â&#x2039;

On vehicles manufactured prior to CB12581:

Remove the hood and disconnect the battery.

Locate the the fastener above the headlamp and remove. The fastener is threaded to a nut on the underside of the headlamp mounting bracket. Carefully unthread the bolt while holding the nut with your finger, preventing it from falling into the vehicle.

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Argo Service Manual

Electrical System

Pull the headlamp assembly from the vehicle. Unwrap the electrical tape from the power wire and disconnect.

Disconnect the ground wire at the headlamp mounting bracket.

Remove the trim screws and separate the lens from the headlamp housing.

Remove the bulb.

Installing the Headlamp Bulb (Earlier Conquest Models)

When installing the new bulb, avoid any contamination of the glass surface. Do not touch the bulb with your fingers. 7.

Secure the bulb inside the housing and route the power wire through the rubber grommet at the bottom of the assembly.

Assemble the lens back to the housing. Ensure that the gasket is in place and not damaged. Replace if necessary.

Install the screws to the headlamp trim.

10. Plug the power wire leading from the new bulb, into the vehicle wire harness. Retape the connection with electrical tape. 11. Place the headlamp assembly back into the upper body, aligning the hole of the headlamp mounting bracket, with the hole in the top of the upper body. 12. Secure with the bolt and nut. Re-connect the battery.

Although replacement bulbs are still available for this headlamp, the lens and housing assembly is not. If the entire assembly needs replacing, an update kit is available to adapt the newer style headlamp to an older vehicle. Removing a Headlamp Bulb Â&#x2039;

On Vehicles manufactured from CB12581, RB12075, S8131, SN8138 BF9121 & C12747:

Remove the engine hood assembly.

To remove the bulb from the lens, reach into the engine compartment and turn the bulb 1/4 turn counter-clockwise. Pull straight out. Photo ES-2

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Electrical System

Argo Service Manual

ES-2 3.

ES-3

Disconnect the bulb from the lens. Pry the 2 locking clips on the bulb apart while pulling it from the wiring. Photo ES-3

Installing a Headlamp Bulb

When installing the new bulb, avoid any contamination of the glass surface. Do not touch the bulb with your fingers. 4.

Clip the new bulb assembly into the wire harness.

Reaching in through the engine access area, align the bulb assembly with the headlamp housing. Push in and turn 1/4 turn clockwise.

Removing the Headlamp Lens Assembly (Conquest Models from CB12581) 1.

Grabbing the rubber headlamp bezel, pull the lens assembly from the upper body. Photo ES-4

Unclip the bulb from the wire harness as described in Photo ES-3

Peel the rubber headlamp bezel from the lense. Photo ES-6

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Argo Service Manual

Electrical System

Installing the Lens Assembly (Conquest Models from CB12581) 1.

Install the rubber headlamp bezel into the headlamp opening. Photo ES-7

Install the bulb into the headlamp housing. Insert and turn 1/4 turn clockwise. Photo ES-8

Snap the lens assembly into the rubber headlamp bezel.

ES-7

ES-8

Headlamp Removal (Earlier Vanguard2 & Vanguard Models) Â&#x2039;

On Vehicles manufactured prior to S8131 & SN8138:

Remove the engine access cover.

Disconnect the battery.

Using a screw driver, remove the 4 screws holding the headlamp rim to the upper body.

Pull the headlamp from the body.

Using a screwdriver, disconnect the wire leads from the headlamp.

Inspect the rubber gasket seal.

Headlamp Installation (Earlier Vanguard2 & Vanguard Models) 1.

Seat the rubber seal into the headlamp opening in the vehicle.

Fasten the wire leads to the headlamp with a screwdriver.

Seat the headlamp into the rubber seal and install the rim fastening it securely with the 4 screws.

4. 5.

Reconnect the battery Install the engine access cover.

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Electrical System

Argo Service Manual

Headlamp Removal ( Response, Bigfoot and Later Vanguard2 & Vanguard Models) 1.

Locate the 4 screws securing the metal headlamp bezel to the upper body. Photo ES-9

Some earlier Response models incorporated a plastic headlamp bezel that secured itself to the upper body by 2 tabs to the inside of the headlamp opening. To remove this bezel, reach in behind the headlamp and squeeze the 2 tabs to pop the bezel free of the upper body. See your illustrated parts manual for these earlier vehicles. 2.

Remove the 4 screws, unthreading them from the backing plate that holds the headlamp from the inside of the vehicle. Photo ES-10

ES-9 3.

ES-10

Pull the headlamp from the vehicle and remove the bulb from the lens by turning 1/4 turn counter-clockwise and pulling straight out.

Headlamp Installation ( Response, Bigfoot and Later Vanguard2 & Vanguard Models) 1.

Install the headlamp from inside the vehicle, placing the inside backing plate over the back of the lens and up against the upper body.

Place the outside bezel trim into position and thread in each screw aligning them with each hole of the backing plate.

Secure all screws.

Reinstall the lamp bulb, inserting it into the lens and turning 1/4 turn clockwise.

Install the engine access cover.

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Argo Service Manual

Electrical System

Removing the Starter (Conquest Models) The Kawasaki starter motor is located between the engine and transmission near the brake cooling duct. Photo ES-11 1. 2.

Perform the servicing procedure, Removing the Firewall, in section VB of this service guide. Perform the servicing procedure, Removing the Drive Belt, in section CS.

Perform the servicing procedure, Removing the Driven Clutch, in section CS.

Locate the starter relay wire and main power cable at the solenoid of the starter motor and disconnect. Photo ES-12 The solenoid is fastened to the top of the starter

ES-11

ES-12

Loosen off the bolts securing the brake cooling duct to the power pack frame and slide the brake cooling duct towards the transmission as far as possible.

Locate the 2 bolts securing the starter motor to the mounting bracket and remove. You will need to use a long extension and socket to reach the heads of the bolts. Photo ES-13

Maneuver the starter motor and solenoid out from the mounting bracket, and turn vertically to pull up between the engine and transmission. Photo ES-14

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Electrical System

Argo Service Manual

Installing the Starter (Conquest Models) 1.

Maneuver the starter and solenoid assembly vertically between the engine and transmission, turning horizontally to mount to the starter bracket.

Align the holes of the starter motor with the threaded holes of the mounting bracket and start the first mounting bolt. A socket on a long extension provides the extended reach needed to start the bolt. Use a magnetic socket or apply a little silicon into the socket head to hold the mounting bolt securely while reaching it into the required area.

Install the second mounting bolt and torque to specifications referring to the engine service manual.

Reconnect the starter cable and starter relay wire. Cover with the rubber boot.

Position the brake cooling duct and secure to the power pack frame with the 2 fasteners.

Perform the servicing procedure, Installing the Driven Clutch, in section CS.

Perform the servicing procedure, Installing the Drive Belt, in section CS.

Perform the servicing procedure, Installing the Firewall In section VB of this service guide.

Removing the Starter (Response, Bigfoot, Vanguard2 & Vanguard Models) Due to the location of the starter motor on the Briggs V Twin, it is recommended that the engine be removed from the vehicle to better access the starter motor area. With the engine on the bench, and the shrouding removed, the mounting hardware can be unfastened using a 13 mm universal swivel socket. Photo ES-15. However, the 2 mounting bolts securing the starter motor may also be accessed without removing the engine. This procedure would involve removing the engine flywheel as described below.

ES-15

Locate and remove the the air filter and base assembly from the top of the engine. Photo ES-16

Remove the fuel pump & fuel pump bracket. Photo ES-17

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Argo Service Manual

Electrical System

ES-16

ES-17

Perform the servicing procedure, Removing the Intake Duct, in section DE of this service guide.

Remove the bolt securing the ground cable to the engine.

5. 6. 7.

Remove the rest of the hardware securing the blower housing to the engine. Remove the blower housing. Photo ES-18 Remove the flywheel nut and recoil cup. Photo ES-19

ES-18 8.

ES-19

Attach a universal puller to the flywheel and pop the flywheel from the magneto side of the crank using a socket and wrench. Photo ES-20

While threading the puller into the flywheel, tap the end of the bolt occasionally with a steel hammer. This will aid the process of popping the flywheel free of the engine 9.

ES-20

Remove the flywheel from the engine.

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Electrical System

Argo Service Manual

The flywheel is aligned with a key on the crankshaft. Be aware of the key and ensure that it is reinstalled when the flywheel is assembled back to the engine.

The flywheel contains magnets used for the charging system of the engine. Place the flywheel on a clean work surface with the magnets facing up to ensure no metalic foreign objects are attracted to the magnet, and go undetected during reassembly. 10. Remove the backing plate at the stator. Photo ES-21 11. Locate and remove the 2 fasteners securing the starter motor to the engine. 12. Disconnect the main starter cable from the starter. Photo ES-22

ES-21

ES-22

Installing the Starter (Response, Bigfoot, Vanguard2 & Vanguard) 1.

Mount the starter to the engine. Torque the fasteners to specification referring to the appropriate Briggs & Stratton Engine manual.

Reconnect the power cable to the starter.

Reinstall the backing plate.

Reinstall the flywheel aligning the keyway of the flywheel with the key installed on the crankshaft.

Before installing the flywheel, ensure that the inside area containing the magnets is clean and free of any foreign material or metalic filings. Severe damage can occur to the flywheel and charging system if this is not observed. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Argo Service Manual

Electrical System

When the flywheel is assembled to the crankshaft, use a small technicians mirror to check the key and keyway alignment. 5. 6.

Install the recoil cup and mounting nut to the crankshaft. Torque the flywheel nut to specifications. Refer to your engine service guide. Install the blower housing.

Install the fuel pump mounting bracket and front engine hook.

Reinstall the fuel pump and reconnect the fuel line.

Attach the main ground cable to the engine.

10. Reassemble the air filter housing and filter back to the top of the engine. 11. Perform the servicing procedure, Installing the Intake Duct, in section DE of this service guide. Removing the Brake Cooling Fan (Response, Bigfoot) Response and Bigfoot models come equipped with a brake cooling system. The cooling fan is mounted to the upper body by 4 rivets, and air flow is routed via an intake hose to a brake cooling duct at the brake discs. 1.

Remove the engine access cover.

Perform the servicing procedure, Removing the Intake Duct, in section DE of this service guide. Locate the brake cooling fan and unfasten the gear clamp securing the hose to the fan. Photo ES-23

Pull the hose from the fan.

Disconnect the power and ground wire from fan.

Drill out the 4 rivets used to fasten the fan to the upper body. Photo ES-24

ES-23

Extreme care should be observed when drilling out rivets. Damage can occur to the upper body if the drill slips and comes into contact with the plastic. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Electrical System

Argo Service Manual

ES-24

ES-25

Remove the fan. Photo ES-25

Remove the mounting bracket from the old fan if it is being replaced, and install it to the new one.

Installing the Brake Cooling Fan (Response & Bigfoot models) 1.

Install the mounting bracket to the fan. Place the fan into the vehicle orienting the outlet towards the front of the vehicle. Photo ES-26

Align the holes in the bracket with the 4 holes in the upper body and insert the 4 rivets. Photo ES-27.

ES-26

ES-27

Pull each of the rivets with either a hand or air operated rivet gun.

Reconnect the wiring from engine harness to fan.

Connect the cooling hose to the fan and secure with the gear clamp.

Perform the servicing procedure, Installing the Intake Duct, in section DE of this service guide.

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Argo Service Manual

Electrical System

Removing the Brake Cooling Fan (Conquest Models) Conquest models have the brake cooling fan mounted to the intake duct assembly located on the right hand side of the vehicle. Conquest models manufactured prior to CB17117, utilize a sheet metal style intake duct, while later models have a molded plastic version. In both cases the brake cooling fan is mounted to the intake duct. To access the mounting hardware it will be necessary to separate the upper and lower body along the general area where the fan is located and mounted to the ducting. 1.

Peel off the rubber bumper assembly from the vehicle. You need only to peel the bumper along the section of rivets to be removed.

Using a 3/16" drill bit, remove the rivets starting from the front center of the vehicle to approximately the dash area. Photo ES-29

Separate the body, supporting it apart with a couple of 2x4 pieces of wood.

Â&#x2039;

On Conquests manufactured prior to CB17117:

The cooling fan is pop riveted to a mounting bracket. This mounting bracket is in turn mounted to the sheet metal intake duct by 4 bolts and lockwashers. Locate the 4 fasteners and remove. Refer to the appropriate illustrated parts manual for detailed hardware breakdown.

ii.

Remove the over flow bottle and holder from the front of the engine.

iii

Disconnect the intake hose from the fan by loosening the gear clamp securing it to the cooling fan.

iv.

Remove the blower fan reaching into the cavity at the front of the vehicle where the overflow bottle and bracket were previously removed.

Pull the fan out through the engine access area and set the fan on top of the upperbody to disconnect the wiring. Photo ES-30

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Electrical System

Argo Service Manual

vi. Remove the fan from the mounting base by drilling out the 4 rivets securing the two components together. vii. If replacing the fan, remove the band clamp from the fan. Install the band clamp to the new fan. Â&#x2039;

On Conquests manufactured from CB17117:

Disconnect the intake hose at the fan. The fan is located at the front right hand corner of the vehicle mounted to the molded plastic intake duct. Photo ES-31

ii.

Unplug the fan wiring.

iii. Through the separated upper and lower body, remove the 4 fasteners that secure the fan to the intake duct. Photo ES-32

ES-31

ES-32

iv.

Navigate the fan out from the vehicle between the separated upper & lower body.

If the fan is being replaced, the mounting bracket will need to be removed for installation to the new blower fan.

Installing the Brake Cooling Fan (Conquest models) Â&#x2039;

On Conquests manufactured prior to CB17117:

Rivet the fan to the mounting bracket assembly. Refer to the appropriate illustrated parts manual for component structure and hardware.

Connect the wiring from the vehicle wire harness to the fan.

Install the fan back to the metal intake duct and secure with the 4 bolts and lockwashers. Orient the fan with the outlet facing towards the front of the vehicle and facing slightly downward.

Reconnect the intake hose to the fan and fasten with the gear clamp.

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Electrical System

Remove the 2x4's used to space the upper and lower body apart and re-rivet the two back together using the required body rivets and washers.

Slip the rubber bumper back on.

Replace the radiator overflow bracket and bottle to the front of the vehicle. Install the lid and connect the overflow hose.

Install the engine access cover.

Â&#x2039;

On Conquests manufactured from CB17117:

Fasten the blower fan to the molded plastic intake duct orienting the fan outlet facing down towards the bottom of the vehicle. See Photo ES-31 on previous page.

Reconnect the fan wiring

Reattach the brake cooling hose and secure with the gear clamp.

Remove the 2x4's used to space the upper and lower body apart and re-rivet the two back together using the required body rivets and washers.

Slip the rubber bumper back on.

Install the engine access cover.

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Electrical System

Argo Service Manual

Models T, TB, HT, HTB FROM 1977 KB FROM 1981-86 K FROM1983 S FROM 1986 SB FROM 1987

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Argo Service Manual

Electrical System

Models T, TB, HT, HTB FROM 1977 KB FROM 1981-86 K FROM1983 S FROM 1986 SB FROM 1987

Argo Standard & Heavy Duty (Models V688-20,V888-20,V888-21 After T6460, TB8446, HTB8592 11/88

After T6460, TB8446, HTB8592

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ES-23

Electrical System

Argo Service Manual

Argo Twin (Model V888-22, V688-22 From SB8355, S6308)

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ES-24

Argo Service Manual

Electrical System

Argo Vangard Model V891/892-22, V691/692-22 from S6834, SB9691

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ES-25

Electrical System

Argo Service Manual Argo Model NKB From 1987 1/87

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ES-26

Argo Service Manual

Electrical System

Argo I/C Model V888-23, V688-23 From NKB 8187, NK 6192 11/88

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Electrical System

Argo Service Manual

Argo Magnum Model V890-23, V690-23 12/89

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ES-28

Argo Service Manual

Electrical System

Argo Magnum Model V890-23, V690-23 From NKB9466, NK 6812 10/90

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ES-29

Electrical System

Argo Service Manual

Argo Magnum Model V891-23 From NKB 10785, Models V891-27, V691-27 06/93

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ES-30

Argo Service Manual

Electrical System

Argo Magnum Model V894-23, V894-27 From NKB 10973 03/94

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ES-31

Electrical System

Argo Service Manual

Response Model V896-65 From RB 12075 08/95

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ES-32

Argo Service Manual

Electrical System

Response Model V896-65 From RB 12702 11/96

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ES-33

Electrical System

Argo Service Manual

Response Model V896-65 From RB 14121 10/97

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ES-34

Argo Service Manual

Electrical System

Reponse Model V899-65 From RB 16104 06/99

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ES-35

Electrical System

Argo Service Manual

Response Model V899-65 From RB 17665 12/00

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ES-36

Argo Service Manual

Electrical System Conquest Parts Manual

Conquest V894-37, V894-38 From CB 10847 01/94

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ES-37

Electrical System

Argo Service Manual

Conquest Model V894-37, V894-38 From CB 12580 03/96

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ES-38

Argo Service Manual

Electrical System

Conquest Model V899-37, V899-38 From CB 16049 05/99

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ES-39

Electrical System

Argo Service Manual

Conquest Model V899-37, V899-38 From CB 17857 02/01

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ES-40

Argo Service Manual

Electrical System

Argo Vanguard Model 693-22 From S6999 02/92

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ES-41

Electrical System

Argo Service Manual

Argo Vanguard Model V693-36 From S7304 06/93

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ES-42

Argo Service Manual

Electrical System

Argo Vanguard Model V697-51 From S8131 09/97

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ES-43

Electrical System

Argo Service Manual

Argo Vanguard Parts Manual Model V699-51 From S12222 03/02

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ES-44

Argo Service Manual

Electrical System

Argo Vanguard2 Model V696-55 From SN7841 04/95

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ES-45

Electrical System

Argo Service Manual

Argo Vanguard2 Model V697-55 From SN8138 11/95

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ES-46

Argo Service Manual

Electrical System

Argo Vanguard2 Model V697-55 From SN8138 11/95

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ES-47

Electrical System

Argo Service Manual

Argo Vanguard2 Model V699-55 From SN12227 02/01

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ES-48

Argo Service Manual

Electrical System

Bigfoot Model V698-58 From BF9212 08/97

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ES-49

Electrical System

Argo Service Manual

Bigfoot Model V698-58 From BF12097 12/00

Electrical System

Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

Bigfoot Parts Manual

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ES-50

Argo Service Manual

Electrical System

Conquest 6x6 Model V601-62 From C12747 11/01

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Electrical System

Argo Service Manual

Calibrating the 613-119 Digital Gauge Package In the event that the Digital Gauge Package needs to be re-calibrated or replaced, follow the below steps. 1) Hold down both the “MODE” and “KM/MILE” buttons and turn the key to “Run”. Release the buttons. 2) 2 bars on water temp will be flashing. Avengers - press “MODE” (and release) Frontiers - press “KM/MILE” to eliminate the flashing bars first, then press MODE. Note: If no bars are flashing after step 1, press MODE button directly. 3) 001 will be flashing in bottom left corner, press “KM/MILE” to change to 002, press “MODE” 4) 25.0 will be flashing, keep pressing “KM/MILE” to change: 20.4 for 8x8 with Frontier tires (24”) 21.2 for 8x8 with Rawhide III tires (25”) 19.2 for 6x6 with Rawhide III tires (25”) 18.4 for 6x6 with Frontier tires (24”) Press “MODE” once number is reached 5) A single digit will be displayed, turn key to off position and run vehicle as usual

IMPORTANT: Magnet located on R.H idler shaft should be installed South Pole side facing up. Gap between 613-126 Speed Sensor and Magnet should be between .125"and .375" for proper speedometer function. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Brake System

SECTION BR Brake System Table of Contents General Instructions............................................................................. BR-3,4 Brake System Maintenance ................................................................. BR-5 Brake Pad Inspection (Hydraulic)....................................................... BR-6 Removing the Brake Pads (Hydraulic)................................................BR-6 Installing Brake Pads (Hydraulic)....................................................... BR-8 Hydraulic Brake Caliper Maintenance Schedule.............................. BR-9 Hydraulic Brake Caliper Removal...................................................... BR-10 Hydraulic Brake Caliper Disassembly................................................ BR-11 Hydraulic Brake Caliper Reassembly................................................. BR-12 Hydraulic Brake Caliper Installation..................................................BR-14 Removing the Master Cylinder............................................................ BR-15 Disassembling the Master Cylinder..................................................... BR-16 Master Cylinder Servicing & Inspection............................................ BR-17 Master Cylinder Reassembly................................................................BR-18 Master Cylinder Installation................................................................ BR-19 Bleeding the Hydraulic Brake System.................................................BR-20 Brake Fluid Inspection..........................................................................BR-21 Changing the Brake Fluid.................................................................... BR-22 Hydraulic Brake Plunger Pin Adjustment..........................................BR-23 Hydraulic Brake Plunger Pin Adjustment(Steering Bar Style) Supplement Pages................................................................................. BR-8A Holding Brake Adjustment (Hydraulic Brake System)..................... BR-25 Inspecting the Hydraulic Brake Hoses................................................ BR-26 Replacing the Hydraulic Brake Hoses.................................................BR-26 Mechanical Brake Maintenance Schedule(6x6 Vanguard Models)..BR-26 Mechanical Brake Caliper Removal....................................................BR-27 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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SECTION BR Brake System Table of Contents Mechanical Brake Pad Inspection & Replacement............................BR-29 Replacing the Brake Pads (Mechanical)..............................................BR-29 Installing the Brake Pads (Mechanical)...............................................BR-30 Mechanical Brake Caliper Installation............................................... BR-31 Adjusting the Mechanical Brake Caliper............................................ BR-33 Steering Lever Adjustment (Mechanical)........................................... BR-34 Holding Brake Adjustment.................................................................. BR-34 Brake Disc Inspection............................................................................BR-35 Removing a Brake Disc.........................................................................BR-36 Installing the Brake Disc.......................................................................BR-39 Parking Brake Assembly (CE Kit Models Only)...............................BR-40 Brake Cooling System........................................................................... BR-46 Dissasembling the Steering Column/Brake Assembly (Moto Cross Style) Supplement Pages................................................ BR-1A (Parking/Emergency Brake System (Avenger, Frontier................... BR-12A

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General Instructions Always refer to the correct PARTS MANUAL in accordance with the specific model and serial number indicated on the serial tag plate of your vehicle. This is essential to locating and ordering the correct components that were used during that particular manufacturing period when the ARGO was built. It is also very helpful using the illustrations to clearly see and define the component being referred to. If components are no longer listed in your Spare Parts Price List (Distributors and Dealers Only), generally the superceded section will indicate which part(s) updates, or replaces it. All parts manuals are available in PDF format on CD.

Hydraulic System (Conquest, Response, Bigfoot, Vanguard2 & 6x6 Conquest)

Mechanical System (6X6 Vangaurd)

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General Instructions

Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual. Before performing a servicing operation, an individual must have determined to his/her satisfaction that a personal injury or vehicle damage will not result from the servicing procedure or tools selected.

All brake work should be performed by a qualified mechanic. Braking/Steering ability and vehicle performance will be seriously impaired if the braking system is not properly adjusted or maintained. Property damage and/or injury or death may result to the operator.

Hydraulic fluid can cause serious irritation to skin and eyes. In case of contact, flush thoroughly with water and contact a doctor if eyes have been exposed.

Use only Dot 5 Silicon Brake Fluid in the hydraulic brake system. Use of other brake fluids may damage components and could void warranty on the brake system. Never allow dirt, water, used brake fluid or any other contaminants to enter the hydraulic brake system. Also, never combine different types of brake fluids keeping in mind they may be incompatible with each other.

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Brake System Maintenance

Regular maintenance of the brake system is essential to both good vehicle performance and personal safety. Poorly maintained brakes can result in a decrease in braking/steering efficiency, vehicle performance or damaged brake discs.

Maintenance schedule 1.

Every 100 hours of vehicle operation, perform the servicing procedure, Brake Pad Inspection ( Mechanical).

Every 25 hours of vehicle operation, Perform the servicing procedure, Brake Pad Inspection (hydraulic).

Every 30 hours of vehicle operation, perform the servicing procedure, Adjusting The Mechanical Brake Caliper (Vanguard Models only).

Every 50 hours of vehicle operation, Perform the servicing procedure, Inspect Brake Fluid Level/Condition.

The intervals shown in this schedule are based on average operating conditions. Vehicles which are subject to more severe use, wet or dusty conditions, will require more frequent servicing.

Please refer to the appropriate illustrated parts manual for the vehicle being serviced. The parts manual is identified with either the vehicleâ&#x20AC;&#x2122;s model number, serial number or both written on the front cover. These parts manuals are availible on CD in PDF format. .

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Brake Pad Inspection Replace the brake pads if: Pad thickness is less than 0.10" (Hydraulic Brake Pads) Pad thickness is worn to (1/8") 3mm. ( Mechanical Brake Pad). The pads are glazed over and brake performance is affected. The pads are coated with oil or grease Removing Brake Pads ( Hydraulic) The hydraulic brake system is used on all models of ARGO vehicles with the exception of the Vanguard 6x6. To replace hydraulic brake pads (Gremica Calipers only)on models manufactured prior to 1996, remove the cotter pins securing the pads within the caliper and slip the brake pads from the caliper towards the drivers compartment. This procedure for replacing pads may be used proir to serial numbers CB12454, RB12473 & SN 8284. Gremica brake caliper halves used in production during this earlier manufacturing period, were secured together by two M10 bolts only, allowing the pads to be pulled from the calipers without having to remove the entire caliper from the mounting bosses on the transmission housing or cover. Vehicles equipped with Knott brake calipers also allow for brake pad removal by removing the 2 cotter pins securing the pads and pulling them straight up and out of the caliper. Vehicles produced from CB12454, RB12473 & SN 8284 (Grimeca brake calipers only) utilize an additional two M8 bolts per caliper. This new setup restricts the pads from being slipped out towards the drivers compartment. The caliper must be removed to slip the pads out through the front of the caliper. The following procedure applies to these later models.

Perform the servicing procedure, Removing the Firewall, in section VB of this service guide.

Raise the vehicle off the ground.

Line up the hole provided in the brake disc, with the 2 hex mounting bolts that

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secure the hydraulic brake caliper to the transmission housing. To do this you will need to rotate the tires by hand until they are lined up. Photo BR-1

NEVER attempt to align these with the engine running and in gear.

You may leave the brake fluid line connected to the caliper 4.

Remove the 2 fasteners and flat washers. Slide the caliper from the brake disc. Photo BR-2

BR-2

The left hand caliper requires the removal of the drive belt and driven clutch to access the mounting bolts to the transmission. Refer to Removing the Driven Clutch in Section CS of this service guide.

When removing the caliper from the transmission, take note of any shims that may have been used between the caliper and transmission mounting boss. Earlier models may have employed shims to correctly align the calipers with the brake discs. Ensure that these are reinstalled when remounting the caliper. 5.

Remove the 2 cotter pins securing the brake pads within the caliper and slide the brake pads out through the front. Photo BR-3

Perform the procedure, Hydraulic Brake Pad Inspection.

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Installing Brake Pads (Hydraulic)

When replacing worn or contaminated pads, replace both pads in the brake caliper assembly even if both pads do not require replacing. Using one new and one old brake pad in a caliper assembly may provide poor braking/steering performance.

When replacing brake pads, always use new cotter pins. 1.

Slip the new pads into the caliper. Install and bend the cotter pins to secure the new pads in place. Photo BR-4

Before installing the pads into the caliper, make sure that the brake caliper pistons are pushed back into the caliper housing as far as possible. This will enure that the new pads can be spread far enough apart from each other to accommodate the thickness of the brake disc when the caliper is slipped back into position and remounted to the transmission.

BR-4 2.

BR-5

Remount the caliper to the transmission by aligning the access hole in the brake disc with that of the threaded mounting boss on the transmission. Photo BR-5 LOCTITE the threads of the 2 hex head mounting bolts with blue LOCTITE 242, and secure the caliper (with the 2 flat washers in place) to the transmission. Do not forget to install any shims that may have initially been between the caliper and transmission mounting bosses. Torque to specifications.

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Hydraulic Brake Calipers Maintenance Schedule - Inspect every 50 hrs of vehicle operation

The brakes must be inspected regularly by a qualified mechanic. Damaged or leaking calipers can seriously impair the ARGO steering/ braking capability. Severe personal injury or property damage could result from a damaged or poorly adjusted brake system. Inspect the calipers for the conditions listed in the chart below and then perform the recommended servicing procedures. Condition

Corrective Action

Servicing Procedure

Cracked or Broken Replace Immediately Calipers Broken or Missing CotterPins

Hydraulic Brake Caliper Removal Brake Caliper Service and Repair

Page BR-10 BR-11

Hydraulic Caliper Installation BR-14

Hydraulic Fluid Leakage

Inspect Caliper Casting and â&#x20AC;&#x153;Oâ&#x20AC;? Ring Inspect Hoses and Connections

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Hydraulic Brake Caliper Removal Brake Caliper Service and Repair Inspecting the Hydraulic Brake line Hydraulic Caliper Installation

BR-9

BR-10

BR-11 BR-26 BR-14

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Argo Service Manual

Remove Hydraulic Brake Caliper 1.

Perform the servicing procedure Removing the Firewall (Quick Release) in section VB.

Raise the vehicle off the ground

Disconnect the brake line at the caliper. Photo BR-6 Be aware of the brake fluid present in the system. Use a rag or small container to collect any initial fluid that may drain from the master cylinder until you can raise and secure the brake line high enough to stop the flow of fluid.

Line up the hole provided in the brake disc, with the hex head mounting bolts that secure the hydraulic brake caliper to the transmission housing. To do this you will need to rotate the tires by hand until they are lined up. Remove the 2 fasteners and flat washers. Slide the caliper from the disc. Photo BR-7

NEVER attempt to align these with the engine running and in gear.

The left hand caliper requires the removal of the drive belt and driven clutch to access the mounting bolts at the transmission. Refer to Removing the Driven Clutch in Section CS of this service guide. When removing the caliper from the transmission, take note of any shims that may have been used between the caliper and transmission mounting boss. Earlier models may have employed shims to correctly align the calipers with the brake discs. Ensure that these are reinstalled when remounting the caliper.

BR-7

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Brake System

Remove the caliper to a clean work area.

Hydraulic Brake Caliper Disassembly 1.

Perform the servicing procedure, Remove Hydraulic Brake Caliper.

Work on a CLEAN dry surface. Locate and remove the 2 cotter pins securing the pads in the caliper and remove the brake pads.

Remove the piston from each half by applying compressed air (Max. 20 psi or less), to the hydraulic hose inlet. Place a rag in between the caliper to absorb the shock of the piston when it pops from the caliper. Photo BR-8

Place the caliper into an aluminum jawed vise with the 4 hex head fasteners facing up.

Always wear eye protection when using compressed air. Caliper parts could fly apart, causing serious injury.

Depending on the manufacturing date of the vehicle being serviced, the caliper halves may be secured together by either 2 or 4 mounting bolts. Vehicles manufactured prior to S/N CB 12455, RB 12474 & SN 8285 utilize the 2 bolt configuration. The 4 bolt style is fully exchangeable and replaces the 2 bolt pattern. 5.

Remove the socket head bolts that secure the caliper halves together. Photo BR-9

Take the caliper assembly from the vise and separate the 2 halves. Photo BR-10

Lift the piston seals and the â&#x20AC;&#x153;Oâ&#x20AC;? ring from the caliper halves and discard. Photo BR-11

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BR-11

BR-10 8.

Remove the bleed screws and check the steel ball from the caliper casting. Photo BR-12

Clean all components in a varsol bath, then a mild soap solution. Use compressed air to blow out the caliper castings. This will free up any dirt or other contaminants you could not reach with the cloth.

BR-12

10. Wipe all components with a lint free cloth or use compressed air to dry. 11. Thoroughly inspect all the components. Replace any worn, cracked, or broken or missing parts. 12. Inspect both piston chambers for any pitting, scratching, scarring or rust. Replace pistons with new,or the entire caliper assembly if necessary. Hydraulic Brake Caliper Reassembly 1.

Begin with all the components on a clean surface.

Lubricate all component parts with fresh DOT 5 Silicon Brake Fluid

Do not allow brake fluid to contact your eyes, clothes, or painted surfaces. Brake fluid is extremely corrosive and can cause severe personal injury. Wear protective eye goggles, gloves and clothing. If brake fluid contacts your eyes, consult a physician immediately. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Brake System

When reassembling the caliper, work with clean hands, tools, and parts. Perform the reassembly on a clean, neat surface. Dirt or contaminants on component parts will cause a reduction in brake efficiency and may damage the brake components. 3.

Place the caliper castings on a clean workbench so that the interior is facing up. Photo BR-13

Insert the rubber seals into each half of the caliper casting. Photo BR-14

Do not scratch or tear the seals during installation. Any damaged seal must be replaced immediately. 5.

Insert the pistons so that the cavity side is facing up.

Place the one half caliper into the aluminum jawed vise being careful not to damage it by overtightening it. Locate the oil journal which requires the small “O” ring. Place the “O” ring over the hole making sure that the flat edge of the ring is facing down. Photo BR-15

Place the other half caliper to the one secured in the vise making sure that the oil journal of the top half is aligned with the previously installed “O” ring in the lower half. Photo BR-16

BR-13

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BR-15

BR-16

Reinstall the socket head bolts which hold the caliper assembly together. Use blue LOCTITE on the threads of the fasteners. Torque the bolts to the specified torque. Photo BR-17

Place the check ball and bleeding screw back into the threaded mount of the caliper casting. Photo BR-18 Cap with the rubber plug.

10. Slide the brake pads into the calipers and secure with 2 new cotter pins.

BR-17

BR-18

Hydraulic Brake Caliper Installation 1.

Remount the caliper to the transmission by aligning the access hole in the brake disc with that of the threaded mounting boss on the transmission. LOCTITE the threads of the 2 hex head mounting bolts with blue LOCTITE 242 and secure the caliper (with the 2 flat washers) to the transmission. Photo BR-19 Torque to specifications. (See bottom NOTE on page BR-10)

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Brake System

Reattach the brake line at the caliper. Photo BR-20

Always use new copper washer seals at all brake line connections 3.

Perform the servicing procedure, Bleeding the Hydraulic Brake System.

BR-20

Removing the Master Cylinder

Clean the master cylinder casting and caliper casting and fittings. This will prevent dirt from contaminating the brake system. Contaminants in the brake fluid can damage components or cause premature wear. This will result in a loss of braking/ steering effectiveness. To rebuild a master cylinder, removal of the component is necessary to insure a clean and thorough job. 1.

Remove the covers from the master cylinders and empty the cylinders of their content. Photo BR-21 If you have access to a vacuum style hand pump, this works well for sucking the fluid from the reservoirs. If this is not an option, disconnect the brake hose from the caliper and allow the reservoir to drain through the hose into a container. Pumping the steering levers speed up the draining process.

BR-22

BR-21 2.

Disconnect the brake line at the master cylinders. Photo BR-22

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There are 2 bolts that hold the master cylinders to their mounting bracket. These are secured by 2 nylon locknuts. Remove the 2 nylon locknuts and remove the master cylinders from the vehicle to a clean work bench. Photo BR-23

BR-23

Be aware of the plunger pins and rubber boots attached to the master cylinders. Remove these to a workbench to prevent them from dropping into the lower body of the vehicle. A new rubber boot is supplied with the master cylinder O ring kit and must be replaced when rebuilding a master cylinder.

Disassembling the Master Cylinder 1.

Perform the servicing procedure, Master Cylinder Removal

Pull the piston and compression spring from the master cylinder. Photo BR-24

BR-24

Do not use a gripping tool to pull out the piston as this will scratch or damage the surface. Use fingers only to pull out the piston. If this does not work, reinstall gasket and cylinder cover and blow compressed air (Low Pressure 20 psi or less) through the fluid inlet hole. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Models manufactured after May 25, 2000 from S/N CB17145, RB17120, BF11608 and SN11630 have a tapered spring which attaches to the end of the piston. Models prior to this had a shorter spring which did not attach to the piston. The newer spring is fully exchangeable with the older style but should be replaced as a set. 3.

Slide the primary and secondary seals off the piston. Discard these old seals.

Do not scratch the piston when removing the seals.

Clean all components with alcohol or a mild soap solution. Use compressed air to blow out the master cylinder castings. This will free up any dirt or other contaminants you could not reach with the cloth.

Master Cylinder Servicing & Inspection

Use only genuine ARGO parts 1.

Thoroughly inspect all components of the master cylinder assembly and replace any worn, cracked or broken parts.

Inspect the condition of the piston. Replace the piston immediately if it is:

Scratched Pitted rusted scored in any way

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2(a) Inspect the condition of the master cylinder housing. Replace immediately if:

the piston bore is scratched, pitted or rusted the casing is cracked the fluid inlet hole is stripped

Lubricate all component parts with clean fresh Dot 5 Silicon Brake Fluid.

Before assembly, a new rubber boot and new primary and secondary seals are required. These are available in the replacement assembly Master Cylinder O- Ring Kit

Master Cylinder Reassembly 1.

Slide the new primary and secondary seals on to the piston. Orient as in Photo BR-25

Do not damage the seals during the installation

BR-25 2.

Install the compression spring on to the piston. Make sure the small end of the spring is mated to the piston. Photo BR-26

Models manufactured prior to May 25, 2000 have a shorter non-tapered spring which need only be inserted into the master cylinder followed by the piston. The older and newer style spring are fully exchangeable if necessary, but should be changed as a set. Vehicles manufactured from S/N CB17145, RB17120, BF11608 & SN11630 will have the newer spring style.

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Install the piston into the piston bore. Slide the end with the primary seal in first. Photo BR-27

BR-26 4.

BR-27

Temporarily install the cover and gasket onto the master cylinder reservoir.

Master Cylinder Installation 1.

Line up the holes in the mounting bracket with those of the master cylinder and insert the 2 mounting bolts. Photo BR-28

BR-28

Conquest models require the rear mounting bolt to also secure the igniter box at the master cylinder. 2.

Reinstall the nylon locknuts and tighten to anchor the master cylinders into position.

Reconnect the brake lines to the master cylinders. Always use new copper washer seals on the banjo bolts. Torque to specifications.

Refill the master cylinders using DOT 5 brake fluid. Use of other types of brake fluids or combining different types of brake fluids, may result in damage to steering/ braking components or seriously impair the way in which the vehicle performs.

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Argo Service Manual

Perform the servicing procedure, Bleeding the Hydraulic Brake System below.

Bleeding the Hydraulic Brake System

Remove the rubber plug from the bleed screw at the brake caliper.

With the bleed screw still tight, purge any air from the system by pumping the steering handles slowly. When there are no longer visible signs of air bubbles observed in the master cylinder, replenish it with more fluid to bring it back up to the top of the window.

. 3.

Next, apply steady pressure to the steering lever until the brake is fully engaged. Hold the steering lever in this position and slowly loosen the caliper bleeding screw 1/4 turn. Open the bleed screw only enough to slowly release fluid out of the screw. If there is any air still present in the system, it will be noticeable through this screw with a slight â&#x20AC;&#x153;spittingâ&#x20AC;? of fluid. Re-tighten the screw and once again pump the brake system slowly a few more times. Apply pressure to the steering lever again and hold. Open the bleed screw gradually until fluid slowly releases. Repeat this procedure until the fluid coming from the bleed screw is a full stream with no visible signs of air in the system.

Catch any purged fluid at the caliper bleed screw with a rag or small container of some sort. 4.

Replenish the master cylinder to the top of the viewing window and secure the cover and rubber gasket.

Clean any stray brake fluid that might have found its way on to the brake disc with brake cleaner. Brake fluid on the brake disc can seriously affect braking capabilities of the ARGO vehicle.

Pump the steering levers a few times to build up proper pressure and locate the pads in the caliper assembly.

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Brake Fluid Inspection

Regular inspection of the brake fluid is very important. Low fluid levels can cause a reduction or loss in braking ability; high fluid levels, or brake fluid contaminated with oil, dirt, or water, can damage the seals or other component parts of the hydraulic brake system. Use only Dot 5 silicon brake fluid. Other brake fluids may not be compatible with ARGO brake components and operating temperatures. Inspecting the Brake Fluid Condition Maintenance Schedule- Inspect every 50 hours of vehicle operation. 1.

Locate the master cylinder in the engine compartment. It is located at the top of the transmission.

To access the master cylinder cover, remove the hood assembly. You can then remove the cover screws with a screwdriver 2.

Clean the casing and lid of the master cylinder. This will prevent dirt or other contaminants from entering the reservoir.

Using a screwdriver, unfasten the cover screws and remove the cylinder cover and gasket.

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Inspect the condition of the brake fluid and replace if: the fluid appears cloudy the fluid appears discoloured the fluid contains particles of dirt, rust, water, or other contaminants the level is below the viewing window If any of these conditions are noted, Perform the servicing procedure, Changing the Brake Fluid below. Changing the Brake Fluid

Clean the master cylinder casing and fittings. This will prevent dirt from contaminating the brake system. Contaminants in the brake fluid can damage components or cause premature wear to them. This will result in a loss of braking effectiveness 1.

To drain and replenish the brake system you will need to remove the firewall of the vehicle. Perform the servicing procedure, Removing the Firewall for your particular model in Section VB of this service guide.

Remove the engine hood to access the master cylinders. Remove both covers using the appropriate screwdriver.

Locate the bleed screw on the hydraulic brake caliper.Slowly loosen the brake caliper bleed screw and gently pump the steering lever to purge the brake fluid from the system. Catch the used brake fluid at the bleed screw with a container for disposal later.

Continue to pump the fluid from the system while monitoring the master cylinder. Repeatedly replenish the master cylinder while pumping the old fluid from the system.

When the old fluid at the rear bleed screw appears to be replaced by fresh fluid, perform the servicing procedure, Bleeding the Hydraulic Brake System.

Add brake fluid to the master cylinder as necessary, to a level just above the viewing window, and secure the cover.

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Hydraulic Brake Plunger Pin Adjustment

IMPORTANT It is critical that the master cylinder pistons are adjusted properly when the steering levers are at the dash block position. Overheating of the brake system could occur due to the piston being adjusted too far in. This could cause a drag on the system and a possible brake lockup. On the other hand, the piston being adjusted too far out could affect the braking ability of the vehicle by causing it to be less aggressive, giving it poor turning capabilities. This adjustment will also set both handle bars at an even distance from the dash block when both are applied.

A 1/4" clearance should be set between the steering levers and the dash block before engagement of the plunger pins. This will provide some leeway if the handle bars are pulled back slightly while driving without the intention of applying them (riding the brakes). 1

Remove the firewall.

Loosen the 1 or 2 set screws securing the collar to the plunger pin. Photo BR-29 This will free the collar to slide along the pin.

A spacer measuring approximately 1/4" must be temporarily placed between the steering levers and the dash block. Photo BR-30

BR-29

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Push the collar up tightly against the tab stop of the steering bracket assembly and re-tighten set screw(s). Apply Blue 242 LOCTITE to the threads of the set screw. The 1/4" clearance between the dash block and engagement of the plunger pin is now set. Photo BR-31

Locate and loosen the jam nut on the adjustable plunger pin. Photo BR-32

BR-31

BR-32

With the jam nut loosened, the plunger pin may be threaded either in or out. In any case the end result should have the master cylinder piston flush with the casting of master cylinder housing. Photo BR-33 Check this adjustment by using your finger, feeling the edge of the master cylinder casting and the top of the piston.

BR-33

Secure the jam nut.

Remove your spacer at the steering assembly dash block.

Sit in the vehicle and pull back on both levers checking to make sure the levers have the 1/4" clearance before engagement, and come back evenly.

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Argo Service Manual

Brake System

Holding Brake Adjustment The holding brake system has been factory adjusted to ensure proper braking effectiveness. However, before the vehicle is used for the first time, and after every 25 hours of operation, the adjustment of the holding brake must be inspected.

The use of an improperly adjusted holding brake is a serious hazard, and could lead to vehicle damage or personal injury. 1.

Pull each steering lever back until you feel resistance.

While holding the levers back, push each holding brake handle down until it rests against the brake lever stop. Photo BR-34

Check the distance between the holding brake stop on each steering lever and the holding brake adjusting screw.

If the distance is approximately 1/16" (1.6mm) the holding brake system is correctly adjusted. Photo BR-35

If not, turn the holding brake adjuster screw in the direction required for correct distance.

If the holding brake system is too tight, excessive pressure in the brake system will damage the seals.

BR-34

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BR-25

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Argo Service Manual

Hydraulic Brake Hoses Maintenance Schedule-Inspect every 25 hrs of vehicle operation. 1. â&#x20AC;˘ â&#x20AC;˘

Inspect the condition of the hydraulic hoses. Replace them if: the hoses are cracked or punctured brake fluid leakage is noted on the hose, nearby assemblies, or around hose fittings

Perform the servicing procedure, Replacing the Hydraulic Brake Hoses, below

Replacing the Hydraulic Brake Hoses

Clean the master cylinder casing and the caliper casting and fittings. This will prevent dirt from contaminating the brake system. Contaminants in the brake fluid can damage components or cause a loss in braking or steering effectiveness. 1.

Remove cover and gasket seal from the master cylinder reservoir.

Disconnect the hose from the caliper. Place a catch tray under the free end of the hydraulic hose and allow the hose and master cylinder reservoir to drain.

Disconnect the hydraulic hose from the master cylinder.

Replace the hose.

Reconnect the hydraulic hose to the master cylinder. Make sure both copper washer seals have been replaced with new ones at the banjo bolts.

Perform the servicing procedure, Bleeding the Hydraulic Brake System.

Mechanical Brakes (Vanguard Models) Maintenance Schedule - Inspect every 25 hrs. of vehicle operation.

The brakes must be inspected regularly by a qualified mechanic. Damaged calipers or badly worn brake pads can seriously scratch the face of the brake discs, and cause a reduction in steering and braking ability of the ARGO vehicle. Severe personal injury could result from a damaged or poorly adjusted brake system. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Brake System

The mechanical brake caliper assembly probably needs adjustment and servicing when: • • • •

a drag on vehicle power and acceleration occurs a loss of braking effectiveness is noted steering does not respond properly excessive strength is required to steer or stop the vehicle Component

Condition of Component

Action Required

Bent, Cracked or Broken

Replace

Worn Shaft or Stripped Shaft

Replace

Compression Springs

Twisted or Broken

Replace

Ball Bearings

Worn or Missing

Replace

Caliper Mounting Bolts

Brake Pads

See Mechanical Brake Pad Inspection & Replacement

For a thorough examination of the brake pads, perform the servicing procedure, Mechanical Brake Pad Inspection & Replacement. Mechanical Brake Caliper Removal 1.

Remove the locknut from the brake travel adjustment rod. BR-36

Remove the front floor pan and the firewall. See servicing procedure, Removing the firewall in section VB of this service guide.

Locate the brake caliper assemblies. Photo BR-37

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Remove all locknuts and jam nuts from the 2 bolts that secure the two halves of the mechanical calipers together at the power pack frame. Photo BR-38

Remove the brake cam assembly and flat washer. Photo BR-39

Remove both mounting bolts and separate the calipers from the power pack frame. Collect the 2 compression springs that are used in each side of the caliper. Photo BR-40

BR-37

BR-38

BR-39

BR-40

If you are disassembling the right hand steering caliper assembly, you will need to remove the parking brake lever and spring from the rear caliper bolt as well. Photo BR-41

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IMPORTANT The cam side half caliper houses 2 small steel bearing balls . These are installed to 2 bearing seats within the casting. These steel balls should be checked for any wear or deformity. Also, check the inside of the brake cam where it comes into contact with these steel ball bearings. If there is any wear noticed such as tracking grooves, replace the brake cam. Any wear grooves in the cam will affect the way in which the calipers return to the normal position when they are released by the driver. Usually they will not return and tend to stick in the brake on position. Mechanical Brake Pad Inspection & Replacement Inspect the condition of the brake pads. Replace the pads when: • • • •

they are worn to 1/8" or less in thickness the pads are worn unevenly (a sign that could relate to a warped or bent caliper) the pads are glazed over and poor braking/steering performance has been noted the brake pads are contaminated with oil or grease

When replacing worn or contaminated brake pads, replace both pads in the brake caliper assembly even if both pads do not require replacing. Using one new and one old brake pad in a caliper assembly may provide poor braking and steering performance. Quality ARGO replacement brake pads are available only in a set of 2. 1.

Perform the servicing procedure, Mechanical Brake Caliper Removal.

Replacing the Brake Pads (Mechanical) 2.

Using a high speed drill remove the heads of the rivets with a 3/16" drill bit. Photo BR-42 (See caution on following page)

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Take care in drilling out old pop rivets. Damage to the caliper casting could occur, requiring a more expensive caliper replacement.

Clear the remainder of the rivets with a 11/64" drill bit.

Remove the pad and discard. Photo BR-43

Installing the Brake Pads (Mechanical)

BR-43

Place the new brake pad on to the caliper. Be sure that the counter-sunk side is facing up. Photo BR-44

Using a pop riveting tool, fasten the brake pad to the caliper. Photo BR-45

The tip of the riveting tool may need to be modified to allow it to fit into the counter bored hole in the pad. This will ensure that the head of the rivet is tight against the pad when it is pulled.

BR-44

BR-45

IMPORTANT Make sure that the brake pad is completely flat to the caliper when pulling the rivets and that there is no obstruction between the caliper and the back side of the pad. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Mechanical Brake Caliper Installation 1. Lay out mechanical brake caliper components onto the work bench. Photo BR-46 Take note of the orientation of the brake cam to the adjustment rod, and be sure to assemble accordingly if this assembly has been disassembled for any reason. 2.

Take the longer of the two mounting bolts and place it through the front hole of the caliper. Photo BR-47

Insert the shorter of the two bolts into the rear hole of the caliper. Photo BR-48

Place 1 compression spring on to the longer of the two mounting bolts. Photo BR-49

BR-47

BR-46

BR-48

BR-49

On the right hand side brake assembly , make sure to assemble the parking brake bracket first before installing it to the power pack bracket. Photo BR-50

Install the left caliper half to the brake bracket on the power pack frame. Photo BR-51

Place the second compression spring to the caliper. Photo BR-52

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BR-51 7.

BR-52

Apply a little axle grease to the two ball bearing cavities of the second caliper and place two ball bearings into these cavities. Lightly tap each ball bearing with a soft faced mallet to seat it within the cavity. Photo BR-53

The caliper with the 2 steel ball bearings are always on the side of the brake cam 8.

Place the second caliper to the mounting bolts.

Install the cam assembly and flat washer, to the longer of the two mounting bolts. Photo BR-54 & 55

BR-53 BR-54

10. Install a flat washer and locking nut to the mounting bolt at the cam and a locking nut at the rear mounting bolt. Photo BR-56

BR-56

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Always use new locknuts whenever servicing mechanical brake calipers. Adjusting the Mechanical Brake Caliper (Vanguard Models) 1.

Remove the vehicle firewall and proceed to tighten both front and rear nuts so that the mechanical caliper assembly is snug to the brake disc. Photo BR-57 This is a good starting point to begin brake caliper clearance adjustment.

Back off the locking jam nut at the cam and apply a small amount of blue 242 LOCTITE to the threads between the jam nut and main adjustment nut.

Snug the locking jam nut up against main adjustment locknut. Photo BR-58

Back off the nut on the rear bolt to free it up just enough to allow it to be turned by hand. Photo BR-59

Slowly back off the front jam nut and adjustment nut until movement is felt in the caliper.

Place a .010 feeler gauge between the left hand brake caliper and the brake disc while pushing the right caliper half against the brake disc. Photo BR-60

BR-57

BR-58

BR-59

BR-60

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Using two opened end wrenches, tighten the jam nut against the adjustment nut.

Recheck the clearance one more time and adjust if necessary.

Install return spring & flat washer to adjustment rod and loosely start the locknut to the end. Photo BR-61

BR-61

10. Perform the servicing procedure, Installing the Firewall in section VB. Steering Lever Adjustment Adjust the steering levers when: Â&#x201E; Â&#x201E; Â&#x201E;

steering levers travel more than 18 cm (7") from the dash to apply the brakes; the levers are not parallel when the brakes are applied; or the brake adjustment nuts have been removed during the removal of the firewall.

To adjust the steering levers, tighten both brake adjustment nuts (refer to DIAGRAM BR-62) clockwise using a 1/2" deep socket and ratchet until the levers are both 18 cm (7") from the dash. DO NOT OVER TIGHTEN. Holding Brake Adjustment Although the holding brake system has been factory adjusted, it should be checked after every 25 operating hours to ensure the correct adjustment.

BR-62 The use of an improperly adjusted holding brake is a serious safety hazard, and could lead to vehicle damage or personal injury. 1.

Pull the left steering lever back.

While holding the lever, lift the spring loaded brake lever until it contacts the pin in the steering lever.

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Release the steering lever, allowing the holding brake lever to lock the left brake on.

If the steering lever grip is approximately 18 cm (7") from the dash, the holding brake system is correctly adjusted.

If the distance from the dash is greater, refer to Steering Lever Adjustment to properly set the left lever.

Brake Disc Inspection Maintenance Schedule - Inspect every 50 hrs. of vehicle operation.

IMPORTANT Badly worn brake pads, or abnormal use of the vehicle, can cause serious damage to the brake discs. Inspect the brake discs for the condition listed in the chart below, and perform the recommended servicing procedures. Brake Disc Condition Rust or Pitting Bends or Cracks Scratches or Scoring Broken or worn Sprocket teeth Glazing Oil or Grease Contamination

Corrective Action Replace Immediately

Clean

Servicing Procedure 1. Brake Disc Removal 2. Brake Disc Installation

1. Brake Disc Removal 2. Brake Disc Installation

IMPORTANT Always refer to the PARTS MANUAL that corresponds to the specific model and serial number indicated on the serial tag plate of your vehicle. This is essential to locating and ordering the correct components that were used during that particular manufacturing period. It is also very helpful using the illustrations to clearly see and define the component being referred to. If components are no longer listed in your Spare Parts Price List (Distributors and Dealers Only) generally the superceded section will indicate which part(s) will update or replace it. All parts manuals are available in PDF format on CD. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Brake System

Argo Service Manual

Removing a Brake Disc When servicing a left side brake disc, you will need to remove the driven clutch from the transmission. Refer to Removing the Driven Clutch in section CS of this service guide. 1.

Perform the servicing procedure, Removing the Firewall, in section VB.

Loosen off the power pack frame

On 6x6 vehicles manufactured prior to S8131 locate and loosen off the four 1/2"20x1.5" power pack frame mounting bolts. Refer to Section 4.0 Power Pack Assembly in the appropriate parts manual. There are two located in front of the idler axles, and two visibly located, behind the idler axles. These bolts are threaded into nuts welded to the lower frame assembly.

On ARGOS manufactured from SN7841, S8131 and all RB, CB, BF & C vehicles, loosen the locknut in front and behind the idler axles. These are threaded to 2 mounting bolts inserted through the power pack frame from right to left and attached at the lower frame. Photo BR-63

BR-63

Next loosen off the idler chains.

On 6x6 models produced from S7304 and prior to S8131, undo the jam nuts at the chain tensioner bolts and using an allen head wrench, turn the adjustment bolts counter-clockwise to lower the back end of the power pack frame. This will slacken the idler chains and allow for removal. Models prior to this serial number will require a 3/4" socket on the adjustment bolt head to lower the power pack frame.

On ARGOS manufactured from SN7841, S8131 and all RB, CB, BF & C vehicles, locate the two 3/8"16x3" bolts threaded into the lower frame channel beneath the rear power pack mounting bolt. Turn each of these clockwise to lower the rear of the power pack frame assembly. Photo BR-64

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Argo Service Manual 4.

Brake System

Perform the servicing procedure, Removing the Brake Caliper (Hydraulic), or Removing the Brake Caliper (Mechanical)

There is no need to disconnect the hydraulic brake fluid lines from the caliper 5.

Rotate the tires to locate the connecting link of the idler chain.

Remove the connecting link clip and pull the connecting link from the chain.

Perform the servicing procedure, Removing the Idler Chain in section WA

Remove the bolt, lock washer and flat washer securing the brake disc to the output shaft of the transmission.

6x6 Vanguards produced prior to S/N S7332 will have a spacer beneath the flat clamping washer. This is slipped over the extended part of the output shaft that protrudes past the end of the brake disc sprocket. The # 40-2x15 Brake discs manufactured from S/N S7332 have been unified in length with the #50-2x13 brake disc and no longer require this spacer. These lengthened brake discs are fully exchangeable with the older style

6x6 vehicles manufactured between S/N S7332 & S7937 & prior to SN7929 use a washer(s) in behind the flat clamping washer to "Lengthen" the output shaft and prevent the 108-18 clamping washer from collapsing. Argos produced from S7937 & SN7929 no longer require these washers because the output shaft dimension has been lengthened. If an earlier vehicle which utilized these washers has had the transmission output shafts replaced with new ones, these washers will no longer be required during reassembly.

If the ARGO is equipped with a brake cooling fan system, as is the case with all CB, RB, BF & C vehicles, you will need to loosen and slide the brake shroud out of the way before the brake disc can be slid off the output shaft. 9.

On Conquest models, loosen the two 1/4"-20x1" pan head screws securing the brake cooling duct to the power pack frame. Photo BR-65 Slide the ducting clear of the brake disc. On Bigfoot & Response Models, loosen off the gear clamp that secures the brake cooling duct to the overhead bracket of the brake discs. Photo BR-66

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Argo Service Manual BR-65

BR-66 10. Slide the brake disc from the output shaft.

To remove the brake disc you may need to raise the power pack up by prying at the rear of the power pack frame. Raise it high enough for the brake disc to clear the drive sprocket when slipping it from the output shaft. Photo BR-67

BR-67

If the brake disc won't move: â&#x20AC;˘

If removing the right-hand brake disc, perform the servicing procedure, Battery Removal in Section ES of this service guide

â&#x20AC;˘

Install a wheel puller on the brake disc and remove it from the transmission output shaft.

Vehicles manufactured prior to October 21, 1999 utilize keyways machined within the brake disc. There are two 1/4" x 1/4" keys used on the keyed output shafts. Vehicles produced from S/N's: S11188, SN11196, CB16459, RB16446 & BF11143, are splined. These accommodate the newer style splined output shafts. These splined brake discs are fully exchangeable with the keyed versions if desired, however this would also mean replacing the output shaft as well. Keyed brake discs and outputs are still available.

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Brake System

Installing the Brake Disc Â&#x2039;

On vehicles produced prior to S/N CB16459, RB16446, BF11143, S11188 & SN11196

i..

Apply an anti-seize compound to both output shafts.

ii.. Place both keys in the keyways of the output shafts. iii. Align the keys with the keyways on the brake disc and slide the disc on to the shaft. The sprocket on the brake disc should be facing outward. Photo BR-68

BR-68

Vehicles equipped with the brake cooling system will require the cooling duct to be moved out of the way far enough to allow the brake disc on. Seat the brake disc firmly against the shoulder of the output shaft. iv.

Re-position the cooling duct and and secure with the two 1/4"-20x1" phillip head screws (CONQUEST MODELS) or retightening the gear clamp on the overhead mounting bracket ( BIGFOOT & RESPONSE MODELS)

Apply blue LOCTITE 242 to the threads of the brake disc mounting bolt and install it along with the lockwasher, clamping washer and any other spacers or washers that were used previously. See NOTES on page BR-37.

Â&#x2039;

On vehicles produced from S/N CB16459, RB16446, BF11143, S11188 & SN11196 :

Apply anti-seize compound to the spline of the output shafts.

IMPORTANT A small number of vehicles used a shim washer in behind the brake disc. This shim washer will need to be reinstalled to the output shaft before the brake disc is slipped on. This is required to align the brake disc to the hydraulic caliper properly. Take note of the transmission serial number to correctly identify these vehicles. All 6 wheel hydraulic brake vehicles with serial numbers between BF11321 & BF11390. All 8 wheel vehicles with serial numbers between RB16700 & CB16778. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Brake System ii

Argo Service Manual

Align the spline of the brake disc with those on the output shaft and slip the disc on and up to the shoulder of the output. (See NOTE previous page)

iii. Re-position the cooling duct and and secure with the two 1/4"-20x1" phillip head screws (CONQUEST MODELS) or retightening the gear clamp on the overhead mounting bracket ( BIGFOOT & RESPONSE MODELS) iv.

Apply blue LOCTITE 242 to the threads of the brake disc mounting bolt and install it along with the lockwasher and clamping washer.

Perform the servicing procedure, Installing the Idler Chains, in Section WA of this service guide.

Perform the servicing procedure, Adjusting the Idler Chains, in Section WA of this service guide.

Perform the servicing procedure, Hydraulic Brake Caliper Installation or Mechanical Brake Caliper Installation in this section of the service guide.

Perform the servicing procedure, Mechanical Brake Caliper Adjustment on all Vanguard models.

Apply the brake at the steering lever to each brake disc, and torque each bolt to the specified torque.

Perform the servicing procedure, Reinstalling the Firewall, in Section VB of this service guide.

Parking Brake Some vehicles may have an additional parking brake system installed. The following illustrates and describes the assembly and components of the parking brake setup. Parking Brake Assembly 1.

Locate the caliper bracket and slip 2 of the longer mounting bolts through the bracket. Install 2 long spacers to the bolts as illustrated in Photo BR-69 Be sure to orient the brake bracket as shown. The top hole closest to the back edge of the bracket should be facing towards you.

Assemble the bracket assembly to the right hand side of the power pack frame and secure with 2 nylon locknuts. Photo BR-70

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BR-69

BR-70

BR-71

BR-72

Assemble the second caliper bracket to the left side of the power pack frame using 2 of the shorter mounting bolts and 2 short spacers. The bracket should be oriented as the right side, with the top hole closest to the back edge of the bracket facing the assembler. Secure with 2 more locknuts. Photoâ&#x20AC;&#x2122;s 71 & 72

Brackets should look as in BR-73 from the assemblerâ&#x20AC;&#x2122;s perspective.

Lay out all mechanical brake components for assembly. Photo BR-74

BR-74

BR-73

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Locate the parking brake lever assembly and insert it at the back of, and in between the power pack frame channel. Slip the left parking brake shaft assembly through the parking brake lever. Photo BR-75

Locate and install the right hand side parking brake shaft through the parking brake lever from the opposite side as in Photo BR-76

BR-75 9.

BR-76

Install 4 roll pins to secure both shafts to the parking brake lever. Photoâ&#x20AC;&#x2122;s BR-77 & 78

BR-77

BR-78

11. Thread the jam nut to the 2 parking emergency brake rods. Photo BR-79 12. Lay out the 4 mechanical brake calipers (1 is notched on one side) on to a clean work area. Apply a small quantity of axle grease to each of the ball bearing cavities on 2 of the calipers and install 4 steel balls. Tap lightly with a steel hammer to seat them into the cavities. Photo BR-80

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BR-80

BR-81

Do not install the bearing balls to the single caliper with the notched area. 13. Assemble the ball joint to the brake cam as shown in Photo BR-81. Secure it with a nylon locknut. Orient the cam as illustrated in the photo. 14. Install 2 long and 2 short bolts to the two calipers without the steel balls. The one caliper is also the one that is notched. Photo BR-82

BR-82

BR-83

15. Locate the notched caliper and slip the compression spring to the longer of the two bolts. Assemble the caliper to the inside of the left side caliper bracket. Place a second compression spring to the bolt. Photo BR-83 16. Place the other half caliper with the steel balls, to the previously installed inside caliper. Photo BR-84 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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17. Place the previously assembled ball joint and cam to the longer of the two bolts. Slip the flat washer on to the bolt at the cam first, then start the 2 way locknut to both the front and rear caliper mounting bolts. Photo BR-85 18. Repeat this procedure for the right hand side caliper assembly. The inner caliper on the right hand side assembly is not notched. 19. Thread the emergency/parking brake rods into each of the ball joints at the cam until there is approximately Â˝â&#x20AC;? inch of thread exposed. Attach the other end of the rod to the shaft assemblies and secure with a cotter pin. Photo BR-86

BR-86

BR-85 20. Tighten down both locknuts of the mechanical caliper system until the brake pads are snug to the brake discs. Photo BR-87

Adjusting the Caliper

BR-87

21. Loosen the locknut of the rear caliper bolt until it turns freely by hand. 22. Loosen the locknut of the caliper at the cam until the caliper is released from the brake disc. There should now be movement in the caliper. Recheck the rear adjustment bolt to see if it still turns by hand. If not, adjust as necessary until it does.

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23. Tighten the jam nut at the ball joint on the parking/emergency brake rod. Photo BR-88 24. Apply blue 242 LOCTITE to the threads of the bolt at the brake cam and thread a second locknut up to and against the first one. Hold the inner nut with an open end wrench while tightening the second one up against it. Photo BR-89 & 90

BR-89

BR-88

BR-90

25. Locate the brake cooling duct and insert a spacer into the 2 mounting holes on each side of the duct. Photo BR-91 26. Mount the brake cooling duct to the top of the transmission using a bolt, flat washer and nylon locknut. Fasten this to the hole in the driven clutch guard. Photo BR-92 & 93

BR-91

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BR-93

BR-94

27. Mount the other side of the brake cooling duct using a bolt, lock washer and flat washer. Attach this end using the same bolt that secures the steering bracket to the rear threaded transmission boss. Photo BR-94

IMPORTANT Before securing the brake cooling duct, be sure that the engine wire harness plug is accessible above the ducting. (Conquest Models Only) Photo BR-95

BR-95 Brake Cooling System All 6x6 Bigfoot and Eight wheel vehicles with hydraulic brakes have a 12 volt fan forcing cool air from outside the engine compartment onto the brake components to protect the system from overheating. Overheating can damage the hydraulic brake components. Make sure the brake cooling fan is operating when the vehicle is being driven. The fan operates when the ignition switch is in the “run” position. Keep the brake cooling system in good working order by: • •

cleaning debris from the air intake screen and ducts. keeping electrical connections tight and components securely mounted.

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SECTION BR

Supplement Pages

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Argo Service Manual

Brake/Steering System

Read all the instructions thoroughly before starting and attempting ANY repairs. Consult your Argo Dealer if you have any questions. Disassembling the Moto Cross Style Steering Column (All Models) 1.

Perform the servicing procedure, Removing the Firewall.

Cut the tie wrap securing cables to the steering column.

Remove the (4) fasteners securing the steering bar to the steering column assembly. Photo ST-1

ST-1

ST-2

Remove the Nylon Locknut and Flat Washer from the top of the Lower Handle Bar Clamp. Discard the nylon locknut. Photo ST-2

Remove the Lower Handle Bar Clamp from the steering shaft. Photo ST-3

IMPORTANT Be aware of the small key(s) installed into the steering shaft and ensure they are installed when reassembling the steering system.

ST-3

Disconnect the hand brake lever cable at the steering arms.

Apply pressure to the left hand side plunger pin by pushing on the steering arm with the palm of your hand and insert a shim between the locking collar and the welded tab stop. Photo ST 4 Repeat on the right hand side master cylinder. Following this procedure will ensure that there is no interference between the plunger pins and steering arms, when sliding the shaft from the steering column.

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Argo Service Manual

Avenger Models Only i.

Slip the Steering Shaft from the Steering Column Assembly. Photo ST-5

ST-4

ST-5

On all models manufactured from C22453, R22452, B14700, A14743, N14708 i.

Remove the (3) fasteners securing the 612-117 steering column assembly to the transmission. Photo ST-18A You must do this in order for the steering shaft to clear the brake calipers below when slipping it from the steering column.

IMPORTANT Be aware of the 108-08 Flat Washer Spacers used between the Steering Column Frame Assembly and the transmission mounting bosses. ii.

Slip the shaft from the column.

Disassemble the steering shaft as follows:.

On Avenger Models Only - Prior to V22441 i.

Place the Steering Shaft on a clean work bench and remove the 4 roll pins. Photo ST-6 Slide each steering arm and centering spring from the shaft.

1 Retaining Ring is located between the two Steering Arms. Vehicles manufactured from V22441, C22453, R22452, B14700, A14743, N14708: i.

Remove the 2 Spring Pins and Steering Arms from the Steering Shaft. Photo ST-7 A Retaining Ring is located between the two steering arms.

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ST-6

ST-7

Reassembling Steering Column (Avenger Models Only - Prior to V22441) i.

Install the Spring Pin into the Steering Shaft at the 4th hole from the end. Photo ST-8 The roll pin should be installed such that the slot of the pin is parallel to the shaft, and an equal amount of pin protrudes on each side of the shaft. Photo ST-9

ST-8 ii.

ST-9

Slip the first Steering Arm on to the Steering Shaft, followed by the Retaining ring, seating it to the groove on the shaft. Install the second Steering arm. Orient them as illustrated in Photo ST-10

iii. Install the 2nd Spring Pin, followed by a centering spring. Install the 3rd Spring Pin, followed by a 2nd centering spring and 4th Spring Pin. Photo ST-11 & 12

Please observe the orientation of the free end of the springs. Each is pointing in the same direction as the steering arms. Photo ST-13

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Brake/Steering System

Argo Service Manual

ST-11

ST-10

ST-12

Roll pin slot ST-13 parallel with shaft Vehicles manufactured from V22441, C22453, R22452, B14700, A14743, N14708: i.

Install the Spring Pin at the 2nd hole from the end on the Steering Shaft The roll pin should be installed such that the slot of the pin is parallel to the shaft, and an equal amount of pin protrudes on each side of the shaft. Photo ST-14

ii.

Slip a steering arm on to the shaft and up against the previously installed Spring Pin.

ST-14

iii. Next, Install a Retaining Ring to the machined groove on the Steering Shaft. This retaining ring will be located between the 2 steering arms. iv.

Install the second steering arm and last spring pin. Photo ST-15. Orient as in Photo ST-16

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Argo Service Manual

Brake/Steering System

ST-15 9.

ST-16

Apply some axle grease to the length of the Steering Shaft, Photo ST-17, and insert it from the bottom up, into the Steering Column Assembly with the small keyway facing towards you. Photo ST-18

ST-18

ST-17

On Vehicles manufactured from C22453, R22452, B14700, A14743, N14708: i.

Re-attach the 612-117 Steering Column Frame Assembly to the transmission. Secure with (2) 103-55 fasteners and (2) 108-24 Washers at the front 2 locations, and (1) 112-132 (longer) fastener and (1) 108-24 Washer at the rear location. Photo ST-18A

ST-18A

IMPORTANT Remember to reinstall the 108-08 Flat Washers between the steering column frame assembly plate and transmission mounting bosses. Refer to your illustrated parts manual to review their location if necessary. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

BR-5A

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Brake/Steering System

Argo Service Manual

10. Place the key to the end of the Steering Shaft. Photo ST-19 Vehicles manufactured from serial numbers N14990, V23535, R23560, A15022 utilize 2 keyways and 2 keys. 11. Align the keyway(s) of the Lower Handle Bar Clamp with that of the previously installed key(s) and assemble to the Steering Shaft. Photo ST-20 & 21

ST-19

ST-20

ST-21

ST-22

12. Install a Flat Washer and a new 117-29 Nylon Locknut to the threaded end of the steering shaft. Photo ST-22 13. Tighten down the Nylon Locknut snug. Back off the Locknut just enough to allow the Flat Washer below to be turned by hand. Do not overtighten. Ensure the shaft turns freely with minimal end play. Photo ST-23

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ST-23

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Argo Service Manual

Brake/Steering System

14. Set the Handle Bar assembly into place and cover with the Upper Handle Bar Clamp. The Handle Bar clamp is secured into place with four fasteners. Tighten down the fasteners in an "X" pattern indifferent to starting location at a torque specification of 10 - 12 Ft. LBS (13.5 - 16N.m) Photo ST-24

ST-24

15. Apply firm pressure to handle bars in each steering direction to seat the roll pins. 16. Reattach the hand brake lever Cable across the two brake Steering Arms. 17. Perform the servicing procedure, Hydraulic Plunger Pin Adjustment.

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Brake/Steering System

Argo Service Manual

Hydraulic Brake Plunger Pin Adjustment

IMPORTANT It is critical that the master cylinder pistons are adjusted properly when the steering handle bar is at the centered position. Overheating of the brake system could occur due to the piston being adjusted too far in. This could cause a drag on the system and a possible brake lockup. The piston being adjusted too far out on the other hand, could affect the braking ability of the vehicle for both turning and stopping efficiently. If this is a steering assembly with NEW spring pins installed, apply firm pressure to handle bars in each steering direction to seat the roll pins before proceeding with the following adjustments. Also, ensure the brake system has been bled properly and purged of any air in the system. 1.

Loosen the set screw securing the collar to the plunger pin. Photo BR-1 This will free the collar to slide along the pin.

BR-1 3.

BR-2

Locate the cable length adjustment for the hand brake lever near the steering arm and thread in to slacken the brake cable across the steering arms. Photo BR-2 Please note this step is only required on earlier models manufactured up to serial number V22440 Photo BR-2

BR-3

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Brake/Steering System

IMPORTANT Both left and right steering arms should be pulled back to their rear most limit before the plunger pin adjustment is made. On earlier models you should use both hands to pull back on each arm to ensure they are back in the rear most position. Photo BR-3 Later models utilize a double spring behind the plunger in the master cylinder which will provide plenty of spring tension to push the steering arms back fully. Setting Plunger Pin Adjustment

BR-4 1.

Sitting in the vehicle driver's seat, ensure sure that the steering handle bar is parallel with the dash. Plunger pins should be threaded so they are in contact at the back with the steering arms. Place the collar tightly up against the welded tab stop and secure the set screws with blue LOCTITE

Thread the plunger pins until the master cylinder plunger piston is flush with the casting of the master cylinder. Photo BR-4 Re-tighten all plunger pin jam nuts. Recheck that steering handle bar is parallel with dash and repeat procedure if necessary.

IMPORTANT

If you have been servicing the brake system, add fresh clean DOT 5 brake fluid and rebleed the brakes, purging all air from the brake system. Reinstall the master cylinder covers. When complete, apply steering input to both sides to " pump up the brakes". Recheck plunger setting and adjust as necessary.

IMPORTANT Ensure the tab stops that the collars come into contact with are not bent in any way. This will affect how the plunger pin sits when the opposite brake is applied. Any deformity in the tab could cause the plunger pin to become misaligned with it's own steering arm during the application of the opposite brake. 7.

Re-adjust the hand brake lever cable until any slack has been removed between the two steering arms and is on the verge of engaging the brakes. Tighten the brake cable jam nut.

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Brake/Steering System 8.

Argo Service Manual

Re-check the brake plunger piston to ensure it is still flush to the casting and fine adjust if necessary. Install the rubber boot.

Steering Bar Centering Adjustment (Early Model Avengers With Handle Bar Centering Springs Only) In some circumstances it may be necessary to adjust the way in which the steering handle bar returns parallel to the dash in the centred position 1.

Ensure that the steering handle bar rests parallel to the dash in the non-braking position when released from a right or left turn position. Photo BR-5

If the steering handle bar does not centre parallel to the dash when released, it may be necessary to adjust this. This may be achieved by manually bending the end of the return springs where they are inserted into the welded retaining bracket on the steering column frame assembly. Depending on the direction of the bend it will either increase the tension or reduce it when the spring end is inserted back into the bracket. Photo BR- 6 & 7

Before making the spring adjustment, thread the plunger pins together to make sure that they are not coming into contact with the steering arms and will in no way affect the way in which the steering handle bar returns to the centred position.

BR-5

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Brake/Steering System

BR-7

Perform the servicing procedure, Hydraulic Plunger Pin Adjustment (Avenger Model), in this section of the service guide.

Re-hook the springs and test. Adjust either upper, lower or both springs as necessary until the desired outcome is achieved.

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Accessory Instructions October 2007

850-98 - Parking Brake Service Assembly

Ref. 1 2 3 4 5 6 7

Qty. 1 1 1 1 1 1 1

Part # 850-98

Description Kit, Service, Parking Brake includes Ref. 2 - 7 Cam Tension Spring (compression) Left & Right Brake Pads Cam Arm Spring (tension) Brake Pad Retaining Screw Castle Nut Cotter Pin

Detailed information on standard workshop and safety procedures, and general installation practices is not included in these instructions, which have been prepared to assist qualified and competent personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any procedure performed, including those procedures outlined in these instructions. Before performing an installation operation, an individual must have determined to his/her satisfaction that personal injury or vehicle damage will not result from the installation procedure, working environment or tools selected.

Vehicles Affected: AVENGER and FRONTIER

BR-12A

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Instructions: Both left and righthand side emergency/parking brake caliper pads should be changed in pairs. Do not attempt to just replace one side. 1. Locate the emergency/parking brake caliper attached to the main brake caliper. Figure 1. Left hand side example.

Figure 3 - Remove Brake Lever. 4. Remove the two (2) mounting bolts holding the caliper assembly together. Figure 4.

Figure 1 - Locate Caliper. 2. Locate the castle nut at the brake cam lever and remove the cotter pin and castle nut. Figure 2.

Figure 4 - Remove Mounting Bolts. 5. Split and remove the caliper assembly. Figure 5 Take note of all spacers, shims and washers within the assembly. Refer to your illustrated parts list in your Argo Parts manual for all locations of these components.

Figure 2 - Remove Cotter Pin. 3. Using both hands, remove the brake lever assembly from the Brake Housing - Live Side and disconnect spring. Figure 3.

6. Locate the 850-84 Dead Side Brake Housing and remove the screw securing the brake puck. Remove the brake puck and discard. Figure 6. 7. Locate the Live Side Brake Housing and turn upside down to remove 2nd brake pad from the housing cavity. Please note that there is also a washer placed beneath the brake pad.

BR-13A

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9. Install the new brake pad to the dead side housing and secure with screw. Apply some LOCTITE 242 Blue to the threads of the screw before installing. 10. Locate the live side brake housing and slip the shim washer into the cavity first (Figure 8), before installing the brake pad.

Figure 5 - Caliper Removed

Figure 8 - Installing Shim. 11. Install the second brake pad to the top of the previously installed shim. Reassembling the Emergency/Parking Brake Caliper to the Vehicle The following example illustrates the assembly of the Left hand side Emergency/Parking Brake Caliper. Figure 6 - Pad Removed. 8. Lay out both Dead Side and Live Side Brake housings with new brake pads. Figure 7.

Mounting bolts for both calipers are always inserted facing to the left with the head of the mounting bolt on the right hand side of the caliper. Refer to Figures A & B for correct orientation of mounting bolts as well as washer & shim locations.

Figure 7 - Lay Out Housings.

Figure A - Left Side.

BR-14A

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Figure 10 - Shim.

Figure B - Right Side. Assembling the Left Hand Side Emergency/Parking Brake Caliper 12. Install the live side housing to the inside of the brake disc. Insert (2) two mounting bolts with spacers to the head of each bolt. Place a thin washer (to each bolt) on the inside of the mounting bracket. Figure 9.

Figure 11- Dead Side Housing. 15. Install (2) more spacers to the ends of the mounting bolts. Figure 12. 16. Secure with the nylon locknuts and torque caliper assembly to 215in. lbs. (24Nm) Figure 13.

Figure 9 - Remounting Dead and Live Side Housings 13. Install the shim plate over the (2) two mounting bolts. Figure 10. 14. Next, install two thick washers to the mounting bolts along with the dead side housing which is placed to the outside of the brake disc. Figure 11.

Figure 12 - Spacers.

BR-15A

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19.

Locate the brake lever assembly and reattach the extension spring to the hole provided. If the spring was completely removed, it should be attached first to the tab on the mounting bracket, then to the cam lever. Figure 16.

Figure 13 - Secure With Nylon Locknuts. 17. Install the compression spring to the stud of the live side housing. Figure 14. 18. Install the (2) dowel pins to the cavities of the live side housing (rounded side facing out). Figure 15.

Figure 16 - Spring Attached. 20.

Install the lever to the stud of the live side housing. Figure 17.

Figure 17 - Cam Installed.

Figure 14 - Install Spring.

21.

Start the castle nut but do not tighten down.yet.

EMERGENCY/PARKING BRAKE ADJUSTMENT (ALL MODELS)

The use of an improperly adjusted emergency/parking brake is a serious hazard, and could lead to vehicle damage or personal injury. The hand brake lever should be adjusted such that when pulled up firmly it is capable of holding the vehicle from rolling on a grade. It should also ensure a good braking response when applied to stop the vehicle during normal operation. Figure 15 - Dowel Pins.

BR-16A

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If the emergency/parking brake system is adjusted too tight when the lever is in the down position, overheating of the brake system will occur due to drag between brake pads and brake discs. Adjusting the Emergency/Parking Brake 1. Ensure the parking brake lever is fully down. 2. Locate the 850-72 Parking Brake Adjustment Bracket attached to the top of the transmission. Figure 7-20. Adjust to remove any slack in the cable that may be present between the brake lever, and the brake cams at the emergency/parking brake calipers. This may require physically pulling down on the equalizer flat bar to ensure all slack is eliminated. See Figure 7-21.

Figure 7-21. Equalizer Flat Bar. 3. Adjust the cable at the transmission until the cam levers are actually starting to pre-load the return springs, and the cam lever actuation pin on the caliper is centered in the â&#x20AC;&#x153;v-groveâ&#x20AC;? of the cam. Figure 7-22.

Figure 7-22. "V-Groove" of the Cam.

Figure 7-20. Location of Bracket

4. Using a 0.004" feeler gauge or a piece of regular photo copy paper (such as a piece cut from these instructions), slip it between the emergency/parking brake pad and brake disc. Ensure that you push the opposite side pad up against the brake disc before setting this gap. 5. Slowly hand tighten the castle nut until the feeler gauge (or piece of paper), becomes snug between the pad and brake disc. 6. Back off the castle just enough for a new cotter pin to be installed. The feeler gauge (or piece of paper), should pull out at this point with just the slightest bit of resistance.

BR-17A

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7. Recheck the cable between the equalizer flat bar and the brake lever cams to ensure it is just on the verge of engaging the calipers. Lock down jam nuts. 8. Check to ensure that the brakes are NOT engaged when the Brake Lever is in the down & off position. 9. Check for drag by driving without activating any brakes for about 100 feet. Stop and check for heat on the brake discs. They should both be cool (or no hotter than the beginning of the test). Adjust if necessary. 10. Check the effectiveness of the parking brake by parking the Argo on the steepest hill encountered and by loading to itâ&#x20AC;&#x2122;s maximum working load. The parking brake should hold the Argo from moving. 11. Check the effectiveness of the emergency brake by activating it while coasting down a slight grade. The Argo should come to a controlled stop without pulling left or right. Re-adjust the brakes if necessary. 12. The emergency/parking brake should be checked for proper adjustment every 25 hours. Note: Oil on the brake disc caused by improper chain oiling will temporarily reduce the effectiveness of the brakes.

BR-18A

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General Information

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GI-28

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Argo Service Manual

Clutch System

SECTION CS Clutch System Table of Contents General Instructions............................................................................. CS-2 Maintenance Information.....................................................................CS-3 Drive Belt Inspection.............................................................................CS-3 Removing the Drive Belt.......................................................................CS-4 Installing the Drive Belt.........................................................................CS-5 Driver Clutch Inspection...................................................................... CS-5 Driver Clutch Removal......................................................................... CS-5 Disassembling the Driver Clutch (Threaded Bushing Spring Cap). CS-7 Disassembling the Driver Clutch (Cap Screw Spring Cap)...............CS-9 Disassembling the Driver Clutch (P/N 127-135) Supplement Pages.CS-9A Assembling the Driver Clutch (P/N 127-135)Supplement Pages...... CS-9A Assembling the Driver Clutch (Threaded Bushing Spring Cap)...... CS-11 Assembling the Driver Clutch (Cap Screw Spring Cap)................... CS-14 Installing the Driver Clutch ............................................................... CS-17 Driven Clutch Lubrication................................................................... CS-18 Driven Clutch Inspection......................................................................CS-18 Driven Clutch Removal........................................................................ CS-20 Driven Clutch Disassembly...................................................................CS-20 Driven Clutch Reassembly....................................................................CS-23 Testing the Spring Load of the Driven Clutch....................................CS-25 Installing the Driven Clutch ................................................................ CS-25

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CS-1

Clutch System

Argo Service Manual

General Instructions

Automatic Torque Converter System The torque converter system automatically regulates the torque delivered by the engine to the transmission. The System consists of a driver clutch located on the engine output shaft, a driven clutch located on the input shaft of the transmission, and a drive belt. On acceleration, the driver clutch moveable face travels towards the fixed face as the weights in the clutch are pushed outwards due to centrifugal force. This in turn compresses the internal spring of the driver clutch. As the driver clutch faces narrow, they grip the drive belt moving it towards the top of the driver clutch. (Top No Load Speed). At the same time, the transmission’s driven clutch plates spread apart as the belt rides down between the faces. The tension in this clutch is also regulated by a spring. As the vehicle comes under load, the spring loaded cam on the driven clutch forces the clutch plates together, causing the CVT to “Back Shift”.

At idle the belt should rest flush or a little beyond the edge of the driven clutch on the transmission. At top no load speed the belt should run near or to the top of the driver clutch.

Worn or dirty clutch components, or a worn drive belt will make the ARGO unreliable and unsafe to operate. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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CS-2

Argo Service Manual

Clutch System

Maintenance Information

The maintenance information provided in this manual refers to an ARGO vehicle operating under normal conditions and use. Service more often when the vehicle is used under heavy duty applications. Servicing of the Automatic Torque Converter system is necessary when:

a drop in vehicle performance occurs the vehicle does not speed up or slow down smoothly the vehicle hesitates or sticks at one speed the vehicle vibrates severely during normal operations the vehicle does not move when placed in gear the vehicle creeps at idle when placed in gear the vehicle is hard to shift into gear or other ranges

Drive Belt Maintenance Schedule-Inspect every 25 hours

Do not attempt to service any part of the torque converter system while the engine is running. Shut the engine off and disconnect the battery before servicing. Drive Belt Inspection

Drive belt tension and clutch alignment are set at the time of vehicle production. No further adjustment is required. 1

Remove the engine access cover.

Perform the servicing procedure, Removing The Drive Belt.

Inspect the condition of the drive belt over it’s full length. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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CS-3

Clutch System

Argo Service Manual

Replace the drive belt if:

the width of the belt is worn to 1 - 1/16" (27mm) the belt is cracked, frayed or shredding the belt has become contaminated with oil or other fluids

Check the condition of the belt in the table below and perform the necessary servicing procedure. Belt Condition

Problem

Servicing Procedure

Glazed Sides

Clutch Malfunction Lubricant Contamination

Driver Clutch Servicing Driven Clutch Servicing Replacing the Drive Belt

Torn Underchords

Wrong Drive Belt Old Drive Belt

Replacing the Drive Belt

Worn Prematurely

Driver or Driven Clutch Problem

Driver Clutch Servicing Driven Clutch Servicing Replacing the Drive Belt

Removing The Drive Belt 1.

Make sure the ignition is turned off.

Remove the engine access cover

Perform the servicing procedure, Removing the Firewall, in section VB

Place the transmission in neutral

CS-1 5.

Ease the belt over the fixed half pulley of the driven clutch starting from the bottom of the clutch, while turning the clutch counter-clockwise until the belt is off. Photo CS-1

Remove the belt from the driver clutch.

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CS-4

Argo Service Manual

Clutch System

Installing Drive Belt

Use only ARGO quality replacement drive belts.

If this procedure is not carried out as described, the edge of the fixed face may cut or damage the drive belt. 1.

Position the belt around the driver clutch first.

Ease the belt over the edge of the fixed face on the driven clutch and at the same time, turn the inside moveable face clockwise. Photo CS-2

CS-2 Driver Clutch Inspection Maintenance Schedule- Inspect every 50 hours of vehicle operation. If the vehicle is not shifting speeds smoothly, if the vehicle hesitates or sticks at one speed, or if the vehicle creeps at idle or is hard to shift into gear, remove and inspect the driver clutch. Service as necessary. Remove and service the driver clutch if:

the clutch plates have tracking grooves caused by drive belt action the clutch plates are bent or cracked the weight blocks are damaged or missing

Driver Clutch Removal 1.

Remove the engine access cover.

Perform the servicing procedure, Removing the Firewall, in section VB

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CS-5

Clutch System

Argo Service Manual

Perform the servicing procedure, Removing the Drive Belt, in this section of the service guide.

Remove the fastener securing the clutch to the PTO of the engine.

On Conquest Vehicles manufactured prior to CB12224:

Locate and loosen out the FHSC M10x1.5x100 fastener using an allen head socket. This fastener’s bevelled head sits flush to the end of the fixed faced pulley shaft. This is due to the countersink in the end of the shaft . There is no lockwasher, only blue 242 LOCTITE used to secure it in place.(Threaded Bushing Spring Cover)

On Conquest vehicles manufactured from CB12224 and prior to CB14236: (Threaded Bushing Spring Cover)

Locate and loosen out the SHCS M10x1.5x90mm fastener using an allen head socket. This fastener, installed along with a lockwasher, sits below the end of the fixed faced pulley shaft. This is due to the counterbore in the end of the shaft. The lockwasher eliminates the need for the LOCTITE application.

The above Conquest clutches or their components in this serial number range, are no longer available. If any clutch or component(s) of the above clutches need replacing, it must be replaced with the newer style 127-71 driver clutch assembly.

On Conquest vehicles manufactured from CB14236: (Cap Screw Spring Cover)

Locate and loosen out the SHCS M10x1.5x90mm fastener using an allen head socket. This fastener installed along with a lockwasher, sits below the end of the fixed faced pulley’s shaft. This is due to the counterbore in the end of the shaft.

On all RB, BF, SN, S, R, N & B Briggs and Stratton V Twin Models:

Locate and loosen out the HHCS 3/8-24x4.5 bolt and lockwasher from the PTO shaft of the engine.

Slide the driver clutch off the PTO of the engine. (See note following page)

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CS-6

Argo Service Manual

Clutch System

The driver clutch must be slid from the PTO with the mounting bolt hardware within the clutch. The mounting bolt is too long to remove first. The driver clutch may contact the lower body first before completely being free of the PTO, however the lower body will give enough in that area to free the clutch. 6.

Remove the clutch to a clean work area for further disassembly.

Disassembling the Driver Clutch (Threaded Bushing Spring Cover) Â&#x2039;

On vehicles manufactured prior to serial numbers CB14236, RB14121, BF9347, SN9551 & S9596:

Bend the tab of the lockwasher at the locknut. Photo CS-3

Remove the locknut by unthreading it from the fixed face shaft. Photo CS-4

CS-3

CS-4

Remove the clutch cap to expose the blocks and weights.

Remove the weights and blocks

Locate and loosen the set screw that secures the threaded bushing cap from turning. Photo CS-5

CS-5 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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CS-7

Clutch System 6.

Argo Service Manual

Unthread the bushing from the moveable face. Photo CS-6

This cap is under spring tension and will fly apart if precautions are not taken to hold it down while it is unthreaded from the moveable face. Be sure to always wear eye protection when servicing the clutches, or any other vehicle component for that matter, with the potential of flying parts. 7.

Remove the spring. Photo CS-7

CS-6

CS-7

Remove the retaining ring and any spacer(s) that may be present. Photo CS-8

Remove the spring guide plate. Photo CS-9

CS-8

CS-9

10. Remove the second retaining ring and any shim(s) that may be present. Photo CS-10 (Response, Bigfoot, Vanguard2 and Vanguard models only). Conquest clutches utilize a machined shoulder eliminating this retaining ring application. 11. Separate the pulley halves. Photo CS-11 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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CS-8

Argo Service Manual

Clutch System

CS-10

CS-11

12. Wash clutch components in a clean varsol bath to eliminate accumulated dirt and grease build up, and perform the servicing procedure, Inspecting the Driver Clutch, in this section of the service guide Disassembling the Driver Clutch (Cap Screw Spring Cover) Â&#x2039;

On vehicles manufactured from serial numbers CB14236, RB14121, BF9347, SN9551, S9596 and all R, B, N, C & A Models(Cap Screw Spring Cap)

Remove the nut and flat washer securing the cap to the fixed face pulley. Photo CS-12

Lift the cap to expose the blocks and weights and remove all three. Photo CS-13

CS-12 3.

CS-13

Remove the 3 socket head cap screws securing the spring cover to the moveable face pulley. Photo CS-14 Be aware of the small locking style flat washers that are installed with each cap screw. Be sure these are reinstalled during assembly.

IMPORTANT The cap screws should be loosened a little at a time in an alternating pattern. This will ensure that the cap will not bind when coming off under spring tension. SEE WARNING FOLLOWING PAGE Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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CS-9

Clutch System

Argo Service Manual

This cap is under spring tension and will fly apart if precautions are not taken to hold it down while the cap screws are removed. Be sure to always wear eye protection when servicing the clutches, or any other vehicle component for that matter, with the potential of flying parts.

CS-14

CS-15

Remove the cap and remove the spring. Photo CS-15

On vehicles manufactured from serial numbers CB17506, RB17610, BF12007, SN12147, S12150 and all R, B, N, C & A models, remove the spring ring from the fixed pulley shaft. Photo CS-16 Clutches prior to the above serial numbered vehicles do not utilize this spring ring.

Slip the spring guide washer from the shaft. Photo CS-17

CS-16 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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CS-10

Argo Service Manual 7.

Clutch System

On all RB, BF, SN, S, R, N & B Models,(Briggs & Stratton), remove the lower retaining ring from the fixed pulley shaft. Photo CS-18

All CB, C & A Models (Conquest) driver clutches have a machined shoulder on the shaft of the fixed half pulley. This eliminates the need for a retaining ring at this location. 8.

Separate the two halves. Photo CS-19

CS-18 9.

CS-19

Wash clutch components in a clean varsol bath to eliminate accumulated dirt and grease build up.

10. Perform the servicing procedure, Driver Clutch Inspection, in this section of the service guide. Assembling the Driver Clutch (Threaded Bushing Spring Cap) Â&#x2039;

On vehicles manufactured prior to serial numbers CB14236, RB14121, BF9347, SN9551 & S9596:

Place the fixed face on a clean work surface with the shaft facing up. Photo CS-20

Slip the moveable face on to the shaft of the fixed face pulley. Photo CS-21

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CS-11

Clutch System

Argo Service Manual

CS-21

CS-00 CS-22

Install the lower retaining ring to the fixed shaft along with any shim(s) to the top of the retaining ring. Photo CS-22 (Response, Bigfoot & Vanguard clutches only)

Place the spring guide washer on next. Photo CS-23

Install the second retaining ring to the fixed face shaft along with any shim(s) that may have been installed before.. Photo CS-24

CS-23

CS-24

Set the spring on to the spring guide washer. Photo CS-25

Install the threaded bushing cap. Photo CS-26 spring.

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Use an arbor press to compress

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CS-12

Argo Service Manual 8.

Clutch System

Thread the spring cap into the top of the moveable face until it sits approximately 0.100" above the top edge of the moveable face. Use a vernier to measure this. Photo CS-27

Once this measurement is set, you may need to turn the threaded cap in either direction to align the machined keyway in the cap with the set screw in the moveable face. 9.

Apply red 271 LOCTITE to the thread of the set screw and tighten. Photo CS-28

CS-27

CS-28

10. Place the blocks and weights into the moveable face and orient as shown in Photo CS-29 11. Install the clutch cover over the weights and blocks making sure that the blocks are aligned with the guides riveted into the cap. Photo CS-30

CS-29

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CS-30

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CS-13

Clutch System

Argo Service Manual

11. Secure the clutch cover with the locknut and lockwasher. Tighten the locknut securely and align one of the tabs in the lockwasher, with one of the keyways of the locknut. Bend the tab into the locknut using a small drift punch and hammer. Photo CS-31

CS-31 12.

Perform the servicing procedure, Installing the Driver Clutch.

Assembling the Driver Clutch (Cap Screw Spring Cap) Â&#x2039;

On vehicles manufactured from serial numbers CB14236, RB14121, BF9347, SN9551, S9596 and all R, B, N, C & A models:

Place the fixed face on a clean work surface with the shaft facing up. Photo CS-32

Slip the moveable face on to the shaft of the fixed face pulley and install the retaining ring. (This retaining ring is used only in clutches installed on RB, BF, SN, B, N, R & S model ARGOS) Photo CS-33 See Note Below.

CS-32

CS-33

This retaining ring is not used in clutches manufactured for the Conquest vehicle. Conquest driver clutches have a machined shoulder on the shaft of the fixed face, eliminating the need for this retaining ring. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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CS-14

Argo Service Manual

Clutch System

Place the spring guide washer on top of the retaining ring (or to the machined shoulder on Conquest clutches). Photo CS-34

Install the spring ring to the second position on the shaft of the fixed pulley. Photo CS-35

This spring ring is only installed on vehicles manufactured from serial numbers CB17506, RB17610, BF12007, SN12147, S12150 and all R, B, N, C & A models. Clutches prior to the above serial numbered vehicles do not utilize this spring ring.

CS-34

CS-35

Set the spring to the top of the spring guide. Photo CS-36

Install the spring cap and fasten with the 3 cap screws. Place the clutch assembly into an arbor press to assist in compressing the spring. Partially compress the spring while at the same time raising the moveable face upwards. Be sure each cap screw is started and tightened down evenly. Torque to specifications. Photo CS-037

IMPORTANT

Each cap screw should have a locking style flat washer

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CS-15

Clutch System 7.

Argo Service Manual

Place each of the weights and blocks into the moveable face and orient as shown in Photo CS-38 & 39

CS-39

CS-38 Clutch Weight Chart Response & Bigfoot Vehicles

225g

Conquest Vehicles prior to CB17506 Conquest Vehicles from CB17506

266g 260g

Vanguard & Vanguard2 Vehicles

200g

Install the cap over the weights and blocks making sure that the blocks are aligned with the guides riveted into the cap. Photo CS-40

Before installing and tightening the flat washer and nut, be certain that hexagon shaped hole in the cap is mated to the one at the base of the threaded shaft. Photo CS-41, 42 & 43

10. Install the nut and torque to specifications.

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CS-16

Argo Service Manual

Clutch System CS-43

CS-42 Installing the Driver Clutch 1.

Apply anti-seize compound to the engine PTO shaft.

Install the key to the keyway of the PTO shaft.

Install the mounting hardware into the driver clutch before attempting to slip the clutch on to the PTO of the engine. The hardware cannot be installed after the clutch has been slipped into place.

Refer to page CS-6 in reference to the hardware used for the particular model and year of vehicle being serviced. 4.

Align the keyway of the driven clutch with that of the previously installed key on the PTO, and slip the clutch on and up to the machined shoulder.

In some cases the lower body may have to be pushed out a little to allow the clutch room to slip on to the PTO shaft.

IMPORTANT

The driver clutch should slip on and up to the shoulder by hand. There should not be any reason to use a mallet to install the clutch. 5.

Torque hardware to specifications.

Perform the servicing procedure, Installing the Drive Belt.

Perform the servicing procedure, Installing the Firewall in section VB.

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CS-17

Clutch System

Argo Service Manual

Driven Clutch Lubrication Lubricate the driven clutch every 50 hours with a silicone based lubricant such as WD-40. Spray the lubricant into the clutch unit, directing the spray onto the spring, bushing and the sliding areas of the cam pulley and the fixed cam where the cam shoes make contact.

Do not attempt to lubricate the driven clutch while the engine is running. Do NOT spray lubricant onto the drive belt, brake disc or clutch faces. Allow the lubricant to dry before using the vehicle. If the lubricant is not dry, use of the vehicle will attract dirt and cause damage to the clutch components. A complete service of the clutch units is required after every 250 hours of operation. To perform this procedure, the clutches must be disassembled. Special tools are required to disassemble the clutch units. Perform the servicing procedures, Driven or Driver Clutch Removal & Disassembly in this section of the service guide. Driven Clutch Inspection Maintenance Schedule-Inspect every 50 hours of vehicle operation Inspect the nylon sliders every 50 hours. The nylon sliders are mounted in the driven clutch moveable pulley. When the clutch shifts, the cam moves on the nylon sliders. Replace the nylon sliders before there is aluminum to aluminum contact between the cam and the moveable pulley. Driven clutch disassembly is required to replace the nylon sliders properly. 1.

Remove the engine access cover.

Perform the servicing procedure, Removing the Firewall, in section VB of this service guide.

Inspect the clutch. Perform the servicing procedure, Driven Clutch Removal/Disassembly, if:

the clutch plates have tracking grooves caused by drive belt action the clutch plates are cracked or bent the nylon cam slider shoes are missing, melted, or worn through the spring is broken or has come loose from the cam or moveable face

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CS-18

Argo Service Manual 4.

Clutch System

Perform the servicing procedure, Driven Clutch Removal/Disassembly if the vehicle: is not changing speed smoothly hesitates or sticks at one speed lacks turning power won’t move when the engine is accelerated in gear and brakes are disengaged does not backshift under load

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CS-19

Clutch System

Argo Service Manual

Removing the Driven Clutch 1.

Perform the servicing procedure, Removing the Firewall, in section VB

Perform the servicing procedure, Removing the Drive Belt.

Locate and remove the bolt, lock washer and flat washer securing the clutch to the input shaft of the transmission.

Slip the driven clutch from the transmission. Photo CS-44

Remove the driven clutch to a clean work area.

Driven Clutch Disassembly 1.

Place the clutch in an arbor press and gently apply pressure to the spring cam until the retaining ring can be removed. The use of an old discarded 34-08 ARGO transmission cage is a useful tool to employ between arbor press and clutch. Photo CS-45

CS-44 CS-45

Depending on the age of the vehicle, the movable cam may be secured by 2 retaining rings and may also have spacers installed beneath the retaining ring. 2.

With the retaining ring removed, slowly release the arbor press off the cam until the cam is free of the fixed pulleyâ&#x20AC;&#x2122;s shaft and the spring has unwound . Photo CS-46

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CS-20

Argo Service Manual

Clutch System The cam is under spring tension. Wear eye protection and keep fingers clear of the clutch. 3.Remove the cam and key from the keyway. Photo CS-47

CS-46

CS-47

Slide the movable face from the fixed pulley. Photo CS-48

Remove the retaining ring and spacer(s) from the shaft of the fixed pulley. Photo CS-49

The Oilite bushing of the 126-24 driven Clutch movable face is secured with a spring pin. Remove the spring pin and press the bushing from the movable face. Photo CS-50

CS-48

The 127-136 Avenger driven clutch does not utilize this oilite bushing in it's design. 7.

The Super Oilite Bushing used in the 127-129 Driven clutch is NOT secured with a spring pin, but uses a retaining style ring at the end to secure the bushing. Photo 50A

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CS-21

Clutch System

Argo Service Manual

CS-50 7.

To replace the nylon cam slider shoes, pry each out with a slot screwdriver or small chisel. You may need to use a small hammer applying quick blows to pop the slider shoes loose. Photo CS-51

CS-50A

CS-51

Press each new slider shoe back into the moveable face pulley. Ensure that they are pressed in completely and seated.

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CS-22

Argo Service Manual

Clutch System

Driven Clutch Reassembly (126-24 & 127-129) 1.

Press the oilite bushing into the movable face and secure with the roll pin or retaining ring. A new bushing requires re-drilling the hole in the movable face (126-24 driven clutches only),once the bushing is in position.

Slip the movable face back on to the fixed pulley after installing all spacers and snap ring to the fixed face shaft. Slide the small key into the key way of the fixed shaft. Photo CS-52

There are 6 spring tension adjustment holes in the cam that are numbered 1 through 6. Insert the one end of the cam spring into the number 3 hole. Photo CS-53

CS-52

There is 1 hole within the movable face pulley. Insert the other end of the cam spring into this hole. Photo CS-54

CS-53

CS-54

Driven Clutch Reassembly (Avenger 127-136) i.

Slip the movable face back on to the fixed pulley after installing all spacers and snap ring to the fixed face shaft. Slide the small key into the key way of the fixed shaft.

ii.

Locate the # 10 marking on the moveable face. The cam spring will be inserted into the hole across from this number. Photo 53A

iii. Insert the other end of the clutch spring into th e # 2 hole of the cam. Photo 54A

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CS-23

Clutch System

Argo Service Manual CS-54A

CS-53A

All Driven Clutches 5.

Install the cam and spring to the fixed face shaft aligning the key on the fixed shaft with the keyway in the cam. Photo CS-55

Take to the arbor press and push the cam onto the shaft while turning the movable face counter clockwise 120 degrees, or one cam notch past the first cam shoe . Once past the cam shoe, press completely down until the retaining ring groove in the fixed pulley shaft is visible and the retaining ring can be reinstalled. Photo CS-56

CS-56

CS-55

Make sure that the retaining ring is seated to the groove. Failure to guarantee that it is seated, could result in personal injury while handling the clutch or damage to the vehicle once installed. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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CS-24

Argo Service Manual

Clutch System

Testing The Spring Load Of The Driven Clutch

CS-57

Place the driven clutch in a soft faced aluminum jawed vise and clamp so that the movable face is free to turn. Clamp a good digital or regular spring fish scale to the edge of the moveable pulley. Pull and note the lbs. force while pulling, while it is moving, and then note the force while releasing, while it is moving. Average the two numbers. That average number should fall between 12.6 and 19.8 for Avenger and 18-22lbs. +/-3.7 for all other other models. Photo CS-57

Driven clutch spring preload may be set higher than the stock setting on Avenger to increase turning (backshifting performance), if necessary. E.g, if the vehicle is under heavy payload or rubber track system is installed.

CS-58

Installing the Driven Clutch 1.

Apply anti-seize compound to the transmission input shaft.

Install the key to the keyway of the input shaft. Photo CS-58

Align the keyway of the driven clutch with that of the previously installed key on the input shaft and slip the clutch on and up to the machined shoulder.

Apply blue 242 LOCTITE to the threads of the fastener and install along with the lockwasher and flat washer. Torque to specifications.

Perform the servicing procedure, Installing the Drive Belt.

Perform the servicing procedure, Installing the Firewall, in section VB

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CS-25

Clutch System

Argo Service Manual IMPORTANT

The driven clutch should slip on and up to the shoulder by hand. There should not be any reason to use a mallet to install the clutch. Be sure that all spacers previously used behind the driven clutch have been reinstalled.

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CS-26

Argo Service Manual

Clutch System

SECTION CS

Supplement Pages

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Clutch System

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Argo Service Manual

Clutch System

Disassembling the Driver Clutch (Avenger Models) 1. Remove the large hex nut, flat washer and cap. Photo 1 2. Remove the (3) block and 275gr weight assemblies. Photo 2 3. Remove the (3) fasteners securing spring cover to the sliding flange. Photo 3

CA UTION CAUTION Cap is under spring tension. Slowly unthread each fastener uniformly and a little at a time until the cap is freed from the sliding flange. 4. Remove the cap, spring and spring guide washer. Photo 4

5. Slip off the 0410-0026 Sliding Flange. Photo 5 Re-assembling the Driver Clutch (Avenger Models) 1. Slip on the 0410-0026 Sliding Flange followed by the spring guide washer. Photo 6 2. Install the spring. Photo 7 3. Install the spring cap and secure with the (3) fasteners. Torque to 90 in. lbs. 10.0Nm Photo 8 See IMPORTANT on following page. CS-9A

Clutch System

Argo Service Manual IMPOR TANT IMPORT

There are (3) small lockwashers on these (3) fasteners. Ensure that they are still in place before re-installing and torquing the spring cap back down.

4. Re-install the nylon block and weight assemblies into the sliding flange. Orient the block with the rounded side up. Photo 9 5. Re-install the cap and secure with flat washer and nut. Torque to 100 FT. LBS. 135.6Nm

NO TE NOTE

To properly torque, re-install the driver to the engine PTO and lock flywheel while using the torque wrench to achieve proper torque.

9 CS-10A

Argo Service Manual

Wheels, Axles & Chains

SECTION WA Wheels, Axles & Chains Table of Contents General Instructions............................................................................. WA-3 Main Frame Information..................................................................... WA-4 Drive Chain Maintenance.................................................................... WA-4 Drive Chain Removal............................................................................WA-5 Drive Chain Inspection......................................................................... WA-6 Drive Chain Installation....................................................................... WA-7 Drive Chain Lubrication...................................................................... WA-9 Drive Chain Cleaning........................................................................... WA-9 Chain Tensioner Inspection (Upper and Lower Block Style)........... WA-10 Replacing the Slider Block (Upper and Lower Block Style).............WA-10 Chain Tensioner Inspection (Lower Block Semi-Self Adjust).......... WA-11 Replacing the Slider Block (Lower Block Semi-Self Adjust)............ WA-12 Disassembling the Chain Tensioner System....................................... WA-12 (Upper and Lower Block Style) Disassembling the Chain Tensioner System.......................................WA-14 (Lower Block Semi-Self Adjust) Assembling the Chain Tensioner System............................................WA-15 (Upper and Lower Block Style). Assembling the Chain Tensioner System............................................WA-17 (Lower Block Semi-Self Adjust) Idler Chain Maintenance......................................................................WA-19 Idler Chain Removal.............................................................................WA-20 Idler Chain Cleaning............................................................................ WA-21 Idler Chain Inspection..........................................................................WA-22 Idler Chain Installation........................................................................WA-23 Idler Chain Adjustment........................................................................WA-24 Removing the Idler Shaft (Conquest 8 & 6, Response, Bigfoot)...... WA-26 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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WA-1

Wheels, Axles & Chains

Argo Service Manual

SECTION WA Wheels, Axles & Chains Table of Contents Removing the Idler Shaft (Vanguard & Vanguard2)........................ WA-29 Idler Shaft Inspection........................................................................... WA-31 Installing the Idler Shaft (Conquest 8& 6, Response,Bigfoot........... WA-33 Installing the Idler Shaft (Avenger & Frontier Models) Supplement Pages..............................WA-32A Installing the Idler Shaft (Vanguard & Vanguard2)......................... WA-38 Aligning the Idler Shaft (Vanguard & Vanguard2)........................... WA-39 Idler Shaft Bearing Lubrication.......................................................... WA-41 Removing an Axle (Without Bearing Extension)............................... WA-42 Removing the Axle Seals....................................................................... WA-43 Installing the Axle Seals........................................................................ WA-44 Installing an Axle (Without Bearing Extension)................................ WA-45 Keyed Front Axles (Earlier 6x6 Vanguards)...................................... WA-48 Outer Axle Flange & Bearing Lubrication......................................... WA-49 Inner Axle Bearing Lubrication.......................................................... WA-49 Removing an Axle (With Bearing Extension).....................................WA-50 Removing an Axle (With 810-91 Bearing Extension) Supplement Pages..................................................................................WA50A Installing an Axle (With Bearing Extension)...................................... WA-50 Installing an Axle (With 810-91 Bearing Extension) Supplement Pages..................................................................................WA-52A Removing the Bearing Extension.........................................................WA-52 Installing the Bearing Extension..........................................................WA-52 Removing the Inner Bearing................................................................ WA-53 Installing the Inner Bearing................................................................. WA-53

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Argo Service Manual

Wheels, Axles & Chains

SECTION WA Wheels, Axles & Chains Table of Contents Removing a Tire.....................................................................................WA-55 Wheel Disassembly................................................................................ WA-55 Tire Pressure...........................................................................................WA-55 TireInspection........................................................................................WA-56 Temporary and General Tire Repair...................................................WA-56 Wheel Reassembly................................................................................. WA-57 Valve Replacement................................................................................ WA-57 Wheel Installation................................................................................. WA-58

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WA-3

Wheels, Axles & Chains

Argo Service Manual

General Instructions

Improperly adjusted idler chains or poorly aligned idler shaft assemblies can result in personal injury to the operator, extensive damage to brake disc sprockets and idler shaft assemblies, and may lead to a costly and inconvenient break down off road. Please ensure that the axle shafts are correctly aligned and that the drive chains and chain tensioner system are in good working condition.

Improperly aligned axle shafts or incorrect chain tension can result in extensive damage to drive chains and axle sprockets, and may cause wear on the vehicle frame and floorpans. Please ensure that axle shafts are correctly aligned and that the drive chains and chain tensioner system are in good working order.

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WA-4

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Argo Service Manual

Wheels, Axles & Chains

Main Frame Information Vanguard Frame Prior to S/N S8131

Frame does not have front tube design

Vanguard2 Frame from S/N SN7841 (1995) Introduced Vanguard2 /Hydraulic Brakes

Front Tube Frame Design (not threaded for bearing extensions)

Vanguard Frame from S/N S8131 (1995) Updated to Vanguard2 parts & frame but with mechanical brakes

Front Tube added to frame design but not threaded for bearing extensions until S/N S8153

Vanguard2 Frame from S/N SN8153 (1995)

Front Tube Threaded for Extensions

Vanguard & Vanguard2 from S/N SN10191 & S10178 (1998)

Extended Wheel Base and New Self Adjust Chain Tensioners

Conquest Frame from S/N CB16049 (1999)

New Frame with revised axle spacing and new Self Adjust Chain Tensioners

Response Frame from S/N RB16104 (1999)

New frame with revised axle spacing and new Self Adjust Chain Tensioners

Drive Chain Maintenance

Regular maintenance of the drive chains is essential to both good vehicle performance and personal safety. Poorly maintained chains can result in rusted, corroded or seized up chains, damaged sprockets, damaged frame, and costly repair bills. 1.

Every 25 hours of vehicle operation perform the servicing procedure, Drive Chain Inspection in this section of the service guide.

Every 10 hours of vehicle operation perform the servicing procedure, Chain Tensioner Inspection.

Every 10 hours of vehicle operation perform the servicing procedure, Drive Chain Lubrication.

Every 100 hours of vehicle operation perform the following servicing procedures:

Drive Chain Removal Drive Chain Cleaning Drive Chain Inspection Chain tensioner Inspection

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WA-5

Wheels, Axles & Chains

Argo Service Manual

Drive Chain Installation Drive Chain Lubrication

Drive Chain Removal 1.

Perform the servicing procedure, Removing the Firewall in section VB of this guide.

Remove the front and rear floorpans.

On 8x8 models manufactured prior to serial numbers CB16049 & RB16104, or 6x6 models prior to serial numbers SN1019 & S10178:

Locate the chain you wish to remove and release the spring holding the chain tensioners together. Photo WA-1

ii.

WA-1

Rotate the chain until the connecting link can be accessed.

iii. Using a screwdriver, pry off the connecting link clip. DIAGRAM WA-2

IMPORTANT

WA-2

Any damage to the connecting link clip during removal requires that it be replaced with a new one. Failure to do so could result in the drive chain becoming disconnected and a costly repair.

WA-3 iv.

Remove the outside plate and tap out the connecting link. There are 2 inside plates located at the center of the RC50 Double Chain. DIAGRAM WA-3

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WA-6

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Argo Service Manual

Wheels, Axles & Chains

Drive Chain Removal

On 8x8 models manufactured from serial numbers CB16049 & RB16104, or 6x6 models from serial numbers BF9212, SN10191 & S10178: i.

Turn the tensioner cam assembly in the direction which winds up the torsion spring and push the assembly down as close as possible to the cam follower block in the bottom of the frame. Secure it in this position with a Vice-Grip 10CR as illustrated in DIAGRAM WA-5.

ii.

Roll the vehicle until the connecting link on one of the chains is visible.

iii. Remove the spring clip from the connecting link as shown in WA-3 (previous page) Remove the outside plate and tap out the connecting link. The inside plates will be released when the connecting link is removed (Frt. & Mid Frt. RC50 Chains Only). The rear chain drive is single RC60 and has no inside plates. Photo WA-6 iv.

Remove the chain from the vehicle.

Repeat steps 4 to 6 until all drive chains are removed if necessary.

Perform the servicing procedure, Drive Chain Inspection below.

WA-5

WA-6

Drive Chain Inspection

The drive chains will stretch and wear after extensive vehicle use, and cause a reduction in vehicle performance and a hazard to personal safety. Roller chain “stretch” results from wear to the chain pins and bushings because of the loss of lubricant. 1. 2.

Remove the front and rear floorpans. Inspect the drive chains and replace, or remove a link and install a half link if enough chain stretch will allow it. Perform any of the above procedures if: the chain tensioner system can no longer take up the slack the chain is seized up, corroded or rusted the chain is causing damage to the sprockets

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WA-7

Wheels, Axles & Chains

Argo Service Manual

If the chain requires replacing, perform the servicing procedure, Drive Chain Removal.

Perform the servicing procedure, Inspecting the Chain Tensioner System.

If drive chain inspection is complete, replace the floor pans.

Drive Chain Installation Â&#x2039;

On 8x8 models manufactured prior to serial numbers CB16049 & RB16104, or 6x6 models prior to serial numbers SN10191 & S10178:

Position the drive chain over the lower slider block and under the upper slider block. Photo WA-7

Pull the ends of the chain together and insert the connecting link as shown in DIAGRAM WA-8 and 9. When connecting the RC50-double chain, insert the inside plates before tapping the connecting link into position.

WA-8

WA-7

WA-9

Use a pair of modified 7R Vice Grips to hold the ends of the chain together while inserting the connecting link. Some drive chains have no slack, and replacement of the connecting link is difficult without this tool. Modified Vice Grips can be ordered from Ontario Drive & Gear (ARGO Part No. 658-08) or refer to Section GI under special tools for modification information. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

WA-8

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Argo Service Manual 3.

Wheels, Axles & Chains

Replace the outside plate and spring clip. The open end of the clip must face rearward when it is on top of the chain. Photo WA-10

Earlier vehicles used an open ended spring clip. New models have a closed ended spring clip. Face this rearward as well. 4.

Remove the vice-grips and connect the chain tensioner spring between the upper and lower chain tensioner arm. Photo WA-11

Reinstall firewall and floorpans.

WA-10

WA-11

Drive Chain Installation Â&#x2039;

On 8x8 models manufactured from serial numbers CB16049 & RB16104, or 6x6 models from serial numbers BF9212, C12747, SN10191 & S10178: 1.

Position the drive chain over the slider block and around the drive sprockets.

The chain tensioner system must be secured in itâ&#x20AC;&#x2122;s lowest position to the frame as illustrated in DIAGRAM WA-5 on page WA-6. 2.

Pull the ends of the chain together and insert the connecting link as shown in DIAGRAM WA-8 & 9. When connecting the RC50-2 chain, insert the inside plates before tapping the connecting link through the second set of links. The rear single RC60 chains have no inside plates.

Replace the outside plate and spring clip. The open end of the clip must face rearward when it is on top of the chain. Newer style clips have a closed end.

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WA-9

Wheels, Axles & Chains

Argo Service Manual

Remove the vice-grips, securing the cam assembly in its lowest position.

With the wheels raised up off the ground, reach under the slider block assembly and pull it up into the highest position that the chain will allow. See DIAGRAM WA-15 on page WA-11

Replace the firewall and floor pans.

Drive Chain Lubrication Maintenance Information - Lubricate every 10 hrs. of vehicle operation. *Lubricate more frequently if the vehicle is being operated under wet or dusty conditions 1.

Perform the servicing procedure, Removing the Firewall, in section VB of this service manual.

Remove both front and rear floor pans.

Lubricate the chains with Aerosol Chain Lube (ARGO part No. 125-86).

Idler Chain Lubrication Lubricate the idler chains after 10 hrs. of operation, and more frequently if the vehicle is operated in dirty or wet conditions. Use an aerosol type of motorcycle chain lube such as the type available through Ontario Drive & Gear. Part No. 125-86 When applying the chain lube, protect the brake disc with a rag or simple cardboard shield. Do not allow chain lube to come into contact with the brake discs or brake pads. Roll the vehicle so that all the idler chain is accessible for lubrication. Drive Chain Cleaning After every 100 hrs. of operation, remove all the drive chains from the vehicle and clean them thoroughly in a suitable solvent, e.g clean varsol bath.

Never use gasoline as a cleaning solvent. Gasoline is extremely flammable and can explode if ignited, causing serious personal injury. Allow the chains to dry thoroughly, re-lubricate generously with ARGO Chain Lube and reinstall. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

WA-10

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Chain Tensioner Inspection (Earlier Style) Â&#x2039;

On 8x8 models manufactured prior to serial numbers CB16049 & RB16104, or 6x6 models prior to serial numbers SN10191 & S10178:

This chain tensioning system consists of an upper and lower chain tensioner arm which is supported by a pivot pin secured between the outer and inner frame channel. A tensioner spring is connected between the upper and lower assembly keeping a constant tension on any slack there may be in the chain. Photo WA-12

WA-12

Maintenance Interval - Inspect every 10 hours of vehicle operation. 1.

Remove the front and rear floor pans.

Press the upper and lower slider blocks together and, using pliers, remove the tensioner spring.

The friction of the chains will cause wear to the nylon slider blocks in the chain tensioning system. Inspect the face of each slider block.

WA-13

If the wear groove on the slider block, as shown in DIAGRAM WA-13, is 1/4" (6mm) or greater, replace the nylon slider block. Replacing the Slider Block 1.

If the nylon slider block needs replacing, pry the old block off of the shaft with a pair of pliers.

Place the new slider block over the shaft of the tensioner arm, and using a needle nose vise grip, squeeze the new block until it snaps on to the shaft of the tensioner arm. Photo WA-14

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Chain Tensioner Inspection (Later Style) Â&#x2039;

On 8x8 models manufactured from serial numbers CB16049 & RB16104, or 6x6 models from serial numbers C12747, BF9212, SN10191 & S10178: This chain tensioning system consists of a torsion spring loaded cam assembly with a slider block which takes up the slack on the bottom side of all but the front final drive chains. As the chain wears, the chain tensioning mechanism adjusts semi-automatically. Under most conditions, the tensioner cam assembly will move to the next step of adjustment simply due to normal drive system dynamics. Sometimes, however, the cam assembly can bind due to debris caught in the area.

IMPORTANT It is very important to check that the cam assembly is progressing properly. Check for proper chain tensioner operation after the intial 2 hours of vehicle break in and then every 10 hours of vehicle operation, when the drive chains are being lubricated. Each step of the cam takes up about 2.5 inches of chain slack. DIAGRAM WA-15

WA-15

The tensioner cannot progress to the next step until there is enough slack in the chain. With the wheels raised off the ground, check if the chain slack exceeds 2.5 inches. If it does, then reach under the slider block assembly and pull up.

Check for proper chain tensioner operation every 10 hours of vehicle operation. Maintenance Interval - Inspect every 10 hours of vehicle operation. 1.

The friction of the chains will cause wear to the nylon slider blocks in the chain tensioning system. Inspect the face of each slider block.

If the wear groove on the slider block, is 1/4" (6mm) or greater, replace the nylon slider block. DIAGRAM WA-13 on previous page.

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Replacing the Slider Block: 1.

Remove the floor pans and the appropriate drive chain.

Turn the tensioner cam assembly in the direction which winds up the torsion spring and push the assembly down as close as possible to the cam follower block across the bottom of the frame channels. Clamp it in this position with a Vice-Grip 10CR or similar plier as illustrated in DIAGRAM WA-16

With pliers, pry the slider block off the cam assembly as illustrated in DIAGRAM WA-16

Place a new slider block over the shaft of the cam assembly.

Using a piece of wood (or similar material) pressed against the top of the slider block, carefully hammer the piece of wood so the slider block snaps onto the cam assembly shaft as shown in DIAGRAM WA-17

WA-16

WA-17

Reinstall the drive chain and remove the locking pliers securing the cam assembly in its lowest position.

Pull up on the cam assembly to allow it to take up as much chain slack as possible.

Replace the floor pans.

Disassembling the Chain Tensioner System Â&#x2039;

On 8x8 models manufactured prior to serial numbers CB16049 & RB16104, or 6x6 models prior to serial numbers SN10191 & S10178:

Remove the front or rear floorpan.

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Locate the required chain take up system and remove the tensioner spring. Photo WA-18

Remove the cotter pin which secures the chain tensioner system to the vehicle frame. Photo WA-19

WA-18

WA-19

Slide out the pivot pin which holds the chain tensioner assembly together. Photo WA-20

Pull the upper and lower assembly from the vehicle and collect the remaining components of the assembly. These include a spacer and spacer spring. Photo WA-21

WA-20

WA-21

If the nylon slider block needs replacing, place the tensioner arm in a vise and lift one corner of the slider block, pulling it straight back off the chain tensioner arm. DIAGRAM WA-22

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Inspect the upper and lower tensioner arms for any cracks or bends and warping. A twisted or bent tensioner arm can cause uneven wear on the block, or cause the spring that tensions the 2 halves together to inadvertently pop off during vehicle operation. Replace as required.

Disassembling the Chain Tensioner System Â&#x2039;

On 8x8 models manufactured from serial numbers CB16049 & RB16104, or 6x6 models from serial numbers C12747, BF9212, SN10191 & S10178: 1.

Remove the floor pans.

Turn the tensioner cam assembly in the direction which winds up the torsion spring and push the assembly down as close as possible to the cam follower to loosen the chain. Clamp it in this position with a Vice-Grip 10CR or similar plier as illustrated in Photo WA-23, then remove the chain.

WA-23

WA-24

WA-00

With the chain removed, unfasten the clamp holding the chain tensioner system and let it unwind to its top most position. Unfasten the spring at the cam's tab. Photo WA-24

To pull the tensioner assembly free of the frame guides, push the the long shaft side of the cam assembly down to the bottom of the guide. At the same time raise the opposite side up and out of the guide. Photo WA-25 & 26

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WA-26 6.

WA-27

Slip the one torsion spring off the cam, and remove the second torsion spring from the frame assembly by removing the cotter pin that secures it. Photo WA-27

Assembling the Chain Tensioner System Â&#x2039;

On 8x8 models manufactured prior to serial numbers CB16049 & RB16104, or 6x6 models prior to serial numbers SN10191 & S10178:

If the nylon slider block needs replacing: 1.

Place the tensioner arm on to a solid surface, such as the top of a vise. Photo WA-028

Position one end of the new slider block on to the tensioner arm.

Press firmly on to the tensioner arm. Use light strokes of a rubber mallet if necessary. Photo WA-29

WA-28

WA-29

If the chain tensioner system is being installed on an outside chain: 4.

Insert the end of the pivot pin with the cotter pin hole, through the inner channel of the vehicle frame. Photo WA-30

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WA-30

WA-31

Place the bushing, spring, lower tensioner arm and upper tensioner arm on to the pivot pin as you push the pivot pin through. Photo WA-31

Insert end of pivot pin into the frame bushing and align the cotter pin holes.

Insert the cotter pin and bend over with a pair of needle nose pliers. Photo WA-32

Press the upper and lower tensioner arms together. Make sure that the faces of the nylons slider blocks are up against the chain. Photo WA-33

WA-32

Install the spring between upper and lower arms. Photo WA-34

WA-33

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Argo Service Manual

If the Chain tensioner is being installed on an inside chain: Photo WA-35 1.

Insert the end of the pivot pin with the cotter pin hole through the inner channel of the vehicle frame.

WA-35

Place bushing, lower tensioner arm, upper tensioner arm and spring on to the pivot pin as you push the pivot pin through.

Insert end of pivot pin into the frame bushing and align the cotter pin holes.

Insert the cotter pin and bend it over with a pair of needle nose pliers.

Press the upper and lower tensioner arms together. Make sure that the faces of the nylons slider blocks are up against the chain.

Install the spring between upper and lower arms.

Assembling the Chain Tensioner System Â&#x2039;

On 8x8 models manufactured from serial numbers CB16049 & RB16104, or 6x6 models from serial numbers BF9212, SN10191 & S10178: If the nylon slider block needs replacing: 1.

Place the tensioner block onto a workbench and position the slider block over the shaft of the assembly.

With a soft faced mallet tap the slider block to snap it on to the shaft. Photo WA-36

Slip a torsion spring over the welded bushing on the frame, and secure with a cotter pin. Orient as in Photo WA-37

Slip the second torsion spring on to the shaft of the tensioner cam assembly. Photo WA-38

WA-36

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WA-37 5.

WA-38

Insert the extended length of the torsion spring, assembled to the cam, into the hole of the welded tab on the frame. Photo WA-39 At the same time, place the same side of the cam's shaft into the tensioner systems guide.

WA-39

WA-40

Push the previously inserted side of the cam to the bottom of the guide and raise the opposite side to insert over the extended length of the second torsion spring on the bushing side. Photo WA-40

Allow the assembly to sit in the up most position. Photo WA-41

Assemble the short stem of the torsion spring, on the cam's shaft, into the tab on the cam. Photo WA-42

WA-41 Turn the cam assembly in the direction which winds up the torsion spring and push the assembly down as close as possible to the cam follower block across the bottom of the frame channels. Clamp it in this position until the chains are reinstalled. Photo WA-43,44 & 45

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Argo Service Manual

WA-42

WA-43

WA-44

WA-45

Idler Chain Maintenance

Regular maintenance of the idler chains is essential to good vehicle performance and personal safety. Poorly maintained idler chains can result in rusted, corroded or seized up chains, damaged brake discs, worn or broken idler shaft assemblies, and costly repair procedures. 1.

Every 20 hours of vehicle operation, perform the servicing procedure, Idler Chain Inspection.

Every 50 hours of vehicle operation, perform the servicing procedure, Idler Chain Adjustment.

Every 10 hours of vehicle operation, perform the servicing procedure, Idler Chain Lubrication.

Every 100 hours of vehicle operation, perform the servicing procedures:

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Idler Chain Removal Idler Chain Cleaning Idler Chain Inspection Idler Shaft Inspection Idler Shaft Installation Idler Chain Adjustment Idler Chain Lubrication

Idler Chain Removal 1. Perform the servicing procedure, Removing the Firewall. 2.

Loosen off the power pack frame

On 6x6 vehicles manufactured prior to S8131, locate and loosen off the four 1/2"20x1.5" power pack frame mounting bolts. Refer to Section 4.0 Power Pack Assembly Illustration in the appropriate parts manual. There is one located on each side of the power pack frame in front of the idler axles, and one visibly located on each side of the power pack frame, behind the idler axles. These bolts are threaded into nuts welded to the lower frame assembly.

On ARGOS manufactured from SN7841, S8131 and all RB, CB, BF & C vehicles, Loosen the locknut in front and behind the idler axles. These are threaded to 2 mounting bolts inserted through the power pack frame from right to left and attached at the lower frame. Photo WA-46

Next loosen off the idler chains.

WA-46 On 6x6 models produced from S7304 and prior to S8131, undo the jam nuts at the chain tensioner bolts and using an allen head wrench, turn the adjustment bolts counter-clockwise to lower the back end of the power pack frame. This will slacken the idler chains and allow for easy removal.

6x6 Models prior to S7304, require a 3/4" socket on the adjustment bolt head to lower the power pack frame.

On ARGOS manufactured from SN7841, S8131 and all RB, CB, BF & C vehicles, locate the two 3/8"-16x3" bolts threaded into the lower frame channel beneath the rear power pack mounting bolt. Turn each of these clockwise to lower the rear of the power pack frame assembly. Photo WA-47

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Argo Service Manual

WA-47

WA-48

Place the vehicle in neutral gear and roll the vehicle until the connecting link on the idler chain is half way between the brake disc sprocket and the idler assembly sprocket. Photo WA-48

Using a small slot screwdriver, pry off the clip securing the connecting link to the chain.

The left hand side idler chain may prove easier to remove if the driven clutch is removed first. Perform the servicing procedure, Driven Clutch Removal, in section CS of this service guide. 6.

Remove the connecting link taking care to collect the end cap and 2 internal spacers that are installed between the double 40 or 50 chain.

Slide the idler chain free of the brake disc and idler shaft assembly. It may be necessary to roll the vehicle forward or backward to achieve this.

If the vehicle can be raised off the ground, the wheels can be easily rotated to remove and reinstall any of the chains in the drive train system. Idler Chain Cleaning Maintenance Schedule-Clean every 100 hours of vehicle operation. 1.

Perform the servicing procedure, Idler Chain Removal.

Clean the chain with a strong solvent such as varsol. This will remove all chain lube, dirt, and accumulated grease.

Never use gasoline as a cleaning solvent. Gas is extremely flammable and can explode if ignited, causing serious personal injury or death. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

WA-22

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Allow the idler chain to dry.

Perform the servicing procedure, Idler Chain Inspection

Perform the servicing procedure, Idler Chain Installation

Perform the servicing procedure, Idler Chain Lubrication

Idler Chain Inpsection

The idler chains will stretch and wear after extensive vehicle use. If not regularly inspected, adjusted and maintained, loose or worn idler chains will cause a reduction in vehicle performance, damage to idler and brake disc sprockets, and a hazard to personal safety. Please inspect regularly. 1.

Perform the servicing procedure, Removing the Firewall.

Inspect the idler chains and adjust if: •

the idler chains deflect more than 1/8". Photo WA-49

Perform the servicing procedure, Idler Chain Adjustment. 3.

Inspect the idler chains and replace if: • the idler chain deflects more than 1/8" and further adjustment is no longer available. • the chain is seized up, corroded or rusted. • the brake disc sprockets are worn or damaged • the idler shaft sprockets are worn or damaged

WA-49

If the idler chains need replacing, perform the servicing procedure, Idler Chain Removal and the procedure, Idler Chain Installation.

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Wheels, Axles & Chains 5.

Argo Service Manual

Perform the servicing procedure Installing the Firewall.

Idler Chain Installation 1.

Rotate the power pack adjustment bolts. This will lower the brake disc sprocket toward the idler sprocket assembly. See the servicing procedure, Idler Chain Removal on Page WA-20 step 3.

Place the transmission in neutral.

Feed one end of idler chain under the idler assembly sprocket. It may be necessary to roll the vehicle forward or backward to achieve this. If the vehicle can be raised off the ground, the tires may be rotated either way by hand to accomplish the same thing.

Place the free end of the idler chain around the brake disc sprocket.

Rotate the idler chain until the open links are halfway between the idler sprocket and brake disc sprocket.

While holding the two open links together, insert the connecting link and assemble 2 connecting link plates to the center of the double 40 or 50 chain. Photo WA-50

Gently push the connecting link through the second set of open links and attach the remaining end link plate.

Secure the assembly with the connecting link clip, with the split end of the clip facing down. Photo WA-51

WA-50

WA-51

Ensure that the connecting link clip has been properly installed. Failure to install this clip correctly could result in severe damage to vehicle drive train components and costly repairs. Use a small technicians mirror to correctly view the clip after it has been installed. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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10. Tension the idler chains

6x6 Models prior to S7304 will require a 3/4" socket on the adjustment bolt head to raise the power pack frame.

On 6x6 models produced from S7304 and prior to S8131, use an allen head wrench to turn the adjustment bolts clockwise. This will raise the back end of the power pack frame and begin to tension the idler chains.

IMPORTANT When adjusting idler chain tension, be sure to always alternate between each adjustment bolt, turning each a little at a time. i.

Adjust the chains until the amount of deflection in both idler chains is less than 1/8" (3mm) See Photo WA-49 on page WA-22

ii.

Secure the jam nuts of each tensioner bolt.

iii. Tighten all power pack mounting bolts. iv.

Perform the servicing procedure, Installing the Firewall.

On ARGOS manufactured from SN7841, S8131 and all RB, CB, BF & C vehicles:

Locate the two 3/8"-16x3" bolts threaded into the lower frame channel beneath the rear power pack mounting bolt. Turn each of these counter-clockwise to raise the rear of the power pack frame assembly and tension the idler chains. See Photo WA-47 on page WA-21

ii.

Adjust the chains until the amount of deflection in both idler chains is less than 1/8" (3mm) See Photo WA-49 on page WA-22

iii. Tighten all power pack mounting bolts. iv.

Perform the servicing procedure, Installing the Firewall.

Idler Chain Adjustment DO NOT over-tighten the idler chains. Chain deflection should be as described on page WA-22. However, a loose idler chain can result in worn chain links, worn or broken teeth on the idler or brake disc sprockets, a reduction in vehicle performance and personal hazard to the operator. Please inspect the idler chain regularly. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Argo Service Manual

Perform the servicing procedure, Removing the Firewall.

Check the deflection of the idler chain. If it deflects more than 1/8", adjust the tension immediately.

Loosen off the power pack frame.

Adjust the chain tension

On 6x6 models produced from S7304 and prior to S8131, undo the jam nuts at the chain tensioner bolts and using an allen head wrench, turn the adjustment bolts clockwise to raise the back end of the power pack frame. This will tighten the idler chains. Models prior to S7304 will require a 3/4" socket on the adjustment bolt head to raise the power pack frame.

On ARGOS manufactured from SN7841, S8131 and all RB, CB, BF & C vehicles, locate the two 3/8"-16x3" bolts threaded into the lower frame channel beneath the rear power pack mounting bolt. Turn each of these counter-clockwise to raise the rear of the power pack frame assembly. See Photo WA-47 on page WA-21

IMPORTANT When adjusting idler chain tension, be sure to always alternate between each adjustment bolt a little at a time. DO NOT over-tighten the idler chains. 5.

Refering to Photo WA-49 on page WA-22, tension the chains until the amount of deflection is less than 1/8"

Secure the jam nuts of each tensioner bolt. (Prior to S8131 6x6’s only).

Tighten all power pack mounting bolts.

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Perform the servicing procedure, Installing the Firewall.

Removing the Idler Shaft (Conquest, Response, Bigfoot & Conquest 6x6)

IMPORTANT Idler shafts on Conquest, Response, Bigfoot & 6x6 Conquest models manufactured from S/N CB16970, RB17033, BF11543 & V6016200000C12747, utilize 1 retaining ring on each shaft. These are seated to a machined groove on each of the shafts. One idler shaft has an “inboard” retaining ring and the other an “outboard” retaining ring. A better explanation of these retaining rings is discussed in the servicing procedure, Removing the Idler Shaft, for those vehicles manufactured in the above serial number range. This retaining ring minimizes the amount the floating sprocket can float. Vehicles prior to the above serial numbers do not have these retaining rings installed to the idler shafts. The newer style idler shaft is fully exchangeable with the earlier ones, however, during reassembly of the floating sprocket to the newer idler shaft, it should be noted that it is installed facing opposite to the way it was originally installed on the older style shaft. Earlier sprockets were installed with the set screw hole facing outwards. The newer style shaft requires the sprocket to be installed with the set screw hole facing inwards. 1.

Perform the servicing procedure, Removing the Firewall.

Perform the servicing procedure, Removing the Battery & unbolt the battery holder from the lower frame, (Right side idler shaft only), in section ES.

Perform the servicing procedure, Removing the Driven Clutch, (Left side idler shaft only), in section CS. (Optional, if you find it easier to access the idler shaft)

Remove the brake caliper (mechanical or hydraulic) on the side of the idler shaft being removed. You do not have to disconnect the brake line from the hydraulic caliper. Refer to steps 1 through 4 of Removing the Brake Pads, in the brake section of this service guide. (Optional as above)

Perform the servicing procedure, Idler Chain Removal.

Perform the servicing procedure, Removing the Brake Disc in section BR. (Optional, if you find it easier to access the idler shaft)

Perform the servicing procedure, Drive Chain Removal. Remove the front drive chain connecting the front wheel to the idler axle, as well as the drive chain connecting the middle (6 wheel) or mid/front (8 wheel) to the idler axle. Photo WA-52

Locate the 2 set screws on the inner and outer bearings and remove.

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WA-27

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Argo Service Manual

With the set screws removed, pry the idler axle until it slides freely by hand within the inner and outer bearing. Photo WA-53

WA-52

WA-53

Â&#x2039;

On vehicles manufactured prior to S/N CB16970, RB17033 and BF11543:

Remove the hardware securing the flanges of the inner and outer bearings. Photo WA-54

ii.

Slide the idler shaft assembly towards the inner bearing, and lift up and out at the outer bearing and flange assembly. Photo WA-55

WA-54

WA-55

iii. Move the idler shaft assembly to a clean work area and remove the bearings, flanges and the floating double sprocket. Photo WA-56

WA-56

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On vehicles manufactured from S/N CB16970, RB17033, BF11543 and C Vehicles: Argos manufactured from the above serial numbers utilize a retaining ring on each idler axle shaft. The left hand side idler axle shaft has 1 retaining ring which is “outboard” to the floating double sprocket. The right hand side idler axle shaft has a retaining ring which is “inboard” to the floating double sprocket. Photo WA-57 & 58 i

For the left side idler shaft, you will need to pull the retaining ring away from the floating sprocket, towards the end of the spline. Photo WA-59

WA-57 ii.

WA-58

Push the idler shaft into the inner bearing, and lift up and out at the bearing and flange assembly on the opposite end of the shaft. Photo WA-60

WA-59

WA-60 iii. For the right hand side idler shaft, you will need to pull the floating sprocket towards you as far as the spline of the shaft will allow. iv.

With a retaining ring pliers pull the inboard retaining ring back and up against the sprocket. Photo WA-61

Push the idler shaft into the inner bearing, and lift up and out at the bearing and flange assembly on the opposite end of the shaft. Photo WA-62

iv.

Move the idler shaft assembly to a clean work area and remove the bearings, flanges, retaining ring, and the floating double sprocket.

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WA-61

Argo Service Manual

WA-62

Removing the Idler Shaft (Vanguard & Vanguard2 Models) Idler shaft assemblies on Vanguard and Vanguard2 vehicles are 1 piece assemblies. There is no floating sprocket.

IMPORTANT When replacing 6x6 Vanguard idler axle assemblies, as in any ARGO vehicle component, it is extremely important to always refer to the correct vehicle parts manual. Refer to the vehicle serial & model plate number and use the corresponding parts manual. This will identify and ensure that the correct idler axle assembly has been installed. E.g. Earlier 6x6 Vanguard vehicles manufactured prior to S/N S8131 utilized a different tooth ratio on the idler axle shaft assembly. Using a newer 6x6 Vanguard idler shaft in an earlier 6x6 Vanguard vehicle, would result in the drive chain from the idler shaft sprocket to the front wheel sprocket, being too loose. The same result would be noticeable at the idler chains, between the brake disc sprocket, and idler shaft sprocket. 1.

Perform the servicing procedure, Removing the Firewall.

Perform the servicing procedure, Removing the Battery, in section ES, and unbolt the battery holder from the lower frame (Right side idler shaft only), in section ES. (Vehicles prior to S/N S8131 have the battery box welded to the lower frame.)

Perform the servicing procedure, Removing the Driven Clutch, (Left side idler shaft only), in section CS. (Optional, if you find it easier to access the idler shaft)

Remove the brake caliper (Mechanical or hydraulic) on the side of the idler shaft being removed. You do not have to disconnect the brake line from the caliper on the Vanguard2 hydraulic brake system. Refer to steps 1 through 4 of Removing the Brake Pads in the brake section of this service guide. (Optional as above)

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Perform the servicing procedure, Idler Chain Removal.

Perform the servicing procedure, Removing the Brake Disc in section BR. (Optional, if you find it easier to access the idler shaft).

Perform the servicing procedure, Drive Chain Removal. Remove the front drive chain connecting the front wheel to the idler axle, as well as the drive chain connecting the center wheel to the idler axle. Photo WA-63

Locate the 2 set screws on the inner and outer bearings and remove. Photo WA-64 & 65

WA-63 9.

WA-64

Using a pry bar at the outer bearing, pry the idler axle assembly towards the inner bearing to loosen up the shaft. Photo WA-66

10. Remove all the hardware from the inner and outer bearing flanges. Â&#x2039;

On vehicles manufactured prior to S10178 & SN10191:

Slide an open end wrench between the lower body and frame, at the outer idler axle bearing flange assembly. Hold the head of the bolt while removing the 2 nuts and lockwashers.

ii.

Remove the hardware on the flange of the inner bearing.

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Argo Service Manual

On vehicles manufactured from S10178 & SN10191:

Remove the 4 nuts and lockwashers at the flange assembly securing the inner and outer idler axle bearings.

11. Slide the idler shaft assembly towards the inner bearing, and lift up and out at the outer bearing and flange assembly. Photo WA-67

WA-67

12. Remove the assembly to a clean work area and separate all components. Idler Shaft Inspection Maintenance Schedule - Inspect every 30 hours of vehicle operation

Damage to the idler shaft and sprockets can result from loose idler chains or sprocket misalignment. Please inspect regularly. 1.

Perform the servicing procedure, Removing the Firewall in section VB.

Inspect the sprockets on the idler shaft thoroughly for:

cracks in the casting worn, broken or missing teeth

If any of these conditions are noted, replace the idler shaft (Vanguard or Vanguard 2 models) and/or the floating sprocket (Conquest, Bigfoot, Response or 6x6 Conquest models) immediately.

IMPORTANT

If any wear is noted on the idler shaft or it’s components, it is advisable to check the brake disc drive sprocket as well to ensure that the misalignment has not caused any damage to this drive component either.

When ordering a replacement idler shaft assembly, please note that different ARGO models use different idler assemblies. Refer to the correct parts manual to ensure the correct replacement part. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Argo Service Manual

Wheels, Axles & Chains

Inspect the idler shaft thoroughly for:

bends rust or corrosion cracks or breaks in the welding joints. (Vanguard and Vanguard2 only)

If any of these conditions are noted, replace the idler shaft immediately. Inspect all the idler shaft fittings for:

seized or worn bearings loose set screws at the bearings loose inner or outer flanges

Replace any seized or worn bearings. Perform the servicing procedure, Removing the Idler Shaft and Installing the Idler Shaft to do this. For all loose but otherwise good idler shaft fittings, perform the servicing procedure, Idler Shaft Alignment. (Vanguard and Vanguard2 models only) Installing the Idler Shaft (Conquest, Response, Bigfoot & Conquest 6x6)

IMPORTANT Idler shafts on Conquest, Response, Bigfoot & 6x6 Conquest models manufactured from S/N CB16970, RB17033, BF11543 & V6016200000C12747 utilize 1 retaining ring on each shaft. These are seated to a machined groove on each of the shafts during assembly of the floating sprocket. The right hand side idler shaft has an “inboard” retaining ring, while the left hand side has an “outboard” retaining ring. Vehicles prior to the above serial numbers do not have these retaining rings installed to the idler shafts. The newer style idler shaft is fully exchangeable with the earlier ones, however, during reassembly of the floating sprocket to the idler shaft, it should be noted that it is installed facing opposite to the way it was originally installed on the older style shaft. Earlier sprockets were installed with the set screw hole facing outwards (towards the outer bearing). The newer style shaft requires the sprocket to be installed with the set screw hole facing inwards (towards the inner bearing).

If reinstalling the original idler shaft and floating sprocket assembly, it would benefit at this time to wash the idler shaft and floating sprocket in a varsol bath to eliminate any accumulated grease or dirt & debris build up between the teeth of the double sprockets. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Argo Service Manual

Begin by applying anti-seize compound along the spline of the idler shaft, as well as at both ends where inner and outer bearings are installed.

Assemble a flange to both inner and outer bearing mount studs on the lower frame. Photo WA-68

Place a gasket to each of the previouly installed flanges. Photo WA-69

WA-68

WA-69

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On vehicles manufactured prior to S/N CB16970, RB17033 and BF11543:

Assemble the floating sprocket to the idler shaft with the set screw side facing outwards (towards the outer bearing). Photo WA-70

ii.

Slip the greasable flange to the same side as the sprocket. Photo WA-71

WA-70

WA-71

iii. Slip the inner bearing on to the shaft with the set screws and collar facing towards the sprocket. Photo WA-72 iv.

Install a greasable flange and the outer bearing to the opposite side of the shaft, once again facing the collar and set screws of the bearing inwards. Photo WA-73

Take note of the machined indents on this end of the shaft. Bearing set screws are aligned and secured at these locations in a later assembly operation. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

WA-34

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WA-73

WA-72 v.

Install the idler shaft assembly into the vehicle. Slip the inner bearing end of the shaft in first, then drop the outer bearing end connecting bearing and flanges to the studs. Photo WA-74

IMPORTANT Ensure that the greasable flanges are installed with the greaseable fitting facing up. Photo WA-75

WA-74

WA-75

vi. Install all bearing flange hardware and tighten securely. Torque to specifications

vii. Align the 2 set screw holes of the outer bearing with the 2 machined countersinks of the idler shaft. Apply blue 242 LOCTITE to both hole and threads of the set screw and install. Photo WA-76 Torque to specifications.

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WA-35

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Argo Service Manual

Align the 2 set screw holes of the inner bearing, with the lower part of the spline on the idler shaft. Apply blue 242 LOCTITE to the holes, as well as the threads of the set screws, and install. Torque to specifications. Photo WA-77

On vehicles manufactured from S/N CB16970, RB17033, BF11543 & V6016200000C12747:

WA-77

Left Hand Side Idler Axle i.

Slip the “outboard” retaining ring on to the idler shaft past both machined grooves (vehicles manufactured from 2007 will have (4) machined grooves on this idler shaft), and to the end of the spline. Photo WA-78

ii.

Next, install the floating sprocket with the set screw hole facing inwards (towards the inner bearing side). Place it up against the retaining ring. Photo WA-79

WA-78

WA-79

Right Hand Side Idler Axle iii. Install the floating sprocket with the set screw hole facing inwards (towards the inner bearing side). Slip it on as far as it will go. Photo WA-80 iv.

Install the “inboard” retaining ring up against the sprocket. Photo WA-81

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WA-36

WA-80

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WA-81 ii.

WA-82

Slip the greasable flange to the same side as the sprocket. Photo WA-82

iii. Slip the inner bearing on to the shaft with the set screws and collar facing towards the sprocket. Photo WA-83 iv.

Install a greasable flange and the outer bearing to the opposite side of the shaft, once again facing the collar and set screws of the bearing inwards. Photo WA-84

Install the idler shaft assembly into the vehicle. Slip the inner bearing end of the shaft in first, then drop the outer bearing end connecting bearing and flanges to the studs. Photo WA-85

IMPORTANT

Ensure that the greasable flanges are installed with the greaseable fitting facing up. Photo WA-86

WA-83

WA-84

WA-85

WA-86

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Argo Service Manual

vi. Install all bearing flange hardware and tighten securely. Torque to specifications. vii. Seat the "outboard" and "inboard" retaining rings to the grooves on the idler shaft. If Idler shaft has (4)four machined retaining ring grooves, refer to Supplement Pages WA- 36A for correct retaining ring groove location. viii. Align the 2 set screw holes of the outer bearing with the 2 machined countersinks of the idler shaft. See photo WA-76 on page WA-34. Apply blue 242 LOCTITE to both hole and threads of the set screw and install. Torque to specifications. ix. Align the 2 set screw holes of the inner bearing, with the lower part of the spline on the idler shaft. Apply blue 242 LOCTITE to the holes, as well as the threads of the set screws, and install. Torque to specifications. Photo WA-87

WA-87

Perform the servicing procedure, Drive Chain Installation. Install the front drive chain connecting the front wheel to the idler axle, as well as the drive chain connecting the middle (6 wheel)or mid/front (8 wheel) to the idler axle.

Perform the servicing procedure, Idler Shaft Bearing Lubrication.

Perform the servicing procedure, Installing the Brake Disc in section BR.

Perform the servicing procedure, Idler Chain Installation.

Reinstall the brake caliper. The brake caliper should still be connected to the brake line.

Before installing the caliper, make sure that the brake caliper pistons and pads are spread far enough apart to accommodate the thickness of the brake disc when the caliper is slipped back into position, and remounted to the transmission. 9.

Perform the servicing procedure, Installing the Driven Clutch, (Left side idler shaft only), in section CS.

10. Perform the servicing procedure, Installing the Battery, and re-fasten the battery box at the lower frame (Right side idler shaft only). Vanguards prior to S8131 have a welded battery box. If the brake caliper was disconnected from the hydraulic system, perform the servicing procedure, Bleeding the Hydraulic Brake System in section BR Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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11. Perform the servicing procedure, Installing the Firewall in section VB. Installing the Idler Shaft (Vanguard & Vanguard2 Models)

IMPORTANT 6x6 Vanguard and Vanguard2 idler axles, unlike those used on Conquest, Response, Bigfoot or Conquest 6x6, have a distinct left and right hand side. When replacing an idler axle, keep this in mind and order accordingly. 1.

Place the inner flange to the studs located beneath the power pack frame. Photo WA-88

Place a gasket to the previously installed flange. Photo WA-89

Assemble the greasable flange to the idler axle assembly.(Larger diameter sprocket end). WA-90

Slip the inner bearing to the same end as the greasable flange, with the collar facing in. Photo WA-91

WA-88

WA-89

WA-90

WA-91

Install inner flange, bearing, and outer flange to the opposite end of the idler shaft. Photo WA-92 See note following page.

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Argo Service Manual

On vehicles manufactured from S10178 & SN10191 both inner and outer flanges are greasable. Earlier models only utilize the greasable flange at the inner bearing.

WA-92

WA-93

Install the idler shaft assembly into the vehicle. Slip the inner bearing end of the shaft in first, then drop the outer bearing end, connecting bearing and flanges to the studs. Photo WA-93

Install all mounting hardware to the flanges and tighten securely. Torque to specifications.

On vehicles manufactured prior to S/N S10178 & SN10191, slide an open end wrench between the lower body and frame at the outer idler axle bearing flange assembly. Hold the head of the bolt while tightening the mounting hardware. 8.

Install the brake disc. Depending on the year of vehicle, the output shafts and brake discs may either be keyed or splined (See NOTE at bottom of page BR-38). Apply blue 242 LOCTITE to the threads of the mounting bolt and secure with lockwasher and flat washer. The brake disc bolt will be easier to torque later once the calipers have been installed and applied to hold it secure.

IMPORTANT Apply anti-seize to output shafts before installing the brake discs. Aligning the Idler Shaft (Vanguard & Vanguard2 Models) 9.

Idler shafts must be aligned with the brake disc sprocket using a square and V Block.

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10. Place the V block and square on to the idler shaft, pushing the square up against the inner drive sprocket. Photo WA-94

WA-94

WA-95

11. Tap the idler shaft using a soft face mallet until the square contacts the upper sprocket. Photo WA-95 12. Once aligned, the idler shaft must be drilled at the two bearing set screw locations of the inner bearing. Using a 3/16" drill bit, drill the idler shaft axle using the set screw hole as a guide. The idler shaft need only be drilled enough to provide a good seat for the set screw when it is installed.

Use extreme caution when drilling to prevent any damage to the inner bearing set screw threads. Be sure drilling is done perpendicular to the shaft and does not come into contact with the threads of the set screw holes. 13. Apply Red 271 LOCTITE to the set screw threads and holes of the inner & outer bearings and tighten securely. Torque to specifications. 14. Perform the servicing procedure, Drive Chain Installation. Install the front drive chain, connecting the front wheel to the idler axle, as well as the drive chain connecting the middle (6 wheel)or mid/front (8 wheel) to the idler axle. 15. Perform the servicing procedure, Idler Shaft Bearing Lubrication. 16. Perform the servicing procedure, Installing the Brake Disc in section BR. 17. Perform the servicing procedure, Idler Chain Installation. 18. Reinstall the brake caliper. The hydraulic brake caliper (Vanguard2), should still be connected to the brake line. See NOTE following page. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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WA-41

Wheels, Axles & Chains

Argo Service Manual

Before installing the hydraulic caliper(Vanguard2), make sure that the brake caliper pistons and pads are spread far enough apart to accommodate the thickness of the brake disc when the caliper is slipped back into position, and remounted to the transmission. 19. Perform the servicing procedure, Installing the Driven Clutch, (left side idler shaft only), in section CS. 20. Perform the servicing procedure, Installing the Battery, and re-fasten the battery box at the lower frame (Right side idler shaft only), Vanguards prior to S8131 have a welded battery box.

If the brake caliper was disconnected from the hydraulic system (Vanguard2), perform the servicing procedure, Bleeding the Hydraulic Brake System, in section BR 21. Perform the servicing procedure, Installing the Firewall, in section VB.

Do not use high pressure or excessive amounts of grease. Damage to the bearing seals could result. Idler Shaft Bearing Lubrication - All Models The idler shaft bearing flanges are fitted with grease fittings. These bearings should be greased with a small amount of a lithium based grease, NLGI #2 or #3 mineral oil (such as Shell Alvania #3) every 100 hours of operation or whenever major maintenance is performed on the vehicle. The grease fittings become more accessible when the idler chains are removed. Alternatively, ARGO Part# 658-16 Right Angle Coupler, can be used to access these fittings (also sold at automotive supply stores as a Right Angle Grease Coupler, Thexton part no. 418) Photo WA-96 & 97

WA-96 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

WA-42

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Argo Service Manual

Wheels, Axles & Chains

Removing an Axle (Without Bearing Extension) 1.

Locate the axle to be removed and perform the servicing procedure, Removing the Drive Chains.

Locate the bolt threaded to end of the axle at the inner bearing and remove. Photo WA-98

6x6 Vanguard vehicles manufactured prior to S/N S7447 do not utilize axles with this end bolt design.

WA-98

Remove the 2 set screws from the inner bearing collar. Photo WA-99

Remove the set screw from the drive sprocket. Photo WA-100 (Except for all front sprockets which float)

Front axles on Vanguard 6x6's manufactured prior to S/N S8131 are not splined. These axles and sprockets are keyed and allow the front sprocket to float. Loosen the set screw on the locking collar used to limit the amount the sprocket can float.

WA-99 5.

WA-100

Remove all hardware securing the flanges of both inner and outer bearings. Photo WA-101

Depending on the axle and location of the drive sprocket, you may have to slide the sprocket along the axle to better access the hardware of the flanges with your wrenches. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Wheels, Axles & Chains

Argo Service Manual

Remove the tire from the axle.

Pull the axle from the vehicle. If necessary use a soft faced mallet to knock the axle at the hub, from behind. Photo WA-102

Retrieve the drive sprocket from inside the vehicle once the axle has been completely removed from the vehicle.

Remove the axle assembly to a clean work bench for further disassembly

10. Remove gaskets and flanges. 11. Remove the set screws of the outer bearing and slide the bearing from the axle. If the bearing does not slide off freely, an arbor press may be needed. Photo WA-103

WA-102

WA-103

12. Remove the greasable flange. Removing the Axle Seals 1.

Perform the servicing procedure, Removing the Axle (With bearing Ext.) or (Without Bearing Ext.)

Remove the seals from the greasable flange using a hammer and drift punch. Photo WA-104

WA-104

6x6 Vanguards manufactured prior to S/N S7447 have only a single seal in the outer bearing greasable flange. Later 6x6 models,as well as all other models, have 2 grease seals in the outer bearing greasable flange. Single seal outer bearing greasable flanges are no longer available and must be updated to the to the double seal if replaced. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Clean the cavity of the greasable flange in a varsol bath to remove any accumulated dirt and grease.

Blow the greasable flange with compressed air to thoroughly dry and remove any remaining dirt.

Installing the Axle Seals 1.

Before you can install the new seal to the greasable flange, you must debur the area in which the grease seal was staked. Use a small pencil die grinder to remove the staked area. Photo WA-105

Do not debur the flange excessively. Over-grinding could produce a loose fitting seal, resulting in a poorly sealed axle.

WA-105

WA-106

On single seal greasable flanges: 1.

Lightly coat the perimeter of the seal with some red 271 LOCTITE.

Orient the seal, face down, and using an arbor press and installation tool, press the seal into the greasable flange ensuring that it has seated to the shoulder in the flange. Photo WA-106

WA-107

Using a center punch and hammer, lightly stake around the perimeter of the seal in as many places as were used previously. Photo WA-107

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Argo Service Manual

WA-108

WA-109

On dual seal greasable flanges: There are 2 different styles of grease seals used in the dual seal outer bearing greasable flange. Photo WA-108 These grease seals are differentiated in size & by 2 part numbers. Assemble the seals into the flange accordingly referring to the illustration in your corresponding parts manual. 1.

Lightly coat the perimeter of the outer grease seal with red 271 LOCTITE and install at the arbour press with an installation tool. Be sure it is seated properly. Photo WA-109

Apply red 271 LOCTITE to the inner seal as above, and install at the arbor press in the same manner, ensuring it has seated to the shoulder within the outer greasable flange. Photo WA-110

WA-110

Using a center punch and hammer, lightly stake around the perimeter of the inner seal in as many places as were used previously. Photo WA-110

Installing an Axle (Without Bearing Extension) 1.

Perform the servicing procedure, Installing the Inner Bearing Assembly, if necessary.

Locate the axle and stand it upright on a clean work bench. Photo WA-111

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Slip the outer bearing greasable flange over the axle shaft. Photo WA-112

Slip the outer bearing over the axle shaft, orienting it with the collar facing up. Photo WA-113

Align the flat machined surface closest to the sprocket end of the axle, with the set screw hole of the bearing. Apply 242 blue LOCTITE to the threads of the set screw and install. Torque to specifications. Photo WA-114

Install the second set screw as above.

Fill the outer bearing cavity with axle grease.

WA-112

WA-113

WA-114 8.

Pull the outer flange up and against the bearing, taking note of the small hole in the bearing. Align this hole with the greasable fitting on the flange. Photo WA-115 & 116

Apply anti-seize compound to the spline of the axle.

WA-115

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Argo Service Manual

10. Place a cork gasket on to the outer flange. Photo WA-117 11. Place the inner flange on top of the cork gasket. Photo WA-118 12. Place a second gasket to the top of the inner flange. Photo WA-119 13. Assemble the 4 carriage bolts to the outer flange and install the axle assembly into the lower body and frame. Orient the greasable fittings so that the outer grease fitting is at the 9 o'clock position, and the inner one is at12 o'clock. Photo WA-120

If you have a single seal greasable flange, the fitting is at 12 o'clock.

WA-117

WA-119

WA-118

WA-120

14. Locate the drive sprocket and slip it on to the axle with the set screw hole facing to the inside. Photo WA-121 Be sure that the set screw hole of the sprocket, is aligned with the spline on the axle with the machined countersinks. 15. Align the end of the axle with the inner WA-121 bearing. Push the axle the remaining way and install the flange hardware. Photo WA-122 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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WA-122

WA-123

16. Tighten down the hardware of both inner and outer bearing flanges. Torque to specifications. 17. Secure the sprocket to the axle shaft. Line up the countersink in the axle shaft with the set screw in the sprocket. Apply blue 242 LOCTITE to the threads of the set screw and tighten. Torque to specifications. Photo WA-123 (All front drive sprockets are floaters and do not require the set screw.) 18. Install the bolt and flat washers to the end of the axle. Apply blue 242 LOCTITE to the threads of the bolt and torque to specifications. Photo WA-124 See NOTE top of page WA-41 regarding 6x6 Vanguards prior to S7447 19. Apply blue 242 LOCTITE to the threads of the 2 set screws of the inner bearing and install. Torque to specifications. .

WA-124

Â&#x2039;

Keyed Front Axles - used on Vanguard 6x6's manufactured prior to S/N S8131:

Assemble the keys to the axle shaft and apply anti-seize to the keyed area.

ii.

Slip the keyed sprocket on to end of the axle shaft with the longer shoulder side facing inwards. At the same time, align the keys on the axle shaft with the keyways

iii. Slide the sprocket on followed by the locking collar used as a stop to limit the amount this sprocket may float. i.

Tighten down and torque all inner and outer bearing flange hardware. Install the front drive chain. Align the axle sprocket, with that of the sprocket on the idler axle.

ii.

Position the locking collar on the front axle shaft so that it limits the amount the front axle sprocket may float to the right of the axle shaft. Apply blue 242 LOCTITE to the set screw on the collar and tighten down securely. Back to step 18

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Argo Service Manual

20. Perform the servicing procedure, Outer Axle & Bearing Lubrication 21. Perform the servicing procedure, Inner Axle Bearing Lubrication Outer Axle Flange & Bearing Lubrication

Do not use high pressure pneumatic greasing equipment Each outer axle flange is equipped with two grease fittings. Grease the outer cavity through the outer fitting of each flange with a lithium based grease, NLGI #2 or #3 mineral oil (such as Shell Alvania #3) frequently, at least every 25 hours of operation, to flush dirt and water that may have entered the axle seal. Only a small amount of pressure should be required. Grease until any contamination has been forced out past the seal and fresh grease is visible. At the same time, inspect all the axle seals for damage. Vegetation wrapping around the axles can damage the rubber lip of the seal, allowing dirt and water into the outer cavity. Perform the servicing procedure, Removing the Axle Seals if they need to be replaced. The second or inner grease fitting of the outer axle flange supplies grease directly to the outer axle bearing. Since the bearing is well sealed and packed with grease when manufactured, it requires re-greasing only every 100 hours of operation or before the vehicle is taken out of service for any extended period. Use a pistol grip type grease gun to avoid dislocating the bearing seals due to excessive grease pressure. Inner Axle Bearing Lubrication The inner axle flanges are equipped with a grease fitting. Lubricate the bearings with a small amount of a lithium based grease, NLGI #2 or #3 mineral oil (such as Shell Alvania #3)or equivalent every 100 hours or before the vehicle is taken out of service for any extended period. Only a small amount of grease is required. 22. Install the tire and torque the nuts to specification. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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23. Perform the servicing procedure, Installing the Drive Chain. Removing an Axle (With Bearing Extension) Response, Bigfoot and Conquest 6x6 vehicles, are manufactured with a cast aluminum bearing extension assembled to the front axles. The Conquest 8x8 model utilizes these extensions at both front and rear axles. The same procedure used for removing a standard axle, can be used for removing an axle with a bearing extension. See servicing procedure, Removing an Axle on page WA-42. The bearing extension can remain bolted to the lower frame. Installing an Axle (With Bearing Extension) When installing the outer bearing to an axle with an aluminum bearing extension, it needs to be secured to the machined area on the axle closest to the wheel hub. Carriage mounting bolts are also longer and need to be assembled to the outer flange first before this bearing is secured to the axle. See Photo WA-127 on following page. There are also some differences in the mounting of the outer flanges to the extension with regards to components, depending on the date of manufacture. On Models manufactured prior to S/N CB19200, RB19204, BF13178 & C13176, there is no inner flange or second gasket assembled to the extension. Install gasket, then bearing and greasable flange. Photo WA-125 Vehicles manufactured from S/N CB19200, RB19204, BF13178 & C13176 require gasket, inner flange, second gasket, then outer bearing and greasable outer flange. Photo WA-126

IMPORTANT

This information is extremely important, especially if the aluminum extension has been replaced. Older style extensions are no longer available and must be replaced with the new design. These new extensions will require the extra components in reassembly.

WA-125 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Wheels, Axles & Chains

Argo Service Manual

Assemble the axle as shown in Photo WA-127

Install the axle assembly into the lower body and extension. Orient the greasable fittings so that the outer grease fitting is at the 9 o'clock position, and the inner one is at 12 o'clock. Photo WA-128

Locate the drive sprocket and slip it on to the axle with the set screw hole facing to the inside. Align the spline of the axle with the machined countersinks, with the set screw hole in the drive sprocket. Photo WA-129

WA-128

WA-127

WA-00 WA-129

IMPORTANT Drive sprockets on front axles of all models are free floating and do not require set screws to secure them to the axle shaft. 4.

Align the end of the axle, with the inner bearing. Push the axle the remaining way and install the flange hardware. Tighten down the hardware of both inner and outer bearing flanges. Torque to specifications. Install the bolt and flat washers to the end of the axle. Apply blue 242 LOCTITE to the threads of the bolt and torque to specifications. Photo WA-130

WA-130

Install the drive chains.

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Removing the Bearing Extension 1.

Perform the servicing procedure, Removing an Axle (With Bearing Extension).

Locate and remove the 6 bolts and flat washers securing the extension to the frame. Photo WA-131

Remove the extension.

Remove any old gasket that may still be present on the lower body from the previous extension. Clean the area thoroughly before assembling the new extension to the lower body frame.

WA-131

Installing the Bearing Extension 1.

Slip 6 bolts through the bearing extension mounting holes and install the gasket to the bottom of the extension. Photo WA-132

IMPORTANT Older style bearing extensions that have been replaced with the new design type, will WA-132 require a new style gasket as well. Vehicles manufactured from S/N CB19200, RB19204, BF13178 & C13176 feature this new design. Older design extensions are no longer available as a stock item. Photo WA-133 & 134

WA-133 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Argo Service Manual

Fasten the extension to the lower body. Torque ot specifications. Photo WA-135

Perform the servicing procedure, Installing an Axle (With Bearing Extension).

Removing the Inner Bearing 1.

Perform the servicing procedure, Removing an Axle, steps 1through 8. The axle needs to be pulled from the inner bearing to be serviced. The axle assembly should be pulled completely at this point so that the old gasket at the outer bearing flange may be replaced with a new one.

Remove the inner bearing flange hardware securing the bearing to the frame and remove the assembly to a clean work surface. Photo WA-136

WA-135

WA-136

Installing the Inner Bearing Assembling the Inner Bearing and Flange Assembly 1.

Place the bearing into the greasable flange with the set screw collar facing down. At the same time align the small hole in the bearing with the grease fitting in the flange. Photo WA-137

WA-137

IMPORTANT 6x6 Vanguards manufactured prior to S/N S7447, differ in axle and bearing setup. These vehicles require the inner bearing to be assembled to the greasable flange with the collar facing up, but still aligning the small hole in the bearing with the grease fitting in the flange.

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Argo Service Manual 2.

Wheels, Axles & Chains

Place a gasket to the top of the greasable flange. Photo WA-138

Vehicles manufactured from serial numbers A13984, R20470, C20468 & B13985 do not require this inner gasket due to a tooling change to the inner flange assembly. 3.

Place regular flange to the top of the gasket. Photo WA-139

WA-138 4.

WA-139

Assemble the bearing and flange assembly to the inner frame channel and secure with the appropriate hardware. Orient the grease fitting facing up. Photo WA-140 & 141

Be sure that the axle has been installed first to the inner bearing before tightening down and torquing all flange mounting hardware.

WA-140

WA-141

Perform the servicing procedure, Installing an Axle.

Perform the servicing procedure, Drive Chain Installation.

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Removing a Tire 1. Loosen each of the wheel nuts on the tire. 2.

Raise the vehicle off the ground and remove all 5 wheel nuts.

Pull the tire from the vehicle.

Wheel Disassembly

IMPORTANT Proper tools are required for tire removal 1.

Remove the valve core to deflate the tire.

Break both tire beads loose.

If it is difficult to break the bead, apply a soap and water solution or tire mounting lubricant to the rim periphery.

Do not damage the tire bead or rim bead seat. Damage to them will prevent proper sealing. 3.

Apply lubricant to both beads.

Use one tire iron to hold the bead and another to work the bead over the rim flange. Place the irons at close intervals, working only small bead sections at a time.

Remove the tire from the rim.

Tire Pressure Normal Cold Tire Pressure: 2.5 - 3 psi. Maximum (to seat bead): 32 psi. or listed on tire.

Tire pressure should be checked when tires are cold. A special low pressure gauge is available through your distributor, dealer or Ontario Drive & Gear Ltd.

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Tire Inspection Maintenance Schedule - Inspect every 25 hours of vehicle operation. Inspect the tires for: • proper tire inflation pressure • valve stem condition • good bead contact with rim • loose wheel nuts • cuts, puntures, excessive wear, etc. • leakage around the tire seal • bead damage • damaged wheel rims and wheel hubs

Replace damaged or worn tires immediately. When a pressure leak is suspected, locate it by spraying around the tire with a leak locating solution or placing in a tank of water. Tire Repair and Replacement

To repair or replace a tire you will need to remove it from the rim.

Use of a non-standard tire on any Argo model will affect the steering characteristics of the vehicle. Serious injury could result. Temporary Repair To temporarily repair a punctured tire, use the plug method. A plug kit, available from most automotive parts stores, will provide the parts, tools and instructions to carry out the repair. General Tire Repair To more permanently repair a damaged or punctured tire, apply a radial tire patch to the inside of the tire if the damage is less than 1/2" (12mm) in diameter. This type of kit is also available from most automotive stores. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Wheels, Axles & Chains

Argo Service Manual

Wheel Reassembly

Be sure the rim is clean and smooth 1.

Apply lubricant to the bead and rim bead seat.

Never use petroleum or silicon based solutions as lubricants. Rim slippage, bead damage or dislodging of the bead may result. Regular tire lube or a thin liquid soap and water solution works best. 2.

Work the bead over the rim flange with tire irons, small sections at a time.

Turn the tire over and work the other side on.

Use a safety cage and remote inflation control valve when seating a tire bead. NEVER stand near a tire when the bead is seating. NEVER exceed the recommended seating pressure. The tire can break with an explosive force which can cause serious injury or death. 4.

Inflate the tire until until each bead has popped and seated to the rim. If it doesn't pop immediately, leave it sit a few minutes under pressure. NEVER exceed the recommended pressure for seating the bead indicated on the tire. Inspect both beads for proper seating.

Install the valve stem and adjust to the proper pressure (2.5 - 3 psi.)

Install valve cap.

Valve Replacement 1.

Demount the outer bead. See servicing procedure, Wheel Disassembly, in this section of the service guide.

Push the valve out of the rim, towards the inside of the tire.

Insert the new valve from the inside of the tire, and pull it into place with a valve pulling tool. Be sure the valve seats evenly into the valve hole of the rim

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Argo Service Manual 4.

Wheels, Axles & Chains

Inflate the tire to remount the bead. See servicing procedure, Wheel Reassembly in this section of the service guide.

Wheel Installation 1.

Apply anti-seize compound to the threads of the axle hub studs.

Place the wheel on to the mounting studs.

Install the wheel nuts with the rounded end of the nut facing into the rim.

Tighten the nuts in a clockwise direction and torque to specifications.

Lower the vehicle to the floor.

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SECTION WA

Supplement Pages

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Wheels, Axles & Chains

Assembling The Idler Shafts To The Vehicle (Avenger Models Prior to 25622) 1.

Apply some LOCTITE anti-sieze compound to each end of the 810-32 idler shafts .

Right Hand Idler Shaft 2.

15A

Install a 606-72 idler sprocket to a 81032 idler shaft. Install it with the collar of the sprocket facing up. Photo 15A Next, install a 101-20 greasable flange followed by a 101-35 bearing to the opposite end of the shaft. Photo 15B

Face the collar of the 101-35 bearing towards the sprocket

15C 15B Left Hand Idler Shaft 1.

Install a 606-72 idler sprocket to a 81032 idler shaft. Install it with the collar of the sprocket facing down. Photo 15C Next, on the opposite end of the shaft install a 101-20 greasable flange followed by a 101-35 bearing. Photo 15D (See NOTE above).

Avenger Models From Serial # V23216 2.

Install the inner axle bearing assemblies to the inner bearing locations on both sides of the vehicle. This consists of a

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101-35 bearing, 101-80 right angled greasable flange & 605-63 flange.. Photo 15E & F Secure Loosely with (4) flat washers and (4) nylon locknuts.

15E

15D

IMPOR TANT IMPORT Avenger models manufactured from serial number V23216 have 90 degree greasable fittings oriented as follows: The left hand side, with the grease fitting located at the bottom, facing rearward, Photo 15E, and the right hand side located at the top, also facing rearward. Photo 15F

15F Avengers Manufactured Prior To Serial Number V23216 1.

Install a 101-35 bearing and 101-78RM swivel greasable flange to the previously installed 605-63 flange at the inner idler axle location, on both left and right side of the frame. Photo 15G Secure Loosely with (4) flat washers and (4)nylon locknuts.

15G

IMPOR TANT IMPORT The swivel grease fitting of the101-78RM is oriented to the bottom of the flange and facing towards the drivers compartment. Photo 15G 2.

Insert the grease tubing into the bulk head grease fitting. Photo 15 H See NOTE following page.

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There are 2 different lengths of grease tubing for the left and right hand side idler shaft assembly. See your Avenger parts manual for correct lengths.

15 H

15 I

Install the 100-111 bulk head fittings to the left and right side of the frame and connect the tube to the swivel grease fittings of the two inner bearings. Photo 15 I

Install the idler shafts to the vehicle, inserting the shaft first into the inner bearing and then attaching at the outer bearing. See orientation of sprocket collars below. Photo 15J & 15 K

15 J

15 K

Assembling Idler Shafts To The Vehicle (Avenger Models From Serial # 25622) 810-59 Idler Shafts used on later Avenger models have a retaining ring installed to each side of the idler shaft drive sprocket. These retaining rings help limit allowable movement of the idler sprocket under application. As these 810-59 Idler Shafts are also common to Conquest, Response and Bigfoot, there are (4) machined retaining ring grooves on each shaft to accommodate each of these models. However, placement of the retaining rings is dependant not only on model, but also whether it is a right hand side or left hand side idler shaft. See Diagrams A and B for correct retaining ring locations (circled) on Avenger models. Ontario Drive & Gear Limited WA-34A PH.(519)- 662-2840 FAX (519)- 662-2421

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Diagram A

Diagram B

Assembling Frontier Idler Shafts to Vehicle

Installation of the 606-78 Idler Shaft assembly on ARGO Frontier models requires the assembly of a 107-10 Retaining Ring to each side of the 606-81 Idler Sprocket. These retaining rings help limit allowable movement of the idler sprocket under application. Each 606-78 Idler Shaft has (4) four retaining ring grooves machined into the shaft to accomodate either a left hand side or right hand side idler shaft replacement. For correct retaining ring locations, refer to Diagram C and D

Diagram C

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Diagram D

Retaining Ring Locations For Conquest, Response and Bigfoot (810-59 Idler Shafts With (4) Retaining ring Grooves)

DIAGRAM E

DIAGRAM F

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Wheels, Axles & Chains

Removing the Front Axle (Avenger Model) 1.

Raise the vehicle off of the ground.

Remove the front tire.

Remove the firewall.Turn the quick release fastener located at the top of the firewall. Pull the top of the firewall rearward and into the drivers compartment.

Remove the front floor pan

Optional: If you wish to remove the drive belt and driven clutch, it may prove easier to access the inner axle bearing, and in general, provide a roomier working environment. Refer to the Clutch Section of the 673-04 Argo Service Guide

WA-1

Remove the drive chain between front sprocket and idler shaft sprocket. Photo WA-1 Refer to Drive Chain Removal in the 673-04 Argo Service Guide.

Remove the inner axle fastener and washer located at the inner bearing on the axle end. Photo WA-2

For ease of removal, place the closed end of the wrench at the fastener head while turning the axle at the wheel hub on the outside of the vehicle. Photo WA-3

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Argo Service Manual

Remove set screws at the inner bearing collar.

10. Loosen off the inner bearing flange hardware. 11. Remove the (4) nuts that secure the outer bearing greaseable flange. Photo WA-4

WA-4

WA-5

12. Using a soft faced hammer, tap the wheel hub from behind to remove the axle from the vehicle. Photo WA-5 & 6 The outer bearing, greasable flange,and axle will be removed as an assembly. Retrieve the drive sprocket from inside the vehicle once the axle has been completely removed from the vehicle.

WA-6

WA-7

13. Remove the set screws from the collar of the outer bearing. 14. Using an arbor press, press the bearing and greasable flange from the axle shaft. Photo WA-7 15. Clean all components in a varsol bath and inspect. 16. Perform the servicing procedure, Removing the Axle Seals, in the Wheels, Axles & Chain section of the 673-04 Argo Service Guide. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Installing the Front Axle (Avenger Models) 1.

Perform the servicing procedure, Installing the Axle Seals, in the Wheels, Axles & Chains section of the 673-04 Argo Service Guide.

Slip the greasable flange over the axle and slide it up close to the hub. Install the bearing to the shaft with the collar side facing up. Position it such that the set screw holes in the collar will be aligned and centred with the flat machined surface on the axle closest to the hub.

Loosen off or remove the set screws from the new bearing before slipping it on to the axle.

WA-9

WA-8

Apply Blue LOCTITE to the set screws and secure to the axle shaft. Torque to specifications. Photo WA-8

Fill the inner grease cavity with axle grease (Lithium based, NLGI #2 or 3 mineral oil based), using a hand grease gun. Photo WA-9

Set the greasable flange to the bearing aligning the grease fitting with the small hole in the bearing. Photo WA-10 & 11

WA-10

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WA-11

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Argo Service Manual

Install a cork gasket at the front aluminum axle extension followed by a steel inner flange and second cork gasket. Photo WA-12

WA-12

WA-13

Apply some anti-seize compound to the spline area of the axle shaft. Photo WA-13

Slip the axle assembly into the front bearing extension. Photo WA-14 On the inside of the vehicle, prepare to install the front sprocket as the axle is pushed through to the inner bearing.

IMPORTANT

The front axle sprocket is a "floater" and requires no set screws. Orient the sprocket with the larger shoulder facing towards the inside of the vehicle. Photo WA15

WA-14 9.

WA-15

Align the mounting holes of the greasable flange with the studs of the aluminum bearing extension and place into position up tight against the cork gasket. Photo WA-16

10. Install flat washers to the studs. Photo WA-17

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WA-16

WA-17

11. Secure with nylon locknuts and torque to specifications. Photo WA-18

WA-18

WA-19

12. Apply blue LOCTITE to the threads of the fastener (Photo WA-19), used to secure the end of the axle to the inner bearing and install. Photo WA-20 Torque to specifications. Refer to your illustrated parts manual for the breakdown of the hardware used.

WA-20 The example front axle replaced in this procedure was on the left side of the vehicle. The hardware used to secure the inner bearing flange assembly on this side, utilizes a longer fastener installed to the top left location. It is also installed from the opposite side as compared to the others. This is used for the installation of the optional accessory bilge pump. Photo WA-22 13. Apply blue LOCTITE to (2) bearing set screws and install into the bearing collar. Torque to specifications. Ontario Drive & Gear Limited WA-54A PH.(519)- 662-2840 FAX (519)- 662-2421

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Argo Service Manual

14. Turn the front tensioner cam assembly in the direction which winds up the torsion spring and push the assembly down as close as possible to the cam follower block across the bottom of the frame channels. Clamp it in this position with a Vice-Grip 10CR or similar plier as illustrated in WA-21 15. Perform the service procedure, Drive Chain Installation, found in the Wheels, Axle and Chains section of th 673-04 Argo Service Guide.

WA-21

16. If you removed the driven clutch and drive belt, reinstall. Refer to Driven Clutch Installation and Drive Belt Installation in the Clutch Section of your 673-04 Argo Service Guide. 17. Replace the firewall and floor pans.

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Fuel System

SECTION FS Fuel System Table of Contents General Instructions............................................................................. FS-2 Fueling the Vehicle................................................................................ FS-3 Removing the Fuel Tank (All Models, except Avenger)..................... FS-4 Removing the Fuel Tank (Avenger Models) Supplement Pages........FS-4A Vented Fuel System............................................................................... FS-4 Removing the Fuel Tank (6x6 Vehicles Prior to S7304).....................FS-7 Installing the Fuel Tank (All Models)..................................................FS-6 Installing the Fuel Tank (6x6 Vehicles Prior to S7304)......................FS-8 Inspecting the Fuel Tank and Fuel Line..............................................FS-6 Fuel Filter............................................................................................... FS-8

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FS-1

Fuel System

Argo Service Manual

General Instructions

Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual. Before performing a servicing operation, an individual must have determined to his/her satisfaction that a personal injury or vehicle damage will not result from the servicing procedure or tools selected.

Keep all open flame or spark away from the Argo while servicing the fuel system. Gasoline is extremely flammable, and can cause serious PERSONAL INJURY or DEATH. Before servicing the fuel tank or fuel line, drain or siphon the fuel tank. Perform all service work on the fuel system in a well ventilated area.

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Fueling the Vehicle

Gasoline is extremely flammable and can explode under certain conditions. Do not add fuel while the engine is running or hot. If fuel is spilled in, on or around the vehicle, wipe it up immediately. Flush out any fuel spilled in the vehicle with water and allow it to drain out through the drain plug holes. Do not smoke when filling the fuel tank. Use clean, fresh, unleaded gasoline in all models of the ARGO. Minimum 87 octane fuel is recommended. The use of Briggs & Stratton Fuel Stabilizer is also recommended with each tankful. Leaded gasoline can be used as a substitute fuel. However, if leaded gasoline is used, the engine will require more frequent servicing. Never use gasoline containing methanol or white gas since engine or fuel system damage could occur. All models of the ARGO are equipped with a 32 litre (7.0 Imp. Gal., 8.4 U.S. Gal.) “seethru” polyethelene fuel tank located underneath the driver’s seat. depending on loading and driving conditions, an ARGO can be driven for 7 to 12 hours on one tank of fuel. Verify your vehicle’s actual fuel consumption before attempting any long trips. Never travel in remote areas or set out on long trips without a full tank of fuel and adequate spare fuel stored in approved watertight fuel containers. The fuel filler neck and fuel cap are located on the right side of the vehicle behind the driver’s seat. Replace the fuel cap if fuel leakage occurs, or if moisture is detected in the fuel. Never fill the tank to the point where the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vent. Portable fuel containers may contain contaminants (dirt, water, etc.) that will cause engine operating problems. Use only clean, approved gasoline containers. After filling the fuel tank, be sure the fuel cap is replaced securely. Do not drive the vehicle unless the fuel cap is properly in place.

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Fuel System

Argo Service Manual

Never use untreated gasoline that has been stored for more than 45 days. Stale gasoline can cause deposits to form in the fuel lines and carburetor. These deposits clog the fuel system and cause engine starting and operating problems. When storing the ARGO for 45 days or more, use ARGO Part No. 127-77 Fuel Stabilizer to treat fuel in the fuel tank and fuel containers. Vented Fuel System - All Models All ARGO models have fuel systems that are vented through a special hose connected to the filler neck assembly that runs along the upper body to a fitting at the left rear.

IMPOR TANT IMPORT Ensure that the vent line is not pinched, or becomes kinked between filler neck and rear outlet fitting. Check the outlet fitting at the lower body occasionally for any dirt or debris that may be plugging the venting system. Vehicle performance can be drastically affected when fuel tank venting becomes restricted. Removing the fuel Tank 1.

Drain any fuel that may be present in the fuel tank.

Remove the seat to expose the storage tray.

Remove the 4 fasteners securing the storage tray to the seat frame. Photo FS-1

Slip the storage tray from the seat assembly, pulling it out towards the driver's compartment. Photo FS-2

FS-1 5. 6.

FS-2

Disconnect the fuel line at the pickup tube on the tank. Remove the tank.

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Fuel System

IMPOR TANT IMPORT Depending on the design of the fuel tank, earlier models may require that the tank be removed from the vehicle by pulling it from the seat frame into the rear compartment. The tank will need to be raised high enough for the sediment bowl to clear the seat frame assembly below. To provide enough clearance, shim the seat support at the 4 corners where the storage tray fasteners were removed. Photo FS-3 7.

FS-3

Undo the gear clamp securing the filler hose at the fuel tank neck and pull the filler neck assembly free of the tank. Pull the assembly from the tank at the fuel cap. Photo FS-4

IMPOR TANT IMPORT

The filler necks of vehicles manufactured prior to CB14963, RB14945, BF10092, SN10111 & S10112, may not be pulled through the upper body filler hole as shown below. Filler necks in these earlier models have a small metal vent tube welded to the filler neck, to which the vent tube is crimped. Pull the tank from the vehicle along with the filler neck assembly until the vent line is visible and can be disconnected from the filler neck tube 8.

Pull the fuel tank up through the seat frame assembly and free of the vehicle. Photo FS-5

Ensure that the vent tube does not pull out from the filler neck and that it is not kinked in any way when the filler neck assembly is reassembled to the new tank.

FS-4 9.

FS-5

Unthread the fuel pickup tube from the tank and discard.

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FS-5

Fuel System

Argo Service Manual

Installing the Fuel Tank 1.

Thread the new pickup tube into the top of the fuel tank. Position the outlet facing the rear of the tank.

IMPOR TANT IMPORT Be sure to replace any missing or damaged cushioning required on the fuel tank frame assembly before installing the tank. All cushioning provides a secure fit for the tank, and protects the tank from wear due to vibration. Photo FS-6

FS-6

Slip the new or cleaned tank through the top of the seat support frame, or in from the rear compartment of the Argo. See IMPORTANT on previous page.

Reconnect the filler hose to the tank and secure with the gear clamp.

Be sure to reconnect the fuel vent hose at the filler neck and ensure that it is facing up and not kinked or pinched in any way.

With the tank in place, reinstall the tool box and secure with the 4 fasteners

Replace the fuel filter with a new one.

Place the front seat back into the vehicle.

Inspecting the Fuel Tank and Fuel Line

Leakage in the fuel system is very dangerous! A spark or open flame can ignite gasoline fumes, causing serious injury or death. Extensive vehicle damage will also occur. Regular inspection of the fuel tank and fuel line is essential to personal safety and good vehicle performance. Inspect the fuel tank for: • • •

cracks or leaks loose or broken clamps loose connection in pick-up pipe

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Fuel System

â&#x20AC;˘

cracks, breaks or punctures in all fuel lines and hoses.

â&#x20AC;˘

cracked fuel filter casing

If any of these conditions exist, replace the affected component parts immediately. Removing the Fuel Tank (6x6 Vanguards prior to S7304) 1.

Drain the fuel tank.

Plug the filler pipe with a rag to prevent any foreign material from entering the tank.

Remove the backrest. Locate and pry loose the 3 grey plugs in the upper body behind the backrest.

Using a socket and extension, remove the 3 bolts and washers holding the backrest to the upper body.

Lift the backrest out of the vehicle.

Remove the front floor pan.

Remove the fasteners securing the bench seat to the top of the fuel tank.

Remove the seat cushion.

Disconnect the fuel line from the pickup tube.

10. Slide the fuel tank and cage 2 or 3 inches toward the firewall. 11. Rotate the fuel tank 90 degrees. 12. Lift the fuel tank out of the seating compartment, sliding the fuel neck assembly out of the upper body.

The vent tubing for the fuel system is attached to the metal filler neck section of the filler neck assembly. Caution should be observed as not to damage the outlet nipple welded to the metal neck assembly. Any bending or kinking of this small tube will prevent the tank from venting causing serious performance issues later on. 13. Undo the gear clamp at the tank and pull the filler hose assembly free of the tank. The vent tubing may remain attached to the metal neck assembly. 14. Remove the tank & seat cage from the vehicle. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Fuel System

Argo Service Manual

15. Perform the servicing procedure, Inspecting the Fuel Tank

Installing the Fuel Tank (6x6 Vanguards prior to S7304) 1.

Install any missing or torn pieces of cushioning to the fuel tank. There are 8 locations that make contact with the fuel cage.

Assemble the cage and tank between the seat supports, at the same time reconnecting the filler hose to the tank. As the fuel tank is completely installed, slide the fuel neck intake assembly into the gas cap hole ensuring that the venting tube is vertical to the vehicle body.

Tighten the gear clamp at the tank.

Reattach the fuel line to the pickup tube.

Fasten the fuel tank cage and seat to the seat support brackets. Tighten the bolts with a socket and extension.

Insert the bolts squarely into the seat cushion and do not overtighten. Incorrectly positioned and tightened bolts will strip or dislodge the thread inserts in the seat cushions, resulting in a costly repair. 6.

Reinstall the backrest.

Reinstall the front floor pan

Fuel Filter All models of the ARGO are equipped with an in-line fuel filter (replacement fuel filter is ARGO Part No. 125-64). On Conquest models the fuel filter is located in the fuel hose, next to the fuel tank. On all other Argo models the fuel filter is located at the engine. Replace the fuel filter after every 250 hours of operation or once a year. To replace the filter, loosen the gear clamps with a standard screw driver and pull the rubber fuel lines off of the filter. Install the new filter with the flow arrow pointing toward the engine. Tighten the clamps securely. Start the engine and check for fuel leaks.

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Fuel System

SECTION FS

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Fuel System

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Argo Service Manual

Fuel System

Removing the fuel Tank (Avenger) 1. Drain any fuel that may be present in the fuel tank. 2.

Remove the seat to expose the storage tray & battery.

Remove the battery.

Drill out the 11 rivets that secure the tool box to the seat frame and remove.

Disconnect the fuel line at the pickup tube on the fuel tank.

Undo the gear clamp securing the filler hose at the fuel tank neck and pull the filler neck assembly free of the tank. Photo FS 1

Remove the tank from the vehicle. The tank will come forward into the drivers compartment. Photo FS 1 & 2

Ensure that the vent tube does not pull out from the filler neck and that it is not kinked in any way when the filler neck assembly is reassembled to the new tank.

FS-1 9.

FS-2

Unthread the fuel pickup tube from the tank and discard.

Installing the Fuel Tank 1.

Thread the new pickup tube into the top of the fuel tank. Position the outlet facing towards the fuel neck side of the vehicle.

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FS-4A

Fuel System

Argo Service Manual

FS-3 2.

FS-4

Slip the new or cleaned tank into the vehicle from the drivers compartment, reconnecting the filler hose to the tank at the same time and secure it with the gear clamp.

IMPOR TANT IMPORT Be sure to reconnect the fuel vent hose at the filler neck and ensure that it is facing up and not kinked or pinched in any way. 3.

With the tank in place, reinstall the tool box and secure with rivets.

Replace the fuel filter with a new one.

Reinstall the battery

Place the front seat back into the vehicle.

â&#x20AC;˘

loose or broken clamps loose connection in pick-up pipe

â&#x20AC;˘

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Argo Service Manual

Vehicle Body

SECTION VB Vehicle Body Table of Contents General Instructions............................................................................. VB-2 Removing the Firewall (Conquest, Response, Bidfoot, Van2)...........VB-3 Installing the Firewall........................................................................... VB-4 Removing the Firewall (6x6 Vanguards)............................................. VB-4 Installing the Firewall (6x6 Vanguards).............................................. VB-5 Removing the Floor Pans......................................................................VB-7 Installing the Floor Pans.......................................................................VB-7 Removing the Rear Seats ( 8x8 models).............................................. VB-8 Installing the Rear Seats ( 8x8 models)............................................... VB-8 Removing the Rear Seats (6x6 models)............................................... VB-8 Installing the Rear Seats (6x6 models)................................................ VB-9 Replacing the Backrest Pad..................................................................VB-9 Removing the Backrest Handrail Assembly....................................... VB-9 Installing the Backrest Handrail Assembly........................................ VB-9 Removing the Drain Plugs....................................................................VB-10 Installing the Drain Plugs..................................................................... VB-10 Upper Body Removal............................................................................ VB-11 Upper Body Installation........................................................................VB-12 Lower Body Removal............................................................................VB-13 Lower Body Installation....................................................................... VB-14 Frame Inspection...................................................................................VB-15

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Argo Service Manual

General Instruction

Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual. Before performing a servicing operation, an individual must have determined to his/her satisfaction that a personal injury or vehicle damage will not result from the servicing procedure or tools selected.

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Removing the Firewall (Conquest, Response, Bigfoot & Vanguard2) All Conquest, Response, Bigfoot and Vanguard2 models utilize a quick release firewall assembly. The firewall may be removed quickly and easily with little effort and no tools required. If replacing the firewall, when ordering, the same part number covers all the above models. 1.

Pull the throttle cable free of the firewall at the rubber grommet. Photo VB-1

The front floor pan need not be removed when pulling the firewall from the vehicle. 2.

Locate the wing stud fastener at the central lower portion of the firewall. Photo VB-2

Turn the wing stud fastener to release the firewall from the clip that secures it to the lower frame.

VB-1

VB-2

There are 4 â&#x20AC;&#x153;fingerâ&#x20AC;? access holes in the bottom part of the firewall. This provides a place to grab the firewall while pulling it out towards the driver's compartment. Photo VB-3

Pull the firewall into the drivers compartment.

VB-3

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Installing the Firewall(Conquest, Response, Bigfoot & Vanguard2) 1.

Place the firewall into the drivers compartment and temporarily route the throttle cable into the area provided for the cable grommet. Photo VB-4

Slip the top of the firewall between the upper body plastic and the metal dash brace. Photo VB-5

VB-4

VB-5

Push the firewall in at the bottom and snap in securely with the wing fastener.

Assemble the throttle cable grommet to the firewall.

Removing the Firewall (6x6 Vanguards) Â&#x2039;

On 6x6 Vanguards produced prior to S8131:

Remove the front floor pan assembly. Pull the clevis pin from each side of the floor pan and pull the floor pan up and out from the vehicle.

Unthread the shift knob from the lever & remove the twist grip throttle from the right steering lever.

Remove the 2 steering adjustment locknuts and lay the steering levers back against the driver's seat.

Remove the fasteners on each side of the firewall at the lower frame assembly. Refer to your illustrated parts manual for firewall design and hardware breakdown.

Remove the 2 fasteners securing the firewall into the T nuts at the lower body.

Remove the firewall.

Â&#x2039;

On 6x6 Vanguards produced from S8131 and prior to S10769:

Remove the front floor pan assembly. Pull the clevis pin from each side of the floor pan and pull the floor pan up and out from the vehicle.

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Unthread the shift knob from the lever & remove the twist grip throttle from the right steering lever.

Remove the 2 steering adjustment locknuts and lay the steering levers back against the driver's seat.

Remove the fasteners securing the firewall to each side of the lower frame assembly. Refer to your illustrated parts manual for firewall design and hardware breakdown.

Pull the firewall from the vehicle grabbing from the bottom of the firewall and pulling into the drivers compartment.

Lift up and out from the vehicle.

Â&#x2039;

On 6x6 Vanguards produced from S10769:

Remove the front floor pan assembly. Pull the clevis pin from each side of the floor pan and pull the floor pan up and out from the vehicle.

Loosen off the 2 steering adjustment locknuts to allow enough steering handle travel for the firewall to be pulled up and out from the vehicle.

Undo the firewall at the dash support. The firewall is secured by 2 quick release wingstuds.

Remove the firewall from the vehicle.

Installing the Firewall(6x6 Vanguards) Â&#x2039;

On 6x6 Vanguards produced prior to S8131:

With the steering levers pulled back against the drivers seat, install the firewall into the vehicle aligning the mounting holes of the firewall, with those in the lower frame assembly, and the T nuts in the lower body.

Fasten the firewall at 4 locations as shown in the appropriate illustrated parts manual using the listed hardware.

Reconnect the steering levers at the brake cams and re-thread the nylon locknuts to the steering rods.

Reinstall the twist grip assembly to the right hand steering lever.

Perform the servicing procedure, Steering Lever Adjustment, in section BR of this service guide.

6. 7.

Install the shift knob. Install the floor pan.

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Â&#x2039;

On 6x6 Vanguards produced from S8131 and prior to S10769:

With the steering levers pulled back against the driver's seat, install the firewall into the vehicle aligning the mounting holes of the firewall, with those in the lower frame assembly.

The top of the firewall should be slipped between the upper body and metal dash brace assembly, similar to the quick release firewalls of other models. See Photo VB-5 on page VB-4. The outside edge of the firewall is also inserted behind the upper body plastic. Photo VB-6 2.

VB-6

Fasten the firewall at the lower frame assembly. Refer to your lllustrated parts manual for the appropriate hardware and location. Reconnect the steering levers at the brake cams and re-thread the nylon locknuts to the steering rods.

Reinstall the twist grip assembly to the right hand steering lever.

5. 6.

Perform the servicing procedure, Steering Lever Adjustment, in section BR of this service guide. Install the shift knob.

Install the floor pan.

Â&#x2039;

On 6x6 Vanguards produced from S10769:

Pull the steering levers back towards the driver seat far enough to allow the firewall to be slipped in behind.

Slip the firewall into position and clip securely at the 2 wingstuds. Photo VB-7 SEE ABOVE NOTE

Perform the servicing procedure, Steering Lever Adjustment, in section BR of this service guide.

VB-7

Install the floor pan.

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Removing the Floor Pans Draining water from the lower body, or any servicing of the Argo drive train, will require the removal of the floor pan assemblies. Removing the Front Floor Pan 1.

Perform the servicing procedure, Removing the Firewall, in this section of the service guide (Conquest, Response, Vanguard2 and Bigfoot only).

Locate and remove the 2 hitch pin clips securing the front floor pan and remove.

Pull up at the front of the floor pan and remove from the vehicle Photo VB-8

Installing the Front Floor Pan 1.

Place the floor pan in rear first and drop in at the front. Align the holes in the floor pan with the clevis pins and secure the pan with the hitch pin clips.

VB-8

IMPOR TANT IMPORT

When installing the front floor pan into vehicles manufactured prior to CB16049, RB16104, SN10191 or S10178, be sure to raise the floorpan high enough at the rear of the pan, to avoid it catching and flipping the mid front chain tensioner block upside down. Removing the Rear Floor Pan 1.

Locate and remove the 2 (6 wheel) or 4 (8 wheel) hitch pin clips securing the rear floor pan and pull the floor pan out of the vehicle. Photo VB-9

Installing the Rear Floor Pan 1.

Insert the rear floor pan into the vehicle. Align the holes in the floor pan with the clevis pins and secure the pan with the hitch pin clips.

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Removing the Rear Seat (All 8x8 Models) Rear seats on all 8x8 models are quick release and require no tools to remove. 1. Grab the rear seat and raise it high enough for the plastic bumper fastened to the underside of the seat cushion, to clear the hole in the upper body below. Photo VB-10 2.

Push the seat towards the inside of the cargo department and lift up and out. Photo VB-11

VB-10

VB-11

Installing the Rear Seats (8x8 models) 1.

Place the rear seat into position aligning the larger routed area with the large lower seat washer. Photo VB-12

Pull the seat towards yourself until the 2 plastic bumpers clip into the holes that are drilled in the upper body. Photo VB-13

VB-12

VB-13

Removing the Rear Seats (6x6 models)

The rear seats of 6x6 models are fastened by a single bolt, fender washer and large plastic washer. These are threaded into an insert within the seat cushion. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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1. 2.

Lift up on the plastic at the rear seat cushion. Using a ratchet wrench and socket, unthread the bolt from the seat.

Remove the seat.

Installing the Rear Seats (6x6 models) 1.

Place the seat into the rear compartment.

Thread the bolt, along with washers, through the upper body and into the bottom of the seat cushion.

Replacing the Backrest Pad (Conquest, Response, Bigfoot, Vanguard2 & Vanguard) There are (4) 1/4X20 fasteners and lockwashers securing the back rest to the handrail assembly. Older Model Vanguards 6x6 Vanguards prior to S7304 use (3) 1/4X20 fasteners securing the back rest to the upper body. To access these bolts you must first remove the 3 plug caps located behind the backrest along the upper body. Refer to the appropriate illustrated parts manual. Removing the Backrest Handrail Assembly

The Backrest handrail assembly is adjustable to 2 settings. This allows the backpad to be adjusted to the drivers preference of either closer, or farther away from his/her back. 1.

Remove the backrest pad.

Remove the fastener on each side of the handrail assembly.

Pull the handrail from the upper body.

Installing the Backrest Handrail Assembly 1.

Install the backpad to the handrail assembly.

Place the handrail to the upper body aligning one of the two T- nut positions available, with the mounting holes in the handrail.

Secure the handrail assembly with the appropriate hardware as listed in your illustrated parts manual.

6x6 Vanguards manufactured prior to S7447, utilize a backrest handrail that is secured to the seat frame assembly by a single set screw on each side of the vehicle. See your illustrated parts manual for component breakdown. To remove the set screws you must raise the drivers seat to access the set screw heads. Once the set screws are removed, pull Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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the handrail up and out of the seat frame below. Backrest handrails of this design are no longer available. If a replacement is required, the vehicle will need to be updated to the newer style backrest assembly. Removing the Drain Plugs There are 2 drain plugs installed into the lower body. These drain plugs provide a means of removing any water that may have found its way into the lower part of the vehicle drive train. To access the plugs you will need to perform the servicing procedure, Removing the Rear Floor Pan. See Photo VB-14

VB-14 Exact location of drain plug depends on year and model of Argo 1.

Locate the plug and lift the lever upwards to loosen the plug.

Pull the plug from the lower body hole.

Installing the Drain Plugs 1.

Seat the rubber portion of the drain plug properly in the lower body hole and push the lever down to lock plug in place. Photo VB-15 To tighten the drain plug, lift the lever up and turn the lever clockwise until it is snug when the lever is pushed back down. Photo VB-16 Relace worn or inoperative drain plugs immediately.

VB-15

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Vehicle Body

Upper Body Removal 1.

Remove the floorpans and firewall as outlined in this section of the service guide.

Lift off the engine access cover.

Remove and disconnect all accessories from the upper body.

Slide the rubber bumper free of the vehicle.

Using a 3/16" drill bit, remove all the rivets holding the upper and lower bodies together.

Be careful not to damage the body plastic during this drilling procedure. 6.

6x6 Vanguards manufactured prior to S7447 will require the backrest/handrail to be removed from the seat frame assembly.

Remove the exhaust system and air intake assemblies as outlined in the Ducting and Exhaust section of this service guide.

Disconnect all wiring from the battery, headlights, ignition switch and solenoid.

If applicable, disconnect the choke cable and wiring running to the headlamp switch.

10. Remove the gas cap and plug the fuel filler tube to prevent any foreign material from entering the tank. 11. Cautiously lift the upper body from the lower body paying attention to anything that still may need to be disconnected. 12. Disconnect the tank venting tube at the filler neck assembly and at the male connector located on the lower body at the rear of the vehicle.

If further disassembly is required: 13. Remove the headlights from the upper body as outlined in section ES of this service guide. 14. Remove the vehicle wire harness, all gauges, indicator lights and any remaining accessory wiring from the upper body. 15. 6x6 Vanguards manufactured prior to S7304 require the back rest pad to be removed from the upper body. See Replacing the Backpad in this section of the service guide. 16. Remove the rear seats and all trim. 17. Unclip the fuel tank vent tubing that runs from the fuel neck hole, to the rear of the vehicle. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Argo Service Manual

Upper Body Installation 1.

Install the rear seats and all trim to the upper body.

Install the headlamps.

Install all gauges and indicator lights.

Install the vehicle wire harness.

On 6x6 Vanguards manufactured prior to S7304, fasten the back rest pad to the upper body. See Replacing the Backpad in this section of the service guide.

Route and secure the fuel tank vent tubing to the nylon clips that are riveted to the upper body. The vent tube runs from the filler neck hole, to the rear of lower body.

Install a new vinyl sealing strip around the entire perimeter of the lower body before placing the top into position.

Place the upper body onto the vehicle. Connect the vent tubing to the filler neck and insert the filler neck through the upper body.

Ensure that the vent line is not pinched, or becomes kinked anywhere along the length between filler neck and rear outlet fitting. Vehicle performance can be drastically affected when fuel tank venting becomes restricted. The vent tubing for the fuel system is attached to the metal filler neck. Caution should be observed as not to damage the outlet nipple that is welded to the metal neck assembly on older model Argos (See IMPORTANT below). Any bending or kinking of this small tube will prevent the tank from venting, causing serious performance issues later on.

IMPOR TANT IMPORT Vehicles manufactured prior to CB14963, RB14945, BF10092, SN10111 & S10112, have a small metal vent tube welded to the filler neck at which the vent tube is crimped. Vehicles manufactured from the above serial numbers have the vent tube inserted directly into a hole punched through the filler neck. 9.

If the upper body is a new replacement:

â&#x20AC;˘

center the upper body on the lower body. secure into place with several sets of clamps around the entire perimeter of the vehicle.

â&#x20AC;˘

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•

Using a 3/16" drill bit, drill upward through the upper body, using the existing holes in the lower body as guides.

•

place body rivets through each hole. Hold a washer over the end of each rivet and fasten using a rivet gun. Refer to your illustrated parts manual for correct hardware description. using a jigsaw, trim the upper body to match the lower body.

•

10. If the upper body is NOT a new replacement: •

align the existing holes in the upper and lower bodies and secure with several sets of clamps around the entire perimeter of the vehicle.

•

place rivets through each hole. Hold a washer over the end of each rivet and fasten with a rivet gun. Refer to your illustrated parts manual for correct hardware description.

11. Remove the plug from the filler neck and install the gas cap. 12. Reinstall the choke cable 13. Connect all wiring to ignition switch, solenoid, engine harness and battery. 14. Install the exhaust system and air intake assemblies as outlined in the Ducting and Exhaust section of this service guide. 15. Install the vinyl bumper 16. Install floorpans and firewall as outlined in this section of the service guide. 17. Reconnect any accessories to the upper body. 18. Install the engine access cover.

Lower body Removal 1.

Perform the servicing procedure, Upper Body Removal, on the previous pages.

Perform the servicing procedure, Removing the Fuel Tank, as outlined in section FS of this service guide

Remove all drive chains according to the servicing procedure, Drive Chain Removal, in section WA of this service guide.

Perform the servicing procedure, Idler Chain Removal, in section WA of this service guide.

Remove the power pack assembly as outlined in the Engine System section of this service guide.

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6. 7.

Remove the the wheels from the vehicle. Perform the servicing procedure, Removing an Axle (with bearing extension) and/or Removing an axle (without bearing Extension) in section WA of this service guide.

Remove the battery.

Attach an overhead hoist and lift the frame from the vehicle lower body.

Lower Body Installation All lower bodies ordered as replacement parts are not predrilled. Holes for axles, trailer hitches etc., should be drilled using the vehicleâ&#x20AC;&#x2122;s original frame as a jig. Position the frame into the new lower body and drill as required from the inside out. Refer to the original body being replaced to calculate the correct hole-saw size for axles, and drill bit sizes for mounting hardware. If the vehicle is equipped with front or rear bearing extensions, temporarily fasten the extension at the appropriate axle hole with the 4 mounting carriage bolts and use the 6 holes of the extension as a guide to locate the new holes in the lower body. Due to variations in the properties of High Density Polyethylene Plastic, it is more accurate and precise to use the original frame of the vehicle as the guide to locate the new axle dimensions rather than to depend on a predrilled factory version. The original frame may also have done some changing (bending, twisting etc.) over time under application and may have become unique to the previous lower body. 1.

Attach an overhead hoist to the vehicle frame and place it into the lower body.

Align the axle mounting holes in the vehicle frame and lower body.

Perform the servicing procedure, Installing an Axle (with bearing extensions) and/ or Installing an Axle (without extensions) in section WA of this service guide.

Install the wheels.

Install the power pack assembly as outlined in the Engine System section of this service guide.

6. 7.

Install the fuel tank assembly as outlined in section FS of this service guide. Perform the servicing procedure, Upper Body Installation, in this section of the service guide.

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Frame Inspection 1.

Inspect the vehicle frame, seat support assembly and power pack frame thoroughly for:

•

cracks or breakage in the welding joints

•

cracked or broken mounting lugs or inserts

•

rusted through or bent frame members

If any of these conditions are noted, remove from the vehicle and attempt repair. If damage to the frame cannot be repaired, replace immediately.

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Ducting & Exhaust

SECTION DE Ducting & Exhaust Table of Contents General Instructions............................................................................. DE-2 Removing the Muffler (Conquest Models Prior to C19672).................................................... DE-3 Disassembling the Muffler Assembly (Conquest Models Prior to C19672).................................................... DE-5 Assembling the Muffler Assembly (Conquest Models Prior to C19672).................................................... DE-6 Removing the Muffler (Conquests from C19672).............................. DE-7 Installing the Muffler (Conquests from C19672)............................... DE-8 Removing the Muffler (Response, Vanguard2 & Vanguard)............ DE-8 Installing the Muffler (Response, Vanguard2 & Vanguard)............. DE-10 Remove the Muffler (Bigfoot Models).................................................DE-11 Installing the Muffler (Bigfoot Models).............................................. DE-11 Spark Arrestor Information & Maintenance..................................... DE-11 Removing the Intake Duct (Response, Bigfoot, Vanguard2 & Vanguard).................................... DE-12 Installing the Intake Duct (Response, Bigfoot, Vanguard2 & Vanguard).................................... DE-13 Removing the Intake Duct (Conquest Models)...................................DE-13 Installing the Intake Duct (Conquest Models)....................................DE-14 Removing the Exhaust Ducting (Response, Bigfoot, Vanguard2 & Vanguard).................................... DE-14 Installing the Exhaust Ducting (Response, Bigfoot, Vanguard2 & Vanguard Models)........................DE-14

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Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual. Before performing a servicing operation, an individual must have determined to his/her satisfaction that a personal injury or vehicle damage will not result from the servicing procedure or tools selected.

Do not service the exhaust system when it is hot! Severe burns can occur to hands and arms. Eye protection must be worn at all times during vehicle servicing.

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Removing the Muffler (Conquest Models) Â&#x2039;

On Conquests manufactured prior to C19672:

Remove the 2 fasteners in the top of the heat shield. Photo DE-1 Depending on the age of the vehicle, a few earlier models utilized a fiberglass heat shield. This part is no longer available but is fully exchangeable with the newer version.

Collect the 2 spacers that are installed beneath each fastener 2.

Remove the 2 fasters securing the manifold cover to the muffler shield assembly and remove the manifold cover. Photo DE-2 & 3

DE-1

DE-2

DE-3

DE-4

The lower shroud is secured by 2 more fasteners. Remove the 2 fasteners and lift the lower shroud from the vehicle. Photo DE-4

Disconnect the muffler at the manifold. Photo DE-5 The muffler and exhaust manifold are joined together with 2 bolts, 4 flatwashers, 2 compression springs and 2 locking style nuts. Refer to the illustration in the appropriate parts manual for a breakdown and orientation of the hardware.

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DE-5 5.

DE-6

There are 2 fasteners securing the the entire muffler assembly to the lower body. These are located at the lower body under the front wheel. It may prove easier to remove the front wheel to access the fastener heads with a socket or wrench. Photo DE-6 & 7

DE-7

DE-8

Pull the muffler and shroud assembly into the engine compartment area enough for the tailpipe to clear the outside exhaust screen. Turn the assembly 90 degrees and shove it back over the wheel well temporarly until the exhaust manifold has been removed. Photo DE-8

Unbolt the exhaust manifold and remove it from the engine. Photo DE-9

Slide the muffler asssembly towards the engine compartment and up and out of the vehicle. Photo DE-10 Compress the rubber shock mounted lower support to narrow the width of the assembly while pulling up, and out from the compartment.

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DE-10

DE-11

Disassembling the Muffler Assembly (Conquest Models) 1.

On a clean work surface, remove the single fastener and spacer securing the heat shield to the muffler assembly. Photo DE-11

The above heat shield removed exposes another fastener securing the muffler to the shrouding. Remove this fastener. Photo DE-12

Flip the assembly over and remove the 2 fasteners securing the muffler on the other side of the shield assembly. Photo DE-13

DE-12

Slide the muffler assembly from the heat shield. Photo DE-14

Remove the fastener securing the tailpipe and spark arrestor and pull the tailpipe from the muffler assembly.

DE-13

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Argo Service Manual

Assembling and Installing the Muffler Assembly (Conquest Models) 1.

On an uncluttered work surface, orient the muffler heat shield assembly with the rubber shock lower support, to the back. Insert the muffler into the shroud with the exhaust inlet situated to the right. Photo DE-15

Turning the tailpipe end of the shroud around to face the assembler will put the tailpipe also to the right side of the shroud. Photo DE-16

DE-15

DE-16

Reinstall the 2 lower fasteners to secure the muffler at the bottom of the shroud. Photo DE-17

Flip the assembly over and secure the muffler at the exhaust inlet end. Photo DE-18

DE-17

DE-18

Secure the heat shield with the appropriate hardware. Refer to your illustrated parts manual for correct hardware and orientation. Photo DE-19

Install the assembly into the vehicle at 90 degrees, compressing the rubber mounted lower support to ease the installation and provide enough clearance in the engine compartment. Photo DE-20 Set the assembly on to the front wheel well temporarily

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DE-19 7.

DE-20

Re-fasten the exhaust manifold to the engine. Torque to specification.

IMPOR TANT IMPORT Exhaust manifold gaskets should be replaced with new ones 8.

Assemble the muffler assembly to the exhaust manifold. The original compression springs may be reused but new hardware is recommended.

IMPOR TANT IMPORT When tightening down the hardware between muffler and exhaust manifold, it is critical not to overtighten the hardware. By no means should the compression spring become coil bound. Tighten only enough to provide a good seal between muffler and manifold. Over tightening can cause undue stress at the muffler inlet due to the twisting and turning of the vehicle under application. Correct tension at the compression spring allows for movement in this area. 9.

Reinstall the manifold heat shield and lower cover. Use the appropriate hardware as illustrated in your parts manual.

10. Fasten the muffler and shroud assembly to the lower body at the front wheel well. The lower rubber mounted support is slotted to provide adjustment for the tailpipe at the exhaust screen hole. Ensure that the tailpipe does not touch any of the surrounding screen area and secure the assembly to the lower body.

Removing the Muffler (Conquest Models) Â&#x2039;

On Conquest vehicles manufactured from C19686, all 6x6 Conquests and all 35th anniversary vehicles:

Remove the 4 fasteners securing the heat shield over the muffler. Photo DE-21

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Disconnect the 2 extension springs connecting the tailpipe to the muffler and remove the tailpipe. Photo DE-22

Unfasten the muffler at the engine and remove.

DE-21

DE-22

Installing the Muffler (Conquest Models ) 1.

Install the muffler to the engine exhaust manifold and torque to specifications.

IMPOR TANT IMPORT New exhaust gaskets are recommended when ever servicing the muffler system. 2.

Install the tailpipe/spark arrestor to the muffler, connecting with 2 extension springs.

Install the heat shield over the muffler, securing with 4 fasteners. Refer to the illustrated parts manual for correct hardware and orientation.

Removing the Muffler (Response, Vanguard2 & Vanguard Models) 1.

Remove the exhaust duct cover.

On 6x6 Vanguards manufactured prior to S8131:

Remove the 3 fasteners securing the exhaust duct cover and remove the cover. This exhaust shroud system utilizes a duct below the muffler. See the appropriate illustrated parts manual for component structure on these earlier models.

On vehicles manufactured from S8131, SN8138, RB12075 and prior to S13434, N13436, R19647:

Remove the 3 fasteners that secure the exhaust duct cover and remove the cover. Photo DE-23

On vehicles manufactured from S13434, N13436, and R19647:

Remove the 4 fasteners that secure the exhaust duct cover and remove the cover.

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Argo Service Manual

Ducting & Exhaust

Disconnect the extension springs.

On models manufactured prior to R19647, S13434 & N13436:

Remove the extension springs connecting the muffler to the exhaust manifold. Photo DE-24

DE-23

DE-24

On models manufactured from R19647, S13434 & N13436:

Disconnect the extension springs connecting the tailpipe to muffler and pull the tailpipe out of the vehicle from the engine compartment. Photo DE-25

Remove the muffler.

On vehicles manufactured from S6999, SN8138, RB12075 and prior to S13434, N13436, R19647:

Pull the muffler from the exhaust ducting. Photo DE-26

DE-25

DE-26

On models manufactured from R19647, S13434 & N13436: Unfasten the muffler from the engine and remove.

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DE-9

Ducting & Exhaust

Argo Service Manual

Installing the Muffler (Response, Vanguard2 and Vanguard Models) 1.

Install the muffler

Â&#x2039;

On vehicles manufactured from S6999, SN8138, RB12075 and prior to S13434, N13436, R19647:

Assemble the muffler into the exhaust ducting aligning the tailpipe with the outlet hole in the exhaust screen. The tailpipe should be facing slightly down and towards the rear of the vehicle. Photo DE-27

Connect the extension springs between the muffler and exhaust manifold.

On 6x6 Vanguard vehicles produced prior to S8131, the outlet pipe of the muffler is straight cut. This tailpipe protrudes straight out of the exhaust screen. Refer to the illustration in the appropriate parts manual for vehicles manufactured in this serial number range. All vehicles manufactured from RB12075, SN7841, S8131 and prior to R19647, S13434 & N13436 are as in Photo DE-27.

DE-27

DE-28

Â&#x2039;

On models manufactured from R19647, S13434 & N13436:

Reassemble the muffler to the engine and torque to specifications.

Slip the tailpipe, from the engine compartment side, through the exhaust screen hole and connect at the muffler with 2 extension springs. Photo DE-28

Reinstall the exhaust duct cover using the appropriate hardware refering to the illustrated parts manual.

6x6 Vangards manufactured prior to S8131, utilize a shroud below the muffler as well. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Argo Service Manual

Ducting & Exhaust

Removing the Muffler (Bigfoot Models) 1.

Remove the four fasteners securing the muffler heat shield and remove the shield.

Disconnect the extension springs between the tailpipe and muffler and pull the tailpipe from the engine compartment.

Remove the muffler at the engine

Installing the Muffler (Bigfoot Models)

IMPOR TANT IMPORT Always replace exhaust gaskets when servicing the muffler system. 1.

Attach the muffler at the engine and torque to specifications

Slip the tailpipe, from the engine compartment side, through the exhaust screen hole and connect at the muffler with 2 extension springs.

Assemble the heat shield to the top of the muffler using the 4 fasteners required.

Spark Arrestors Cleaning the Spark Arrestor (Only for equipped models) Models Equipped with Spark Arrestors. Conquest

All Models

Response

Models manufactured from R19647

Bigfoot

Models manufactured from BF13028

Vanguard2

Models manufactured from N13436

Vanguard

Models manufactured from S13434

Conquest 6x6

Models manufactured from C12747

After operating the engine, do not touch any part of the exhaust system until it has sufficient time to cool! 1.

Keep a record of the number of hours of engine use. The spark arrester should be removed, cleaned and inspected every 50 hours of operation.

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DE-11

Ducting & Exhaust

Argo Service Manual

Remove the tail pipe assembly by disconnecting the springs from the muffler attached to the tail pipe.

The screen-type spark arrester assembly is located inside the tail pipe. It is fastened with one (1) slotted washer-head hex screw. Find the screw on the side of the outlet tube.

Remove the screw and save it for step 9.

Take off the screen-type spark arrester assembly.

Shake loose particles out of the screen assembly.

Clean the screen with a wire brush. (Soak it in oil solvent if necessary.)

If any breaks in the screen or weldments are discovered, replace the assembly.

Return the screen assembly to the outlet tube and refasten it with the screw from Step 4.

Removing the Intake Duct (Response, Bigfoot, Vanguard2 & Vanguard Models) 1.

Locate the 2 fasteners securing the intake duct to the hood frame assembly and remove. There are 2 spacers assembled with the fasteners. Photo DE-29

Undo the fuel line from the nylon clips securing it to the intake duct.

Pull the ducting from the vehicle. Navigate it towards the front of the vehicle pulling it up, and out. Photo DE-30

DE-29

DE-30

6x6 Vanguards manufactured prior to S8131 will have a spring attached at the rear of the intake and connected to a small molly hook that is riveted to the lower body wheel well. See the appropriate illustrated parts manual. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

DE-12

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Argo Service Manual

Ducting & Exhaust

Installing the Intake Duct (Response, Bigfoot, Vanguard2 & Vanguard Models) 1.

Install the intake duct inserting it closest to the front of the vehicle. This is where the widest available area allows it to be pushed into the vehicle. Position it in front of the engine flywheel fan assembly.

Fasten the intake duct to the hood support assembly using the spacers and 2 fasteners.

On 6x6 Vanguards manufactured prior to S8131, reconnect the extension spring from the intake duct to the molly hook on the lower body. 3.

Secure the fuel line to the nylon clips at the intake duct.

Removing the Intake Duct (Conquest Models)

Conquest models maufactured prior to CB17117 utilize a sheet metal style intake duct. Intake ducts on Models manufactured from the above serial number, are made of moulded plastic. Earlier sheet metal ducts are no longer available, but the newer style is fully exchangeable. However, optional parts are necessary when ordering your replacement. To remove the intake duct on Conquest models, the upper body must be split from the lower body. 1.

Peel off the rubber bumper assembly from the vehicle. You need only strip it off far enough off to drill out the specified rivets.

Using a 3/16" drill bit, remove the rivets starting from the front center of the vehicle to approximately the dash area. Photo DE-31

DE-31

Separate the upper and lower body, supporting it apart using a couple of 2x4 pieces of wood.

Locate the fasteners securing the intake duct to the lower body and remove.

Raise the upper body from the lower high enough to accommodate the height of the duct as you pull it out from between the two.

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DE-13

Ducting & Exhaust

Argo Service Manual

Installing the Intake Duct (Conquest Models) 1.

Slip the intake duct between upper and lower body.

Position the duct so that both duct and lower body mounting holes are aligned.

Install the hardware required to fasten the duct to the lower body

Re-rivet the upper body to the lower using washers on the underside of the vehicle. Reinstall the rubber bumper.

Removing the Exhaust Ducting (Response, Bigfoot, Vanguard2 & Vanguard Models 1.

Perform the servicing procedure, Removing the Muffler (Response, Vanguard2 & Vanguard Models) or: Perform the servicing procedure, Removing the Muffler (Bigfoot Models)

Remove the 2 fasteners securing the exhaust ducting to the hood support brace. Photo DE-32

The exhaust ducting is secured at the other end by 2 body rivets located at the upper body beneath the rubber bumper. Photo DE-33 Peel back the bumper and drill out both rivets.

DE-32 4.

DE-33

Pull the duct assembly in towards the engine compartment and up and out of the vehicle.

Installing the Exhaust Ducting (Response, Bigfoot, Vanguard2 & Vanguard Models) 1.

Insert the ducting into the engine compartment. Slip the exhaust duct support between the upper and lower body aligning the holes in the support, with the rivet holes of the previously removed rivets.

Insert 2 body rivets through the body and shroud support, and secure with 2 washers below.

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Argo Service Manual

Ducting & Exhaust

Fasten the duct at the upper hood brace assembly

Perform the servicing procedure, Installing the Muffler (Response, Vanguard2 and Vanguard Models) or: Installing the Muffler (Bigfoot Models)

Reinstall the bumper.

Removing the Exhaust Ducting (Conquest from C19686, all 6x6 Conquests and all 35th anniversary vehicles) 1.

Perform the servicing procedure, Removing the Muffler (Conquest) on page DE-7 of this service guide.

Remove the 2 fasteners securing the exhaust ducting to the hood support brace. See Photo DE-32 previous page.

The exhaust ducting is secured at the other end by a body rivet located at the upper body beneath the rubber bumper. See Photo DE-33 previous page Peel back the bumper and drill out both rivets.

Pull the duct assembly in towards the engine compartment and up and out of the vehicle.

Installing the Exhaust Ducting (Conquest from C19686, all 6x6 Conquests and all 35th anniversary vehicles) 1.

Insert 2 body rivets through the body and shroud support, and secure with 2 washers below. Fasten the duct at the upper hood brace assembly

3. 4.

Perform the servicing procedure, Installing the Muffler (Conquest) on page DE-8 of this service guide.

Reinstall the bumper.

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DE-15

Argo Service Manual

Transmission

SECTION TR Transmission Table of Contents General Instructions...........................................................................TR-2 Transmission Oil/Maintenance Schedule..........................................TR-3 Recommended Oil....................................................................... ........TR-3 Oil Level Inspection............................................................................ TR-4 Changing the Transmission Oil..........................................................TR-5 Refilling the Transmission with Oil........................................... ........TR-7 General Inspection of the Transmission............................................TR-7 Removing the Transmission....................................................... ........TR-8 Disassembling the Transmission ....................................................... TR-10 Disassembling the Transmission (34-100)Supplement Pages..........TR-2A Separating the Side Cover (Earlier Models).....................................TR-11 Separating the Side Cover (Later Models).......................................TR-12 Disassembling the Shifter Assembly.................................................. TR-18 Disassembling the Differential................................................... ........TR-19 Transmission Component Inspection........................................ ........TR-23 Transmission Component Changes Chart........................................TR-25 Transmission Assembly ......................................................................TR-27 Transmission Assembly (34-100) Supplement Pages....................... TR10A Assembling the Differential................................................................TR-27 Assembling the Differential (34-100) Supplement Pages.................TR-17A Assembling the Shifter Assembly.......................................................TR-33 Assembling the Housing & Cover...................................................... TR-36 Install the Differential.........................................................................TR-42 Install the Shifter Assembly................................................................TR-42 Install the Reverse Idler......................................................................TR-43 Installing the Transmission................................................................ TR-54 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-1

General Information

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GI-28

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Transmission

Argo Service Manual

General Instructions

Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual. Before performing a servicing operation, an individual must have determined to his/her satisfaction that a personal injury or vehicle damage will not result from the servicing procedure or tools selected.

All transmission work should be performed by a qualified mechanic. Severe damage and/or reduced performance can result from an improperly serviced transmission.

Do not attempt to move the gearshift from the neutral starting position until the engine idles down completely. The Argo is equipped with an automatic clutch that is activated by engine speed. If the engine idle speed is too high, the transmission will grind during gear engagement.

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TR-2

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Argo Service Manual

Transmission

Transmission Oil Maintenance Schedule The transmission oil should be changed after the initial 25 hours of vehicle operation. After this, it should be changed every 150 operating hours.

Proper transmission lubrication will reduce wear, and extend gearbox life. Please use the type, and quantity of transmission oil specified below.

Inspecting the condition and level of oil in the transmission must be done on a regular basis. Do not operate the ARGO if the transmission oil level on the dipstick is above or below the grooved indicator. Damage to the transmission or a reduction in vehicle performance could occur. Recommended Oil Type Oil Type: 80W90 Gear Oil HYPOY-C or an EP Rated 80W90 Gear Oil for Extreme Pressure Gear applications. Using any other than the recommended oil could cause serious damage to the transmission components. The approximate refill capacity of the ARGO transmission is 0.85 Liters (1.5 imperial pints, 1.8 U.S pints). However, be sure that it is filled to the full mark on the dipstick. DO NOT OVERFILL.

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TR-3

Transmission

Argo Service Manual

Oil Level Inspection Inspect the transmission oil on a daily basis

Do not run the ARGO if the oil level in the transmission shows above or below the mark on the dipstick. Damage to transmission components could occur 1.

Place the vehicle on a level surface. This will allow the correct measurement of gear lube in the transmission.

Remove the engine access cover and locate the transmission dipstick. Photo to right

Clean the transmission around the dipstick location to prevent any dirt from entering the gearbox and causing premature wear to the internal components.

TR-01

Remove the dipstick and wipe it clean of oil. Return the dipstick to the transmission and remove it once again.

Depending on the age of the vehicle, the dipstick may require a 3/8" opened end wrench to unthread the dipstick from the transmission housing. This could be the case for models built prior to mid 1994. To check the oil level correctly with this style dipstick, unthread it and wipe it clean. Re-thread it back into the housing finger tight, then remove it to view the level. 5.

Inspect the oil level. If the level indicated is not even with the mark on the dipstick, go to step 6. Otherwise return the dipstick to the transmission.

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TR-4

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Argo Service Manual

Transmission

6(a) Oil Level Above The Groove i.

Insert a vacu-pump hose into the dipstick opening

Do not insert the Vacu-pump hose into the transmission if the gearbox oil is extremely hot. Vacu-pump components may melt. ii.

Draw out a small quantity of gear oil from the transmission.

iii. Remove the vacu-pump from the transmission iv.

Repeat steps 1 to 5.

6 (b) Oil Level is Below The Groove i.

Place a clean long spouted funnel into the oil fill/dipstick hole

ii.

Add a small quantity of fresh clean oil as specified in the Recommended Oil Type on page TR-3 of this manual.

iii. Remove the funnel and replace the dipstick. Apply a small amount of anti-seize compound to the thread of the dipstick (Older Models) and retighten into the housing with a 3/8" opened end wrench. Changing The Transmission Oil You may drain the transmissionâ&#x20AC;&#x2122;s oil through the oil fill/dipstick, by using a vacuum style pump such as the one available through your ARGO dealer (part # 638-02) or preferably, at the drain plug located at the bottom of the transmission just behind the firewall. Refer to the maintenance schedule in section GI for time change intervals. 1.

Drive the vehicle until the transmission is warmed up thoroughly.

Park the vehicle on a level surface.

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TR-5

Transmission

Argo Service Manual

Perform the servicing procedure, Removing the Firewall, in Section VB of this service manual.

Perform the servicing procedure, Removing the Front Floor Pan, in Section VB of this service manual.

Remove the hood.

Clean the transmission around the dipstick location. This will keep dirt from entering the gearbox.

Remove the dipstick. Vehicles manufactured prior to mid 1994 will require the dipstick to be threaded from the gearbox using a 3/8" opened end wrench. Dipsticks on newer models utilize an "O" ring and need only be pulled straight up and out from the transmission, however the gearshift lever may need to be shifted into low or high gear to allow the dipstick to be removed.

Form a piece of sheet metal to place beneath the drain plug to route the oil from the transmission to a plastic bag on the front floor. Photo TR-02

Remove the drain plug and clean off any metal filings from the magnet.

TR-02

To remove the drain plug easily and effectively, a 7/16" 8 Point Socket must be used. An opened end style wrench or vise grip wrench is not recommended as they will damage the plug. 10

Dispose of the used transmission oil.

Be sure to follow any federal or state laws regarding the proper procedure for disposing of oils. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-6

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Argo Service Manual

Transmission

Refilling the Transmission with Oil

Apply a pipe sealant compound or tape to the drain plug and reinstall. Do not over tighten!

Place a clean funnel into the oil fill dipstick hole.

Fill the gear box with approximately 0.85 litres (1.5 Imperial Pints, 1.8 U.S. Pints) of clean fresh 80W/90 Gear Lube Hypoy-C or an EP rated 80W/90 gear oil for Extreme Gear Pressure applications. Inspect the level with the dipstick occasionally.

Perform the servicing procedure, Transmission Oil Level Inspection.

Replace the dipstick. If the dipstick is the thread in type, apply a little anti-seize compound to the threads before installing it back into the transmission.

General Inspection Of The Transmission Maintenance Schedule - Inspect every 50 hours. Inspect more often if the vehicle is used under heavy-duty applications. 1.

Lift the engine access cover. Problems can occur if ARGO component parts are used for heavy-duty applications. Inspect the transmission for the problems listed below, and perform the recommended servicing procedures.

Inspect the transmission casting on both housing and cover for: • cracks or breakage • transmission leakage through the casing

If either of these conditions are noted, replace either or both immediately. 2.

Inspect the outside of the transmission for: • fluid leakage around seals • fluid leakage around bolt holes • loose bolts

If any of these conditions are noted, replace the gasket or seals immediately and tighten all cover bolts to torque specifications. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-7

Transmission

Argo Service Manual

Removing the Transmission

Disconnect all wiring to the battery before proceeding with the following component removal.

Perform the servicing procedure, Removing the Firewall (Quick Release), for Response, Bigfoot and Conquest in Section VB of this manual. Or: Removing the Firewall for Vanguard models prior to May 19, 1999 Or : Removing the Firewall (Quick Release) for Vanguard models manufactured after May 19, 1999.

Perform the servicing procedure, Removing the Front Floor Pan, in the Vehicle Body Section of this service manual.

Perform the servicing procedure, Removing the Driven Clutch, in the Clutch Section of this manual.

Perform the servicing procedure, Removing the Brake Pads ( Hydraulic ) steps 15, or Removing the Mechanical Brake Calipers, in the Brake System Section of this manual.

Locate the (3) mounting bolts that secure the hydraulic brake caliper system to the transmission and remove them. Photo TR-03

On Conquest models, disconnect the wiring at the igniter box which is mounted to the steering assembly. Photo TR-04

TR-03 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-04

TR-8

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Argo Service Manual

Transmission

Unfasten the twist grip assembly from the steering handle and remove it. Photo TR-05

Remove the entire hydraulic brake system from the vehicle. The calipers, master cylinders and brake lines can all remain attached without the loss of any brake fluid. Photo TR-06

TR-06

TR-05 10. Perform the servicing procedure Removing the Drive Chains, in Section WA of this service manual. 11. Perform the servicing procedure, Removing the Brake Disc, in Section BR of this service manual. 12. Locate, unfasten and remove the (2) bolts, lock washers and nuts that secure the transmission to the power pack frame. Photo TR-07

TR-07

13. Remove the transmission guard from the transmission. It is secured with (2) bolts and (2) flatwashers. Photo TR-08 14. Loosen off the carriage bolt of the dash support and turn it 90 degrees. Tilt the transmission back towards the drivers compartment and lift it from the vehicle.

TR-08

15. Place the transmission on a clean workbench for disassembly. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-9

Transmission

Argo Service Manual

Disassembling the Transmission

Remove the Drain Plug & drain the oil from the transmission. Photo TR-09

Remove the Dipstick.

Remove the Retaining Ring that secures the Reverse Idler Dowel Pin on the outside of the Cover. Photo TR-10

Tap the Dowel pin back into the transmission far enough to free it from the Side Cover. You will need a drift punch to tap it below the surface of the cover. TR-11

Remove all side cover fasteners. Photo TR-12

TR-09

TR-10

TR-11

TR-12

Position the transmission to remove the Retaining Ring on the Output Shaft of the Housing side. Photo TR-13

Remove the Shim from the Output Shaft. Photo TR-14

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Transmission

TR-13

TR-14

All retaining rings, spacers & seals need to be replaced during a transmission rebuild. It is usually recommended to replace all bearings as well. Bearings should only be reused if the technician has determined to his/her own satisfaction that they are okay to reuse. Separating the Side Cover on Transmissions Manufactured Prior to Serial Numbers:

25631GU, 25668HU 25700MU

With a dead blow mallet, alternate between striking the Input Shaft and Output Shaft until the Cover begins to separate from the Housing. Continue until the Cover is completely free of the Housing. In most cases the differential will remain with the Cover. Photo TR-15 & 16

TR-15

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TR-16

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TR-11

Transmission

Argo Service Manual

Separating the Side Cover on Transmissions Manufactured From Serial Numbers:

25631GU, 25668HU 25700MU

These Side Covers utilize a threaded boss in 2 locations. Photo TR-17

10. Remove the Retaining Ring and Shim on the Output Shaft side of the Cover, Photo TR-18, and ensure that the reverse idler dowel pin has been freed of the cover as in step 3 & 4 11. Thread (2) 5/16"x18 bolts into the threaded boss at both locations on the Side Cover. As the bolts come in to contact with the Housing below, the Cover is pulled from the Output Shaft. Thread the bolts a little at time alternating between the two. This will ensure that it does not bind during separation. Photo TR-19

TR-17

TR-18

TR-19

TR-20

Make sure that the bolts threaded into the Cover are long enough to guarantee that the Cover will completely separate itself from the Housing and may be easily lifted off by hand. In most cases, with this type of separation, the differential will remain within the Housing. Photo TR-20 Remove the differential from the Housing as described in step 8. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-12

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Argo Service Manual

Transmission

12. Remove the Shifter Assembly. Locate the Plug Plate on the Housing side and with a hammer and punch, knock the Plug Plate through at the center until the Shifter Assembly is freed from the Bearing. Photo TR-21 13. If the 101-01 Bearing has remained on the Input Shaft it will be necessary to remove it using a gear puller. Photo TR-22 & 23 14. Slip the Reverse Idler gear from the ½” Dowel Pin. Photo TR-24

15.

TR-21

TR-22

TR-23

TR-24

Remove the Input Shaft’s Oil Seal. Photo TR-25

16. Remove the Input Shaft’s Retaining Ring. Photo TR-26 17. Remove the Shim installed below the Retaining Ring. Photo TR-27 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-13

Transmission

Argo Service Manual

TR-27

TR-26

Some transmissions may have (2) Shims instead of (1). In rare cases there may be none used. In any case, when reassembling, use the same amount as were used originally. 18. Using a soft faced hammer, tap the Input Shaft out of the Housing. Photo TR-28 19. Place the Housing in the assembly fixture to remove all Bearings, Retaining Rings, Seals and the Plug Plate. 20. Remove the old Cover Gasket. Photo TR-29

TR-28

TR-29

21. Knock the outer Bearing from the Housing using a hammer and drift punch. Tap around the perimeter of the Bearing through the backside of the housing to ensure that it will not bind . Photo TR-30 22

Knock out the Housing Plug Plate. Photo TR-31

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Argo Service Manual

Transmission

TR-30

TR-31

23. Flip the Housing over to remove the outer Retaining Ring. Photo TR-32 24. Using the drift punch and hammer remove the inner Bearing in the same manner as in step 20. Photo TR-33

IMPOR TANT IMPORT When removing this Bearing, take note of the number of Shims that were installed behind it. This may vary from 1 to 2 shims. In any case, be sure to install the same amount as was used previously. Photo TR-34

25. Flip the transmission and remove the inner Retaining Ring. Photo TR-35

TR-32

TR-33

TR-34

TR-35

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TR-15

Transmission

Argo Service Manual

26. Remove the inner Seal with a hammer and drift punch. Photo TR-36 27. If the transmission you are disassembling still has the differential assembly in the Side Cover as described in step 8, it will have to be removed from the Cover using an arbor press. First you must remove the Retaining Ring and Shim washer from the Output Shaft. Photo TR-37 & 38 28. Supporting the Cover on each side with 2 short 2x4â&#x20AC;&#x2122;s, place it in an arbor press and apply pressure to the Output Shaft. Press the differential from the Cover. Photo TR-39 29. Place the Cover into the assembly fixture and remove all Bearings, Seals & Retaining Rings in a similar manner as performed on the housing. There are 2 plug plates in the Cover side compared to the single one used in the Housing.

There are no Shims used behind the inner Bearing of the Cover

TR-36

TR-37

TR-38

TR-39

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Argo Service Manual

Transmission

IMPOR TANT IMPORT Transmissions manufactured from Oct of 2000 have had a design change to the Side Cover. This new Side Cover begins on vehicles manufactured from serial numbers: SN11905 TB Oct. 4/00 S11906 TB Oct. 4/00 BF11917 OB Oct. 10/00 CB17471 YB Oct. 12/00 RB17525 TB Oct. 24/00

This Side Cover no longer requires the 31-07 plug or the 106-01 Retaining Ring. The Side Cover has been cast and machined in this area to eliminate the need for both of these parts. The cover will replace all earlier side covers. Photo TR-40 The procedure for removing the 101-01 Bearings will require the use of an internal style of puller as described below.

TR-40

TR-41

30. Place the Side Cover into the assembly fixture with the Bearings facing up. Photo TR-41 31. Adjust the internal bearing puller to the closed position. Photo TR-42 32. Insert the bearing puller into the inner race of the 101-01 bearing and tighten the adjustment nut until the puller has spread enough to secure the bearing from the inside. Photo TR-43 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-17

Transmission

Argo Service Manual

TR-43

TR-44

33. Take a piece of flat stock with a hole drilled to the center and slip it on to the threaded adjustment rod of the puller. Secure it with a nut. Photo TR-44 34. Flip the Cover on the assembly jig so that the 101-01 Bearings are facing down. Photo TR-45 35. Use a mallet to strike the flat stock and knock the 101-01 Bearing from the casting. Photo TR-46

TR-46

TR-45 Disassembling the Shifter Assembly 36. The Shifter Assembly consists of the Splined Shaft, Drive Gear and Double Gear. Photo TR-47 The Double Gear slides along the Splined Shaft and locks into 4 different shift gate positions (Reverse, Neutral, Low & High Gear). Each position is locked by a Ball & Spring within the Double Gear, and gates machined within the Splined Shaft. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-18

TR-47

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Argo Service Manual

Transmission

37. Place the Shifter Assembly into the arbor and press the Splined Shaft from the 101-01 Bearing and the Double Gear. Photo TR-48

Be aware of the Ball & Spring within the Double Gear when pressing the spline shaft from the assembly. 38. Turn the Splined Shaft to the other end to remove the 101-01 Bearing and Drive Gear. Photo TR-49

TR-48

TR-49

Disassembling the Differential

40. Secure the Differential by the Output shaft on the cage side within a vise. A vise equipped with aluminum jaws must be used to avoid any damage to the output shaft. Photo TR-51

TR-51 When removing the 3 fasteners that secure the differential's Gear Plate and Aluminum cage together, earlier transmissions may also have a lockwasher installed. If this is the case, when reassembling the differential, eliminate the lockwashers and use Red 271 LOCTITE on both the threads of the fastener as well as on the internal threads of the aluminum cage. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-19

Transmission

Argo Service Manual

41. Hold the Output Shaft from turning while removing the 3 Fasteners that hold the Gear Plate and Aluminum Cage together. Photo TR-52 42. With the Fasteners removed, gently tap the Gear Plate from the Aluminum Cage using a soft faced mallet. Photo TR-53

TR-52

TR-53

When lifting the Gear Plate from the Cage, be aware of any Pinions that may come with the Gear Plate. Avoid any of these falling to the floor. Any damage to these pinions can result in reduction of gear life or noise issues. 43. Remove each of the (6) Pinions. Photo TR-54 44. Remove the Retaining Ring that secures the Sun Gear to the Output Shaft on the Aluminum Cage side. Photo TR-55

TR-55

TR-54 45. Slip the Sun Gear from the Output Shaft. Photo TR-56

46. Remove the Retaining Ring that secures the second Sun Gear to the Output Shaft on the Gear Plate side. Photo TR-57 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-20

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Argo Service Manual

Transmission

TR-56

TR-57

47. Slip the Sun Gear from the Output Shaft. Photo TR-58 48. Press the Output Shafts from both Cage and Gear Plate. Photo TR-59 & 60

TR-59

TR-58

TR-60

49. Remove each of the 101-15 Bearings from both Cage and Gear Plate. Slip the bearing remover tool into each of the aforementioned components and tap with your hand or soft faced mallet. Photo TR-61 & 62

TR-61 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-21

Transmission

Argo Service Manual

TR-62

TR-63

50. Remove all (12) Oilite Bushings from both Cage and Gear Plate using a bushing removal tool. This procedure will also push out the Output Shaft Bearing that has more than likely remained assembled to both of these components. Photo TR-63, 64 & 65 51. Remove the Bearing from the Input Shaft. Place the Input Shaft into an aluminum jawed vise, lightly clamping it to the High Gear. The vise, need only make contact with the gear. Being the Bearing is slightly larger in diameter than the High Gear, the vise jaws will hold the bearing up while gently tapping the Input Shaft down with a soft faced mallet. Photo TR-66

TR-64

TR-65

TR-66 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-22

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Argo Service Manual

Transmission

52. Wash all parts in a clean varsol bath and dry all parts with compressed air or a lint free rag. Lay out all parts for inspection. Photo TR-67

TR-67 Always exercise extreme caution when using compressed air. Compressed air can be potentially dangerous causing serious injury or even death if misused. Transmission Component Inspection Mechanical transmissions do not need a great deal of maintenance beyond periodic and regular oil changes. However, once a problem has been detected and the transmission has been disassembled, it is important to examine all transmission components for wear, cracks or breakage. Repairing or replacing all faulty components will prevent further premature breakdowns and the need to disassemble the transmission again in the near future. Inspect all transmission components and look for Broken or badly worn teeth Worn out or seized up bearings Badly worn spline shafts Cracks in the transmission housing or cover Gear Wear Lack of lubrication, wrong type of lubrication or transmission overheating may cause excessive wear or damage to transmission gears. When inspecting gears, follow these guidelines. Normal Wear As gears operate, the meshing operation and oil wash will polish the gear teeth, removing any sharp edges, imperfections or shards. The polished surface should cover the entire length and depth of the teeth. Well lubricated gears will show this condition after many

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TR-23

Transmission

Argo Service Manual

hours of operation. The initial 25 hrs of operation on a new transmission will indicate this process when the oil is changed for the first time. The oil will appear very silvery and fine metal filings will be noticeable on the drain plug's magnet. Abrasive Wear and Scratching Metal particles which flake off gears, shafts and castings are carried in the lubricant and can cause uneven and premature wear to gear teeth. Thorough cleaning of all components at disassembly and fresh transmission oil can normally prevent further wear of this kind. Breakage Any gear or spline shaft with cracked, broken or missing teeth should be replaced immediately. The installation of a badly damaged gear or shaft will lead to premature wear of other components and other potential breakdowns. Replace all badly worn, broken or missing components immediately with genuine ARGO replacement parts. If there is any doubt as to whether the transmission component needs replacing, generally the best thing to do is to replace it while the job is at hand. Aluminum Cage Inspect the aluminum cage for any hairline cracks, especially at the shoulder where the inner bearing is seated. Photo TR-68

Bearings

TR-68 Unless the ARGO technician has determined to his/her own satisfaction that the bearings are suitable to reuse, it is recommended that all bearings be replaced when rebuilding a transmission.

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TR-24

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Argo Service Manual

Transmission

Argo Transmission Assembly Transmission Component Changes Since 1992 This chart indicates changes to some of the transmission components since 1992. Most, if not all are fully exchangeable if your original part is no longer available. When ordering replacement parts, begin by referring to the correct parts manual for your year and model of ARGO. If the component is no longer listed in your Spare Parts Price List (Distributors & Dealers Only), check the Superceded Section for the correct part(s) that replace(s) the original.

Transmission Component

Shaft, Splined & Gear, Helical Affects earlier Vanguards 34-81 Output Shaft 610-24H Brake Disc 810-01 Brake Disc From Serial Numbers: CB16459 TB Oct. 27/99 RB16446TB Oct. 26/99 BF11143 TB Oct. 21/99 S11188 TB Nov. 17/99 SN11196 TB Nov. 17/99 Shift Gate (New) From Serial Numbers:

Description of Change Apr 29/1992 Keys are eliminated on the spline shaft. Helical gears and splined shafts are coupled by an extended 6PL.-spline. Fully Exchangeable. Jul 07/1999 The output shaft and brake discs are now splined eliminating the need for the 110-14 keys. Older stock is still available. Fully Exchangeable but both shaft and disc need to be replaced together. Refer to the appropriate illustrated parts manual for the new part numbers.

Jun 12/2000 Reason for Change -To limit the possibility of the transmission coming out of gear in certain situations.

SN11905 TB Oct. 4/00 S11906 TB Oct. 4/00 BF11917 TB Oct. 10/00 CB17471 YB Oct. 12/00 RB17525 Oct. 24/00

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TR-25

Transmission

Argo Service Manual

Transmission Component Transmission Cover From Serial Numbers: SN11905 TB Oct. 4/00 S11906 TB Oct. 4/00 BF11917 OB Oct. 10/00 CB17471 YB Oct. 12/00 RB17525 TB Oct. 24/00 Reverse Idler (34-16A) From vehicles manufactured from July 3, 2001

Shim Washer between Housing and Shifter Assy.

Description of Change Aug 11/2000 The side cover is cast solid in the area of the input shaft and shifter assembly at the 101-01 bearings. This eliminates the need for the 31-07 plug plates & 106-01 retaining rings normally used here. Fully Exchangeable.

July 3, 2001 Reverse Idler has two 105-03 bushings instead of a single, 105-05 bushing, along with two radial holes drilled in for better lubrication. Fully Exchangeable

Apr 16/2002 To address the issue of the retaining ring in some cases, popping off of the shift yoke due to interference on the casting. Any transmission being serviced and rebuilt between Serial Numbers: CB17404 - CB19432, RB17525 RB19502, BF11917 - BF13347, SN11905 - SN13349, or S11906 - S13350, would benefit from having this new 108-74 shim washer installed at the time of a rebuild. Even though this may not have been an issue, it will be a good precautionary measure for the future.

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TR-26

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Argo Service Manual

Transmission

Transmission Assembly Assembling the Differential 1.

Secure the Aluminum Cage to the base of the arbor press using a spacer and nut. Photo TR-69

Install (6) Oilite Bushings into the Aluminum Cage. Photo TR70

Repeat the process installing these bushings into the appropriate Gear Plate. Photo TR-71 The (3) Gear Plates used are: M-Gear Plate H-Gear Plate G-Gear Plate

Blow all foreign debris from the Cage and Gear Plate. Photo TR-72

TR-69

TR-70

TR-71 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-27

Transmission

Argo Service Manual

Install a Bearing into both Cage and Gear plate. Photo TR-73 & 74

Wipe the Output Shaft free of debris with a lint free rag. Install this Output Shaft into the Aluminum Cage. Photo TR-75 & 76

See Transmission Component Changes chart on page TR-25 regarding output shafts.

TR-73

TR-74

TR-75

TR-76

Use a spacing tool to secure the previously installed Bearing inside the Aluminum Cage while the Output Shaft is pressed into place. Photo TR-77

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TR-28

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Argo Service Manual

Transmission

Orient the Sun Gear as in Photo TR-78 with the higher shoulder side facing up. Install it to the splined end of the Output Shaft. Photo TR-79 & 80

Secure the Sun Gear with a Snap Ring. Photo TR-81

Be sure the Retaining Ring is properly seated to the machined groove of the Output Shaft. Photo TR-82 Press the Output Shaft from the inside of the cage to seat the Retaining Ring snuggly against the Sun Gear. Photo TR-83

TR-78

TR-79

TR-80

TR-81

TR-82

TR-83

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TR-29

Transmission

Argo Service Manual

10. Wipe down the 2nd Output Shaft and assemble to the Gear Plate using the same method as described for the Aluminum Cage. Photo TR-84, 85 & 86

TR-84

TR-85

TR-86

TR-87

11. Orient the 2nd Sun Gear as in instruction 8 and install and secure it with a 107-04 Retaining Ring using the same method as described for the Aluminum Cage in instruction 10. Photo TR-87, 88, 89 & 90

TR-89

TR-88

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TR-30

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Argo Service Manual

Transmission

TR-90

TR-91

12. Set the assembled Aluminum Cage into an assembly stand or an aluminum jawed vise Photo TR-91 13. Install (6) Pinions into the Oilite Bushings of the Aluminum Cage alternating the Pinions in an up and down manner as shown in Photo TR-92 & 93 14. LOCTITE the (3) threaded holes of the Aluminum Cage with Red 271 LOCTITE. Photo TR-94 15. Assemble the Gear Plate to the Aluminum Cage. Align the top of the Pinions in the Cage, with the Oilite Bushings in the Gear Plate. Photo TR-95 & 96

TR-92

TR-93

TR-94

TR-95

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TR-31

Transmission

Argo Service Manual

16. Seat the Gear Plate to the Aluminum Cage using a soft faced mallet. Photo TR-97 17

Apply Red 271 LOCTITE to each of the (3) fasteners, Photo TR- 98, and tighten down. Torque to specifications. Photo TR-99 & 100

TR-96

TR-97

TR-98

TR-99

TR-100

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TR-32

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Argo Service Manual

Transmission

18. Locate the Spline Shaft and assemble the appropriate Drive Gear to the splined end of it. Orient the gear with the machined side down. Photo TR-101, 102 & 103

Drive Gears are as follows: M Drive Gear H Drive Gear G Drive Gear

19. Place a Double Gear into the assembly stand or an aluminum jawed vise on the work bench. Place it into the stand with the machined hole side up. Photo TR-104 & 105 20. Install a Spring to the inner hole of the Double Gear. Photo TR-106 & 107

TR-101

TR-102

TR-103

TR-104

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TR-33

Transmission

Argo Service Manual

TR-105

TR-107

TR-106

TR-108

21. Place a Ball Bearing to the top of the spring. Photo TR-108 & 109

TR-109

22. Compress the Ball Bearing into the hole of the Double Gear with a flat screwdriver, at the same time inserting the Spline Shaft from the opposite side with the shift gate notches facing down. These notches will mate with the Ball Bearing within the Double Gear when the shifter assembly is completed. Photo TR-110, 111 & 112 (following page.)

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TR-34

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Argo Service Manual

Transmission

TR-110

TR-111

TR-112

TR-113

23. Use a soft face mallet to tap the Spline Shaft completely through the Double Gear. Photo TR-113 & 114 24. Remove the assembly to the bench. Grabbing the Double Gear in your hands, shift the Double Gear up and down the length of the Spline to check that all shift gates are smooth and lock securely. Photo TR-115

TR-114

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TR-35

Transmission

Argo Service Manual

Assembling the Housing and Cover 25. Install a Retaining Ring into the inner groove on the Output Shaft side of the Transmission Cover. Photo TR-116 & 117 26. Install the Bearing into the Side Cover with the arbor press. Seat it to the previously installed Retaining Ring. Photo TR-118 & 119

TR-116

TR-118

TR-117

TR-119

27. Apply yellow LOCTITE 641 to the outer edge of (2) Bearings and press them into the Side Cover. Be sure the shielded side is facing down. Photo TR120, 121 & 122

IMPOR TANT IMPORT Vehicles Manufactured prior to S/N CB17471, RB17525, BF11917, SN11905 & S11906 require 2 retainings rings to be installed to the cover first before the bearings are pressed into place. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-36

TR-120

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Argo Service Manual

Transmission

TR-121

TR-122

28. Install a Retaining Ring to the inner groove of the Housingâ&#x20AC;&#x2122;s Output Shaft side. Photo TR-123 & 124 29. Install a Retaining Ring into the Housing at the shifter assemblies bearing side. Photo TR-125 & 126

TR-123

TR-124

TR-125

TR-126

30. Apply 592 LOCTITE Teflon pipe sealant to the Magnetic Oil Drain Plug and install it into the housing. Tighten only snug into Housing. Photo TR-127 & 128 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-37

Transmission

Argo Service Manual

TR-127

TR-128

31. Tap a burnishing tool through the shifter assembly's Oilite Bushing if the old bushing has been replaced with a new one Photo TR-129 32. Place a Shim Washer on top of the previously installed Retaining Ring in the Housingâ&#x20AC;&#x2122;s Output Shaft side. Photo TR-130 & 131 (This may vary between 1 or 2 shims. Use the quantity previously used.) 33. Install the Bearing to the top of the shim and seat with the arbor press. Photo TR132 & 133 34. Install (1) Bearing, shielded side down, into the Housingâ&#x20AC;&#x2122;s Shifter Assembly side. Photo TR-134 & 135 (following Page)

TR-129

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TR-38

TR-130

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Argo Service Manual

Transmission

TR-133

TR-134

TR-135

TR-136

35. Install the 34-63 Shifter Yoke to the 34-65 Shifter Assembly securing it with a 10705 Retaining Ring. Photo TR-136, 137 & 138

TR-137

TR-138

36. Install the 113-01 â&#x20AC;&#x153;Oâ&#x20AC;? ring to the 34-65 Shifter Assembly. Photo TR-139 & 140 (following page) 37. From the inside of the Housing, slip the Shifter Assembly through the Oilite Bushing at the top of the Housing. Photo TR-141 (following page). Any transmission being serviced and rebuilt between Serial Numbers: CB17471 - CB19432, RB17525 - RB19441, BF11917 - BF13347, SN11905 - SN13349, or S11906 - S13350, would benefit from having this new 108-74 shim washer installed at the time of the rebuild. Even though this may not have been an issue, it will be a good precautionary measure for the future. Photo TR-142 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-39

Transmission

Argo Service Manual

TR-139

TR-140 TR-142

TR-141 38. Orient and secure the Shift Lever Holder to the Shift Shaft using (2) Roll Pins as shown in Photo TR-143. Be sure to support the shaft from below with a piece of metal stock when hammering the pins through the Holder. Photo TR-144

TR-143 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-40

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Argo Service Manual

Transmission

39. Insert the Dowel Pin into the boss of the transmission housing and using a soft face mallet, tap it flush to the sealing edge of the housing. Photo TR-145

TR-145

40. Install the Retaining Ring to the bottom of the Dowel Pin. Photo TR-146

TR-146 41. Attach the Shifter Lever assembly temporarily to the Holder. Photo TR-147

42. Place the Housing into a fixture for final assembly. Photo TR-148

TR-147

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TR-148

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TR-41

Transmission

Argo Service Manual

43. Use compressed air to blow any foreign debris from the Housing before attempting to install the sub-assembled components. Photo TR-149

TR-149 Install the Differential Assembly. 44. Place the Differential into the Housing, slipping the Output Shaft into the Output Shaft Bearing. Press at the arbor until the shoulder of the Aluminum Cage is seated to the Bearing. Photo TR-150, 151 & 152 Install the Shifter Assembly 45. Take the pre-assembled Shifter Assembly and place the Double Gear into the high gear gate on the spline (Lowest Position). Photo TR-153

TR-150

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TR-42

TR-151

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Argo Service Manual

Transmission

TR-152 46. Install the Shifter Assembly into the Housing, lining up the one end of the Spline Shaft with the bearing in the Housing. At the same time, be sure to slip the Shift Yoke over the larger diameter gear of the Double Gear. Photo TR-154

TR-153 TR-154

47. Tap the assembly with a soft faced hammer until the shoulder of the Spline Shaft seats to the Bearing. Photo TR155 & 156

TR-155 TR-156 Install the Reverse Idler

48. Press (2) Oilite Bushings into the Reverse Idler. Press one in from each end. Photo TR-157 & 158 Models manufactured prior to July 3, 2001 have a single oilite bushing and no radial holes drilled in the reverse gear Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-43

Transmission

Argo Service Manual TR-159

TR-158 49. If the old bushing(s) was/were replaced with new, press a burnishing tool through the Oilite Bushing of the Reverse Idler. Photo TR-159 & 160 50. Slip the Reverse Idler on to the Dowel Pin making sure that the chamfer side is facing down. Photo TR-161, 162 & 163

TR-160

TR-161

TR-162

TR-163

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TR-44

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Argo Service Manual

Transmission

51. While one hand holds the top of the Shifter Assembly, Use the other to shift the Lever through all gates. Check that all shift smoothly. Photo TR-164 52. Spin the entire assembly at the Output Shaft to check for any tight spots or unusual noises. Photo TR-165

TR-164

TR-165

53. Apply Black 598 LOCTITE RTV Silicon Gasket Maker to the bottom half of the Housing. Photo TR-166 54. Install the Cover Gasket to the sealing edge of the Housing. Photo TR-167

TR-166

TR-167

55. Apply the same gasket compound to the lower edge of the Side Cover as well. Photo TR-168 (following page) 56. Install the Cover to the Housing and press to fit. Photo TR-169,170 & 171 When applying pressure to the cover at the press, use a soft faced mallet to tap the top end of the cover at the same time to ensure that the cover is not installed crooked. Photo TR-172 & 173 (following page) Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-45

Transmission

Argo Service Manual

TR-168

TR-169

TR-170

TR-171

TR-172

TR-173

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Argo Service Manual

Transmission

57. Secure the Cover using (1) Cap Screw, (4) Bolts and (4) Lock Washers. Apply LOCTITE Silver Grade anti-seize to the cap screw before installing to the lower end of the transmission assembly. Photo TR-174 & 175

TR-174

TR-175

58. Secure the Cover and torque to specifications. Photo TR-176 & 177

Tighten down all fasteners in a cross corner sequence.

TR-176

Apply a little gear oil to the inner lip of the Oil Seal to ease assembly around the Output Shaft and prevent any deformity during installation. Photo TR-178

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TR-177

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TR-47

Transmission

Argo Service Manual

59. Press the inner Oil Seal to the Output Shaft. Seat it to the Retaining Ring that was previously installed in the Housing in step 29. Do not over press. Photo TR-179, 180 & 181 60. Install a Retaining Ring to the top of the Oil Seal. Photo TR-182 & 183

TR-179

TR-180

TR-181

TR-182

TR-183

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Argo Service Manual

Transmission

61. Press the outer Sealed Bearing into the Side Cover and seat it to the Retaining Ring. Photo TR-184, 185 & 186 62. Rotate the transmission assembly and repeat steps 59-61 to the Housing side.

TR-184

TR-185

TR-186

TR-187

63. Place the transmission back into the rotating fixture and thread the output shaft puller on to the Output Shaft. Photo TR-187 64. While holding the Output Shaft with the specialized tool holder, thread the hex head bolt into the Output Shaft and tighten it down until the shaft has been pulled towards the outside of the Housing. Pull the shaft far enough to install the Shim Washer and Retaining Ring to the machined groove of the Output Shaft. Photo TR-188, 189, 190 & 191 (following Pages)

IMPOR TANT IMPORT Output Shaft Shims come in two thicknesses. Generally, the .040" Shim Washer is installed on the cover side, and the .020" Shim Washer, is installed on the Housing Side. However, there may be cases when only the thinner of the two washers fit on the Cover Side and rare cases when the Output Shafts receive no Shim Washers at all Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-49

Transmission

Argo Service Manual

TR-188

TR-189

TR-190

TR-191

65. Rotate the transmission to access the Input Shaft side of the transmission. Photo TR-192 66. Seat the Reverse Idler Pin's Retaining Ring to the pin boss located in the transmission Housing. Through the Input Shaft opening, use a hammer and pin installer to tap the Reverse Idler Pin through the boss and out the Transmission Cover side. Seat the Retaining Ring to the boss. Photo TR-193 & 194 Do not over drive the Idler Pin Retaining Ring against the boss. Damage and deformation to the retaining ring could result in the possibility of it coming off during application.

TR-192 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-193 TR-50

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Argo Service Manual

Transmission

TR-194

TR-195

67. Rotate the Transmission and secure the opposite end of the Reverse Idler Pin with a 2nd Retaining Ring. Photo TR-195 68. Once the Retaining Ring has been secured to the Cover Side, use a hammer and tap the pin back in the opposite direction to seat the Retaining Ring to the Cover. Photo TR-196

TR-196

TR-197

69. Wipe off the Input Shaft with a lint free rag to remove any oil and debris and insert it into the Input Shaft opening. Use a soft faced mallet to seat the Input Shaft to the Bearing on the Cover Side. Photo TR-197, 198 & 199

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TR-51

Transmission

Argo Service Manual

70. Rotate the Input Shaft to check that it turns freely. Photo TR-200 71. Place the Input Bearing over the Input Shaft and seat it with a soft faced mallet and installation tool. Photo TR-201, 202 & 203

TR-200

TR-201

TR-202

TR-203

72. Place (1) Shim Washer on top of the previously installed Bearing. Photo TR-204 A transmission may utilize either 1 or 2 shims here. When reassembling, always install the original quantity. 73. Install and seat the Retaining Ring. Photo TR-205 & 206

TR-205

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Argo Service Manual

Transmission

TR-206

TR-207

TR-208

TR-209

74. Install the Oil Seal to the Input Shaft using a soft faced mallet and seal installation tool. Photo TR-207, 208 & 209 75. Apply 680 Green LOCTITE to the plug plate sealing edge and tap it into the Housing using a steel hammer. Photo TR-210, 211 & 212

TR-210

See Transmission Component Changes chart on page TR-26 regarding plug plates and side covers.

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TR-53

Transmission

Argo Service Manual

TR-212

TR-213

76. Place the transmission on the bench and perform a final shift through all gears. 77. Fill with .805 Litres of 80/90 Gear Oil. Photo TR-213 78. Install the Dipstick and check oil level. Installing the Transmission 1.

Locate the dash support and move it 90 degrees so that it will not interfere when installing the transmission back into the vehicle. Photo TR-214

Place the transmisson back into the power pack frame of the vehicle and install both mounting bolts. Apply blue 242 LOCTITE to the threads of the bolts and secure with a lockwasher and nut. Torque to specifications. Photo TR-215

TR-215

TR-214 3.

Next install the driven clutch guard. Apply blue 242 LOCTITE to the 2 mounting bolts and secure tightly. Torque to specifications. Photo TR-216

Reposition the dash support back down to the top of the transmission and tighten. Photo TR-217

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Argo Service Manual

Transmission

TR-217

TR-216 5.

If the vehicle utilizes the hydraulic brake system, reattach the entire assembly to the transmission using the 3 mounting bolts and lockwashers. Torque to specifications. Photo TR-218

TR-218

All brake lines and calipers should still be attached to the assembly. If not, once the hydraulic brake calipers have been remounted to the transmission and the brake lines reconnected, the brake fluid system will need to be filled with fresh new fluid and the brake system will have to bled. Refer to Bleeding the Hydraulic Brake System in this service guide if necessary. 6.

Perform the servicing procedure, Installing the Brake Disc.

IMPOR TANT IMPORT A small number of vehicles used a shim washer in behind the brake disc. This shim washer will need to be installed to the output shaft before the brake disc is slipped on. This is required to align the brake disc to the hydraulic caliper properly. Take note of the transmission serial number to correctly identify these vehicles. They are as follows: All 6 wheel hydraulic brake vehicles with serial numbers between BF11321 & BF11390 All 8 wheel vehicles with serial numbers between RB16700 & CB16778

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TR-55

Transmission

Argo Service Manual

Perform the servicing procedure, Installing the Idler Chain.

Perform the servicing procedure, Installing the Driven Clutch.

Perform the servicing procedure, Installing the Drive Belt.

10. Perform the servicing procedure, Installing the Firewall.

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TR-56

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GI-28

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Argo Service Manual

Transmission

SECTION TR

Supplement Pages

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Transmission

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Argo Service Manual

Transmission

Transmission Re & Re

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TR-1A

Transmission

Argo Service Manual

Argo Transmission Disassembly 1.

Drain oil and unthread the 4 fasteners securing the shifter lever assembly to top end of the transmission and remove the lever. Photo TR-1 & 2

TR-1

TR-2

Remove all fasteners securing the housing halves together. There are 11 located on the input shaft side and 4 located on the opposite side. Ensure that all fasteners have been removed before proceeding to seperate the transmission housings.

3. 4.

Remove the oil seal from the input shaft. Photo TR-3 Remove the retaining ring from the input shaft. Photo TR-4

TR-4

TR-3 5.

Remove the retaining rings from both output shafts. There may or may not be shims below the retaining rings. Photo TR-5

Separating the Transmission 6.

There are 3 threaded tab locations provided on the Avenger transmission housing (input shaft side). These locations are used to assist in separating the two halves of the transmission during disassembly. As 3 bolts are threaded into the housing, they come into contact with the opposite housing, pushing and separating the 2 halves.

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TR-2A

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Argo Service Manual

Transmission

Thread each of these bolts a little at a time and in an uniform alternating pattern. DO NOT overtighten to avoid the risk of breaking the housing tab. Stop occasionally to tap the output shaft with a soft faced hammer. Repeat this until the cover has separated. Photo TR-6 7.

Pull the housing halve, up and off from the input shaft side. Photo TR-7

TR-5

TR-6

TR-7

TR-8

Shift to top position.(High Gear) and remove roll pin from the shift block on the high/low shift shaft. Photos TR-8 & 9

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TR-3A

Transmission 9.

Argo Service Manual

Place shift shaft back into neutral. Photo TR-10

10. Place reverse shift shaft into reverse. Photo TR-11

TR-10

TR-11

11. Pull the input shaft from the transmission housing. Photo TR-12 12. Remove the spline shaft drive gear assembly. Photo TR-13 13. Remove the set screw securing the ball and spring within the housing at the hi/lo shift shaft assembly. Photo TR-14 14. Remove the spring and steel ball. Photo TR-15 & 16 15. Place the reverse shift shaft block back down against the housing (out of reverse). Photo TR-17 16. Remove the hi/lo shift shaft from the housing. Photo TR-18

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TR-4A

TR-12

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Argo Service Manual

Transmission

TR-15

TR-16

TR-17

TR-18

17. Using an arbor press, remove the smaller ball bearing from the end of the input shaft. Photo TR-19 18. Remove the retaining ring at the reverse gear. Photo TR-20

TR-19

TR-20

19. Remove the reverse and low gear from the input shaft at the arbor press. Photo TR-21 20. Slip the dog clutch from the input shaft and remove the retaining ring & Thrust Washer found above the High Gear. Photo TR-22 21. Slip the high gear from the input shaft, PhotoTR-22 and remove the thrust washer and Retaining Ring found below it. Photo TR-23 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-5A

Transmission

Argo Service Manual

TR-22

TR-21

TR-23

TR-24

22. Remove the last ball bearing from the input shaft at the arbor press. Photo TR-24 Disassemble the Spline Shaft Drive Gear Assembly 23. Remove the bearing and high gear from the spline shaft at the arbor press. Photo TR-25 24. Remove low gear, reverse gear, drive gear and bearing from the spline shaft using the the arbor press. Photo TR-26

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TR-6A

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Argo Service Manual

Transmission TR-26

26. Press the differential from the housing at the arbor press. Photo TR-28

The use of wood blocks beneath the housing prevents damage to the sealing edge of the casting as well as provides height for removing the differential

TR-28

TR-29

27. Disassemble the reverse shift shaft block by removing the roll pin securing it to the shaft. Photo TR-29 & 30

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TR-7A

Transmission

Argo Service Manual

28. Remove the 3 steel balls located in the housing, between the hi/lo shift shaft and the reverse shift shaft. Photo TR-34

TR-35

TR-34

29. To remove the reverse shift shaft and reverse idler gear from the housing, first remove the retaining ring located above the reverse idler. Photo TR-35 30. Raise the reverse idler up and remove the retaining ring found below. Photo TR-36

TR-36

TR-37

31. Pull the reverse shift shaft up and free from the housing. Photo TR-37 32. Remove the Steel Dowel Pin from the reverse shift shaft.

IMPOR TANT IMPORT There is 1 Thrust Washer to the top side of the reverse idler gear and a Retaining Thrust Washer to the underside of the reverse idler gear 33. Remove the reverse shift shaft from the housing. Photo TR-38 34. Remove the last ball and spring from the housing. Photo TR-39

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Argo Service Manual

Transmission

TR-38

TR-39

35. Remove all remaining Retaining Rings, Bearings and Seals from both the left and righthand side housings. 36. Wash and soak all components in a degreasing bath before inspection. Reassembling the Transmission

IMPOR TANT IMPORT Installing the correct Retaining Ring to each of the components during the assembly of the Avenger transmission is extremely important. Small variances in retaining ring sizes can make it difficult at first glance to distinguish these differences. This could result with the improper placement of a retaining ring to a component.

The 107-02 Retaining Ring is installed to one side of the High Gear Pinion on the Input Shaft assembly, while the 107-10 Retaining Ring is installed on the other side. The one Retaining ring is slightly larger. Ensure that each is installed to the correct retaining ring seat according to the instructions outlined on the following pages.

Caution should also be observed with the 107-04 and 107-12 Retaining Rings. The 107-04(smaller), is used to secure each sun gear to the end of the Output Shafts within the differential. The 107-12 (larger), is seated just above the Reverse Gear Pinion on the Input Shaft Assembly. WHEN COMPARING THESE TWO THEY ARE VERY SIMILAR IN SIZE. IF IN DOUBT, A MEASUREMENT SHOULD BE TAKEN.

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TR-9A

Transmission

Argo Service Manual

Reassembling the Transmission 1. Lay out all components of the AVENGER Transmission on a clean work surface. See Photo below and following page.

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TR-10A

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Argo Service Manual

Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

Transmission

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TR-11A

Transmission

Argo Service Manual

Assembling the Idler Gear Bore Assembly

Install the 34-109 High Gear to the short side of the 34-112 Splined Shaft. Photo TR-41

IMPOR TANT IMPORT

Install the High Gear with the machined shoulder up. See Photo TR-41 2.

Press the 101-01 Bearing to the High Gear end of the Splined Shaft with the shielded side facing out. Photo TR-42

TR-41

TR-42 3.

TR-43

Install the 34-110 Low Gear to the opposite side of the Splined Shaft (long side). Photo TR-43

IMPOR TANT IMPORT Install the Low Gear with the machined shoulder up. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-12A

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Argo Service Manual 4.

Transmission

Slip on the 34-111 Reverse Gear up against the previously installed Low gear. Photo TR-45

TR-44

IMPOR TANT IMPORT The 34-111 Reverse gear must be assembled to the Splined Shaft with the chamfered teeth side facing up. Photo TR-45 5.

Install the 34-123 Drive gear to the top of the previously installed Reverse Gear. Photo TR-46

TR-46 6.

TR-47

Press on the 101-01 bearing to the end of the shaft, shielded side up. Photo TR-47 See assembled component on the following page.

IMPOR TANT IMPORT Do not install this 101-01 Bearing to the end of the shaft if the differential assembly has the high ratio 3.3 Gear Plate. This bearing should be installed to the housing at the same time as the 101-03 Bearing (step 16 of Assembling Transmission Components to Housing pg. TR-25). Interference between this Bearing and Gear Plate teeth will be apparent later on when installing along side the differential assembly if this is not observed. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-13A

Transmission

Argo Service Manual

Assembling the Input Shaft (Transmissions built prior to A5883) For transmissions built from A5883 see Pages TR-35A for revised Input Shaft Assembly guidance. 1. Install the 107-02 Retaining Ring to the 34-104 Input Shaft. Photo TR-48

IMPOR TANT IMPORT Remember to do the comparison check of this retaining ring as described on page TR-9 2.

Slip a 108-79 Thrust Washer on to the Input Shaft and up against the previously installed retaining ring. Photo TR-49

TR-48

TR-49 3.

Slip the 34-105 High Gear Pinion (with 4 dog teeth), or 34-128 High Gear Pinion (with 3 dog teeth), up against the Thrust Washer. Photo TR-50 See Note Regarding number of teeth on following page

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TR-14A

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Argo Service Manual

Transmission

Transmissions manufactured prior to serial #A2856 utilize 4 dog teeth and from #A2856, 3 dog teeth. Photo TR-50 Orient the the High Gear Pinion with the dog teeth facing up. 4.

Install the second Thrust Washer to the top of the High Gear Pinion. Photo TR-51

TR-50

TR-51

Install the 107-10 retaining ring to secure the second thrust washer. Photo TR-52

Slip the 34-103 Dog Clutch (4 Tooth, prior to serial #A2856)or 34-127 Dog Clutch (3 tooth, from serial #A2856),to the Input Shaft. Photo TR-53

TR-52

TR-53

Install the 34-106 Low Gear Pinion (4 Tooth, prior to serial #A2856) or 34-129 (3 tooth, from serial #A2856)with the dogs facing towards the previously installed Dog Clutch. Photo TR-54

Press the 34-107 Reverse Gear Pinion on to the Input Shaft and up against the Low

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TR-15A

Transmission

Argo Service Manual

Gear Pinion. Orient the Reverse Gear Pinion with the chamfered teeth facing up. Photo TR-55

TR-54 9.

TR-55

Secure the Reverse Gear Pinion with a 107-12 Retaining Ring. Photo TR-56

10. Press a 101-01 bearing to the end of the Input Shaft with the shielded side up. Photo TR-57

TR-56

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TR-16A

TR-57

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Argo Service Manual

Transmission

Assembling the Differential 1.

Install all 105-03 Oilite Bushings into both 34-122 cage and 34-124 Gear Plate. Photo TR-58 & 59

TR-59

TR-58 2.

Blow all foreign debris from the Cage and Gear Plate.

Install the 101-15 Bearing into both Cage and Gear plate. Photo TR-60 & 61

Wipe the 34-98 Output Shaft free of debris with a lint free rag. Install this Output Shaft into the Aluminum Cage. Photo TR-62 & 63 See Note following page.

TR-60

TR-61

TR-62

TR-63

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TR-17A

Transmission

Argo Service Manual

Use a specialized spacing tool to secure the previously installed 101-15 Bearing inside the Aluminum Cage while the Output Shaft is press into place. Photo TR-64 7.

Orient the 34-14 Sun Gear as in Photo TR-65 with the higher shoulder side facing up. Install it to the splined end of the Output Shaft. Photo TR-66 & 67

TR-64

Secure the Sun Gear with a 107-04 Snap Ring. Photo TR-68

TR-65

TR-66

TR-67

TR-68

Be sure the Retaining Ring is properly seated to the machined groove of the Output Shaft. Photo TR-69 Press the Output Shaft from the inside of the cage to seat the Retaining Ring snuggly against the Sun Gear. Photo TR-70

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Argo Service Manual

Transmission

TR-69

TR-70

10. Wipe down the 2nd 34-98 Output Shaft and assemble to the Gear Plate using the same method as described for the Aluminum Cage. Photo TR-71, 72 & 73

TR-71

TR-72

TR-73

TR-74

11. Orient the 2nd 34-14 Sun Gear as in instruction 8 and install and secure it with a 10704 Retaining Ring using the same method as described for the Aluminum Cage in instruction 10. Photo TR-74, 75, 76 & 77

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TR-19A

Transmission

Argo Service Manual

TR-75

TR-76

TR-77

TR-78

12. Set the assembled 34-122 Aluminum Cage into an assembly stand. Photo TR-78 13. Install (3) 105-23 Hollow Dowl Pins into the mounting holes of the aluminum cage. Photo TR-79

TR-79

TR-80

14. Install (6) 34-13 Pinions into the Oilite Bushings of the Aluminum Cage alternating the Pinions in an up and down manner as shown in Photo TR-80 & 81

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Argo Service Manual

Transmission

TR-81

TR-82

TR-83

TR-84

16. Assemble the Gear Plate to the Aluminum Cage. Align the top of the Pinions in the Cage, with the Oilite Bushings in the Gear Plate. Photo TR-82 & 83 17. Seat the Gear Plate to the Aluminum Cage using a soft faced mallet. Photo TR-84 18

Apply Red 271 LOCTITE to each of the (3) 112-143 fasteners, Photo TR- 85, and tighten down to 35 FT/LBS. Photo TR-86

TR-85

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TR-21A

Transmission

Argo Service Manual

Assembling Transmission Components to Housing 1.

Apply some LOCTITE pipe sealant to the threads of the 103-02 drain plug and install into the housing. Photo TR-87 & 88

TR-87 2. 3.

TR-88

Start the 34-114 Reverse Shift Shaft into the housing boss as illustrated in Photo TR-89. Place a 108-78 Thrust washer above the 34-108 Reverse Idler, and a 108-81 Retaining Thrust Washer (machined side down), below the Reverse Idler. Push the 34-114 Reverse Shift Shaft completely through the Reverse Gear and washers and into the opposite side of the housing. Install the Reverse gear with the chamfered teeth facing up. Photo TR-90 & 91

TR-89

TR-90

Install the 34-32 Spring into the machined hole of the 34-102 Right Hand Housing at the Reverse Shift Shaft location. Photo TR-92

Install the 109-05 Steel Ball to the top of the Spring. Photo TR-93

Push down on the Steel Ball using the access hole from the top of the Transmission Housing. While the ball is compressed, press the shaft over top of the ball. Photo TR-94

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Argo Service Manual

Transmission

TR-91

TR-92

TR-93

TR-94

IMPOR TANT IMPORT Transmissions Manufactured From Serial Number A3784, require a 113-16 O-Ring installed to the machined groove located near the end of the reverse shift shaft and require these extra steps to install it. i

Continue to push the reverse shift shaft through the housing until the machined groove for the O-ring location is visible to the outside of the housing. Photo TR94A

Install the 113-16 O-ring to the groove and apply some oil lubrication. Photo TR94B

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TR-23A

Transmission

Argo Service Manual

iii

Push the reverse shift shaft back through the housing ensuring that you don't damage the O-ring as re-enters the housing.

Pull the Reverse Shift Shaft up until the lower retaining ring groove location is visible. shaft is Photo TR-95

Install the 107-11 Retaining Ring onto the Reverse Shift Shaft. Photo TR-96 & 97

TR-95

TR-96

10. Lower the Reverse Idler Gear and install the second 107-11 Retaining Ring to the machined groove at the top of the Reverse Idler Gear. Photo TR-98 & 99

TR-97

TR-98

11. Insert a tool, eg. an allen wrench, into the machined hole of the Reverse Shift Shaft and turn the shaft until the keyways of both shaft and transmission boss are aligned. Photo TR-100

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Argo Service Manual

Transmission

TR-99 12.

TR-100

Install the 104-40 Dowel Pin to secure the Reverse Shift Shaft. Photo TR-101

13. Assemble the 34-115 Reverse Shift Block to the Reverse Shift Shaft by aligning the keyway with the previously installed Dowel Pin. Photo TR-102

TR-101

TR-102

14. Tap the Shift Block on until the machined hole in both the Reverse Shift Shaft and the Shift Block are aligned, then install the 104-39 Spring Pin. Photo TR-103, 104 & 105

Install the Roll Pin flush to the machine corner of the shift block as shown in Photo TR105

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TR-25A

Transmission

Argo Service Manual

TR-104

TR-103

TR-105

TR-106

15. Install a 106-03 Retaining Ring to top groove of the Housing. Photo TR-106 16. Press and install the 101-03 bearing into the Housing. Photo TR-107 & 108

TR-107

TR-108

If the differential consists of the high ratio 3.3 Gear Plate, it will be advantages to install the 101-01 Bearing into the cover as well at this point to avoid any interference later when installing the assembled Idler Gear Bore Assembly. See IMPORTANT on page TR-13 17. Press the assembled differential into the Housing. Photo TR-109 & 110 18. Install the Idler Gear Bore Assembly at the arbor press. Photo TR-111 & 112 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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Argo Service Manual

Transmission

TR-109

TR-110

TR-111 TR-113

TR-112 19. Next, push the Reverse Shift Shaft and Block down against the Housing boss (out of reverse). Install (3) 109-05 Steel Balls into the Hi/Low Shift Shaft cavity of the Housing, and push each one into the machined hole at the Reverse Shift Shaft. These (3) Steel balls will be located between the Reverse Shift Shaft and Hi/Low Shift Shaft. Photo TR-113 & 114 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-27A

Transmission

Argo Service Manual

20. Install the 34-113 Hi/Low Shift Shaft into the Housing with the 3 machined gates facing to the outside of the housing and the 1 machined gate facing the Reverse Shift Shaft. Photo TR-115

TR-115

TR-116

21. Align the middle gate in the Hi/Lo Shift Shaft with the access hole in the casting and install a 109-05 Steel Ball and 34-32 Spring. Photo TR-116, 117 & 118

TR-117

TR-118

22. Apply Blue LOCTITE to the threads of the 112-145 Set Screw and tighten into the Housing approximately 2 1/2 turns. This may need to be adjusted later depending on how hard or easy the transmission shifts when tested. Photo TR119 23. Assemble the 34-116 Shift Fork to the Dog Clutch on the Input Shaft Assembly. Photo TR-120

TR-119

24. Raise the Reverse Shift Block up (into reverse). Align the the machined hole of the Hi/Lo Shift Block Fork, with that of the Hi/Lo Shift Shaft, and install the complete Input Shaft assembly into the housing. Photo TR-121 & 122 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-28A

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Argo Service Manual

Transmission

TR-120

TR-121

TR-122

TR-123

25. Place the transmission into the neutral position. Photo TR-123 26. Secure the Hi/Lo Shift Fork to the Shift Shaft using a 104-39 Spring Pin. Photo TR-124

TR-124

TR-125

27. Install a 106-03 Retaining Ring to the top groove of the 34-101 Left Transmission Housing at the output shaft opening, and a 106-05 Retaining ring at the input shaft opening Photo TR-125 28. Place a 114-01 shim to the top of the 106-03 Retaining Ring. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-29A

Transmission

Argo Service Manual

28. Press a 101-03 & 101-16 Bearing into the Left Transmission Housing. Photo TR126 29. Apply Black 598 LOCTITE RTV Silicon Gasket Maker around the perimeter of the Transmission Housing 30. Press the Left Hand Housing to the Right Hand Housing at the arbor press. Tap with a soft face mallet while pressing at the output shaft area. This will ensure that the housing is pressed on squarely and evenly to the lower half. Photo TR-127

TR-126

TR-127

31. Secure the halves of the transmission together using (10) 112-143, (1) 112-144 fasteners & (11) 108-05 lockwashers installed from the left side of the Housing. Three (3) 112-143, (1) 112-144 fasteners and (4) 108-05 lockwashers are installed from the right side of the Housing. Photo TR-128 Torque to 20FT-LBS

Two of these fasteners are shorter and are assembled into the transmission casting at blind holes. One is assembled at the drain plug area from the left side of the housing, Photo TR-129, and the other at the Shifter Lever area from the right side of the housing. Photo TR-130

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TR-129

TR-30A

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Argo Service Manual

Transmission TR-131

TR-130 35. Install the 102-05 Oil Seal to the Input Shaft. Photo TR-131 & 132 36. Install the 102-03 Oil Seal to the Output Shaft. Seat below the Retaining Ring groove. Photo TR-133 & 134 37. Seat a 106-03 Retaining ring to the machined groove just above the previously installed Oil Seal. Photo TR-135

TR-132

TR-133

TR-134

TR-135

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TR-31A

Transmission

Argo Service Manual

38. Install a 101-05 Bearing to the Output Shaft. Photo TR-136 & 137

TR-136

TR-137

39. Repeat Steps 36 through 38 for the other Output Shaft. 40. Using the Output Shaft puller, pull each of the Output Shafts. Install a 114-04 Shim under the 107-02 Retaining Ring at the Output Shaft on the Left Side Housing. Install a 114-05 Shim under the 107-02 Retaining Ring at the Output Shaft on the Right Hand Side Housing. Photo TR-138, 139 & 140

IMPOR TANT IMPORT Ensure that all retaining rings are seated properly

TR-138

TR-139

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TR-32A

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Argo Service Manual

Transmission

TR-141 41. Locate the shift lever opening and place the transmission shift blocks in the neutral postion. See Photo TR-141 42. Place the 113-11 O-ring into the 34-118 Shifter Plate. Photo TR-142 43. Assemble the 34-117 Shift Lever to the Shifter Plate. Apply a small amount of axle grease to the ball area of the shifter lever. Photo TR-143

TR-142

TR-143

44. Apply Blue LOCTITE to each of the 112-04 Fasteners and secure the Shift Lever assembly to transmission. Photo TR-144 & 145

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TR-33A

Transmission

Argo Service Manual

46. Install the CE-035 Dipstick. Photo TR-146 47. Fill the transmission with 1.1 L (38.7 oz of 80 W 90 Gear Lube HYPOY-C.

TR-146

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TR-34A

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Argo Service Manual

Transmission

1. Transmissions built from A5883: Locate the 34-130 Input Shaft and install the first half of the 107-14 Retaining Ring to the machined groove at the High Gear Pinion location. Photo 1 & 2

2. Interlock the second half of the 107-14 Retaining Ring into the previously installed one. Photo 3 At the opposite side, squeeze the retaining ring assembly together to lock and seat securely into the machined groove. Photo 4 & 5

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TR-35A

Transmission

Argo Service Manual

4. Locate the 108-85 Retaining Thrust Washer and slip it over the input shaft (cupped side towards retaining ring) and up against the retaining ring assembly. Photo 6 & 7

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5. Install the High Gear Pinion on to the Input Shaft (dog teeth facing towards the Thrust Washer). Rest it against the Thrust Washer. Photo 8

TR-36A

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Argo Service Manual

Transmission

6. Slip a 108-79 Thrust Washer to the other side of the High Gear Pinion and secure with a 107-02 Retaining Ring. Photos 9, 10 & 11

11 6. Slip the Dog Clutch to the Input Shaft. Photo 12

IMPOR TANT IMPORT The Dog Clutch needs to be oriented correctly when assembled to the Input Shaft. The dogs on one side of the clutch have a small machined shoulder. These dogs will engage with the Low Gear Pinion so they face away from the previously installed High Gear Pinion Photo 12 7. Install the Low Gear Pinion with the dogs facing towards the previously installed Dog Clutch. Photo 13 8. Slip the Reverse Gear Pinion on to the Input Shaft and up against the Low Gear Pinion. Orient the Reverse Gear Pinion with the chamfered teeth facing up. Photo 14

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TR-37A

Transmission

Argo Service Manual

9. Secure the Reverse Gear Pinion with a 107-15 Retaining Ring. Photos 15 & 16

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TR-38A

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General Information

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Argo Service Manual

GI-28

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ARGO SERVICE MANUAL

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673-06 Argo Service Manual Supplement Pages To be inserted into the 673-04 Argo Service Manual 1.

Replace original indexes with supplied revised indexes

Replace clutch pages CS-19 through CS-26 with revised pages

Replace torque pages in Section GI with revised torque pages

Insert dividers at the end of each correlating section followed by the supplement pages for that section

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673-06

05/06

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Argo Service Manual

Brake System

BR-1

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Brake System

Argo Service Manual

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BR-2

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Argo Service Manual

Brake System

SECTION BR

Supplement Pages

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Brake System

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Argo Service Manual

Brake/Steering System

Read all the instructions thoroughly before starting and attempting ANY repairs. Consult your Argo Dealer if you have any questions. Disassembling the Moto Cross Style Steering Column (All Models) 1.

Perform the servicing procedure, Removing the Firewall.

Cut the tie wrap securing cables to the steering column.

Remove the (4) fasteners securing the steering bar to the steering column assembly. Photo ST-1

ST-1

ST-2

Remove the Nylon Locknut and Flat Washer from the top of the Lower Handle Bar Clamp. Discard the nylon locknut. Photo ST-2

Remove the Lower Handle Bar Clamp from the steering shaft. Photo ST-3

IMPORTANT Be aware of the small key(s) installed into the steering shaft and ensure they are installed when reassembling the steering system.

ST-3

Disconnect the hand brake lever cable at the steering arms.

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BR-1A

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Brake/Steering System

Argo Service Manual

Avenger Models Only i.

Slip the Steering Shaft from the Steering Column Assembly. Photo ST-5

ST-4

ST-5

On all models manufactured from C22453, R22452, B14700, A14743, N14708 i.

IMPORTANT Be aware of the 108-08 Flat Washer Spacers used between the Steering Column Frame Assembly and the transmission mounting bosses. ii.

Slip the shaft from the column.

Disassemble the steering shaft as follows:.

On Avenger Models Only - Prior to V22441 i.

Place the Steering Shaft on a clean work bench and remove the 4 roll pins. Photo ST-6 Slide each steering arm and centering spring from the shaft.

1 Retaining Ring is located between the two Steering Arms. Vehicles manufactured from V22441, C22453, R22452, B14700, A14743, N14708: i.

Remove the 2 Spring Pins and Steering Arms from the Steering Shaft. Photo ST-7 A Retaining Ring is located between the two steering arms.

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BR-2A

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Argo Service Manual

Brake/Steering System

ST-6

ST-7

Reassembling Steering Column (Avenger Models Only - Prior to V22441) i.

ST-8 ii.

ST-9

Slip the first Steering Arm on to the Steering Shaft, followed by the Retaining ring, seating it to the groove on the shaft. Install the second Steering arm. Orient them as illustrated in Photo ST-10

iii. Install the 2nd Spring Pin, followed by a centering spring. Install the 3rd Spring Pin, followed by a 2nd centering spring and 4th Spring Pin. Photo ST-11 & 12

Please observe the orientation of the free end of the springs. Each is pointing in the same direction as the steering arms. Photo ST-13

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Brake/Steering System

Argo Service Manual

ST-11

ST-10

ST-12

Roll pin slot ST-13 parallel with shaft Vehicles manufactured from V22441, C22453, R22452, B14700, A14743, N14708: i.

ii.

Slip a steering arm on to the shaft and up against the previously installed Spring Pin.

ST-14

iii. Next, Install a Retaining Ring to the machined groove on the Steering Shaft. This retaining ring will be located between the 2 steering arms. iv.

Install the second steering arm and last spring pin. Photo ST-15. Orient as in Photo ST-16

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BR-4A

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Argo Service Manual

Brake/Steering System

ST-15 9.

ST-16

Apply some axle grease to the length of the Steering Shaft, Photo ST-17, and insert it from the bottom up, into the Steering Column Assembly with the small keyway facing towards you. Photo ST-18

ST-18

ST-17

On Vehicles manufactured from C22453, R22452, B14700, A14743, N14708: i.

ST-18A

BR-5A

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Brake/Steering System

Argo Service Manual

ST-19

ST-20

ST-21

ST-22

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BR-6A

ST-23

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Argo Service Manual

Brake/Steering System

ST-24

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BR-7A

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Brake/Steering System

Argo Service Manual

Hydraulic Brake Plunger Pin Adjustment

Loosen the set screw securing the collar to the plunger pin. Photo BR-1 This will free the collar to slide along the pin.

BR-1 3.

BR-2

Locate the cable length adjustment for the hand brake lever near the steering arm and thread in to slacken the brake cable across the steering arms. Please note this step is only required on earlier models manufactured up to serial number V22440 Photo BR-2

BR-3

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Argo Service Manual

Brake/Steering System

IMPORTANT Both left and right steering arms should be pulled back to their rear most limit before the plunger pin adjustment is made. On earlier models you should use both hands to pull back on each arm to ensure they are back in the rear most position. Photo BR-3 Vehicles manufactured from serial number V22441 utilize a double spring behind the plunger in the master cylinder which will provide plenty of spring tension to push the steering arms back fully. Setting Plunger Pin Adjustment

BR-4 1.

IMPORTANT

Re-adjust the hand brake lever cable until any slack has been removed between the two steering arms and is on the verge of engaging the brakes. Tighten the brake cable jam nut.

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BR-9A

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Brake/Steering System 8.

Argo Service Manual

Re-check the brake plunger piston to ensure it is still flush to the casting and fine adjust if necessary. Install the rubber boot.

Ensure that the steering handle bar rests parallel to the dash in the non-braking position when released from a right or left turn position. Photo BR-5

BR-5

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BR-6

BR-10A

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Argo Service Manual

Brake/Steering System

BR-7

Perform the servicing procedure, Hydraulic Plunger Pin Adjustment (Avenger Model), in this section of the service guide.

Re-hook the springs and test. Adjust either upper, lower or both springs as necessary until the desired outcome is achieved.

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BR-11A

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Brake/Steering System

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BR-12A

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Argo Service Manual

Clutch System

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CS-1

Clutch System

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CS-2

Argo Service Manual

Clutch System

SECTION CS

Supplement Pages

Ontario Drive & Gear ltd. (519) 662-2840 FAX (519) 662-2421

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Clutch System

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Argo Service Manual

Clutch System

Argo Service Manual IMPOR TANT IMPORT

There are (3) small lockwashers on these (3) fasteners. Ensure that they are still in place before re-installing and torquing the spring cap back down.

NO TE NOTE

To properly torque, re-install the driver to the engine PTO and lock flywheel while using the torque wrench to achieve proper torque.

9 CS-10A

Argo Service Manual

Engine System

SECTION EN Engine System Table of Contents Briggs V Twin & Kawasaki L/C Engine Photographs.....................EN-2 General Instructions............................................................................. EN-3 Checking the Engine Oil....................................................................... EN-4 Recommended Engine Oil.................................................................... EN-4 Changing the Engine Oil...................................................................... EN-5 Draining the Engine Oil........................................................................EN-5 Oil Filter Replacement..........................................................................EN-6 Refilling the Engine...............................................................................EN-7 Air Filter................................................................................................. EN-7 Spark Plugs............................................................................................ EN-7 Removing the Engine(Kawasaki FD620D L/C)..................................EN-8 Assembling the Engine to the Power Pack Frame (Kawasaki)......... EN-13 Installing the Engine............................................................................. EN-14 Removing the Engine(Briggs Models)................................................. EN-18 Installing the Engine (Briggs Models)................................................. EN-20 Removing the Engine (Kohler Aegis) Supplement Pages................ EN-20A Installing the Engine (Kohler Aegis) Supplement Pages.................. EN-25A

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EN-1

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Engine System

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EN-2

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Argo Service Manual

Engine System

SECTION EN

Supplement Pages

Ontario Drive & Gear ltd. (519) 662-2840 FAX (519) 662-2421

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Engine System

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Argo Service Manual

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Argo Service Manual

Engine System

Removing the Engine (Kohler Aegis N.A) 1.

Locate the tailpipe assembly and detach the connecting springs between the tailpipe assembly and muffler. Photo 1 & 2 Pull the assembly out through the hood area.

Remove the heat deflector shield covering the muffler. Photo 3

Disconnect the fuel line from the fuel filter at the carburetor. Photo 4

Disconnect All Wiring 4. Disconnect the ground cable at the engine. Photo 5 & 6

5 Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

EN-20A

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Engine System

Argo Service Manual

Disconnect the ground wire attached at the front of the engine to the valve cover fastener. Photo 7

Locate the main wire harness plug-ins at the front of the engine compartment and disconnect all wires. Photo 8

Locate the starter at the front of the engine compartment and disconnect both red and black power wires from the starter solenoid. Photo 9 These wires are enclosed within a red rubber boot.

Remove the drive belt between engine and transmission. Photo 10

9 9.

Remove the driven clutch from the transmission input shaft. Photo 11 & 12

12 Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-21A

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Argo Service Manual

Engine System

16 Ontario Drive & Gear Limited. PH. (519)- 662-2840 FAX (519)- 662-2421

EN-22A

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Engine System

Argo Service Manual

Lifting the Engine From the Vehicle

20 Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

21 EN-23A

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Argo Service Manual

Engine System

IMPORTANT These shims MUST be reinstalled before the driver clutch.

20. Remove all fluids.

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EN-24A

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Engine System

Argo Service Manual

Installing The Engine (Kohler Avenger Model) 1.

Install the (5) shims to the PTO of the engine. Photo 1

Apply anti-seize compound to the PTO. Photo 2

Install the key to the keyway of the PTO. Photo 3

Slide the driver clutch on and up to the shoulder of the PTO. Photo 4

3 5.

Secure the driver with the hex head fastener. Apply blue LOCTITE and Torque to specifications. Photo 5

IMPORTANT

For part number and descriptions of all components and hardware, always refer to your illustrated Argo parts manual. 6.

Install the muffler assembly to the engine manifold. Photo 6

IMPORTANT Always use new manifold gaskets Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-25A

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Argo Service Manual

Engine System

7 7.

Attach the hoist hooks to the engine location as described in 14 of Removing The Engine.

Swing the engine assembly over the open hood area of the Avenger vehicle. Locate the (4) mounting studs on the power pack frame. Photo 9

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EN-26A

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Engine System 9.

Argo Service Manual

IMPORTANT Once the engine is seated into place, ensure that the rubber rad seal is properly sealing at the face of the radiator. Photo 12

EN-27A

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Argo Service Manual

Engine System

15. Reinstall the drive belt between engine and transmission.

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EN-28A

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Engine System

Argo Service Manual

19. Reconnect the ground cable at the engine. Photo 22 & 23

22 20. Reconnect the fuel line to the carburator. Photo 24 21. Reinstall the heat deflector shield over the muffler. Photo 25 Ontario Drive & Gear Limited PH. (519)- 662-2840 FAX (519)- 662-2421

EN-29A

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Argo Service Manual

Engine System

22. Locate and install the tailpipe assembly. Attach the connecting springs between tailpipe assembly and muffler. Photo26 & 27 Feed the tailpipe assembly in through the hood area.

23. Replenish all fluid levels.

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Engine System

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Argo Service Manual

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Argo Service Manual

Wheels, Axles & Chains

SECTION WA Wheels, Axles & Chains Table of Contents Removing the Idler Shaft (Vanguard & Vanguard2)........................ WA-29 Idler Shaft Inspection........................................................................... WA-31 Installing the Idler Shaft (Conquest 8& 6, Response,Bigfoot........... WA-32 Installing the Idler Shaft (Avenger Models) Supplement Pages....... WA-32A Installing the Idler Shaft (Vanguard & Vanguard2)......................... WA-38 Aligning the Idler Shaft (Vanguard & Vanguard2)........................... WA-39 Idler Shaft Bearing Lubrication.......................................................... WA-41 Removing an Axle (Without Bearing Extension)............................... WA-42 Removing the Axle Seals....................................................................... WA-43 Installing the Axle Seals........................................................................ WA-44 Installing an Axle (Without Bearing Extension)................................ WA-45 Keyed Front Axles (Earlier 6x6 Vanguards)...................................... WA-48 Outer Axle Flange & Bearing Lubrication......................................... WA-49 Inner Axle Bearing Lubrication.......................................................... WA-49 Removing an Axle (With Bearing Extension).....................................WA-50 Removing an Axle (With 810-91 Bearing Extension) Supplement Pages..................................................................................WA50A Installing an Axle (With Bearing Extension)...................................... WA-50 Installing an Axle (With 810-91 Bearing Extension) Supplement Pages..................................................................................WA-52A Removing the Bearing Extension.........................................................WA-52 Installing the Bearing Extension..........................................................WA-52 Removing the Inner Bearing................................................................ WA-53 Installing the Inner Bearing................................................................. WA-53 Removing a Tire.....................................................................................WA-55

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WA-2

Wheels, Axles & Chains

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Argo Service Manual

WA-2

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Argo Service Manual

Wheels, Axles & Chains

SECTION WA

Supplement Pages

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Wheels, Axles & Chains

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Argo Service Manual

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Argo Service Manual

Wheels, Axles & Chains

Assembling The Idler Shafts To The Vehicle (Avenger Models) 1.

Apply some LOCTITE anti-sieze compound to each end of the 810-32 idler shafts .

Right Hand Idler Shaft 2.

15A

Face the collar of the 101-35 bearing towards the sprocket

15C 15B Left Hand Idler Shaft 1.

Avenger Models From Serial # V23216 2.

Install the inner axle bearing assemblies to the inner bearing locations on both sides of the vehicle. This consists of a

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Wheels, Axles & Chains

Argo Service Manual

101-35 bearing, 101-80 right angled greasable flange & 605-63 flange.. Photo 15E & F Secure Loosely with (4) flat washers and (4) nylon locknuts.

15E

15D

15F Avengers Manufactured Prior To Serial Number V23216 1.

15G

IMPOR TANT IMPORT The swivel grease fitting of the101-78RM is oriented to the bottom of the flange and facing towards the drivers compartment. Photo 15G 2.

Insert the grease tubing into the bulk head grease fitting. Photo 15 H See NOTE following page.

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WA-33A

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Argo Service Manual

Wheels, Axles & Chains

There are 2 different lengths of grease tubing for the left and right hand side idler shaft assembly. See your Avenger parts manual for correct lengths.

15 H

15 I

Install the 100-111 bulk head fittings to the left and right side of the frame and connect the tube to the swivel grease fittings of the two inner bearings. Photo 15 I

Install the idler shafts to the vehicle, inserting the shaft first into the inner bearing and then attaching at the outer bearing. See orientation of sprocket collars below. Photo 15J & 15 K

15 J

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15 K

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Wheels, Axles & Chains

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Argo Service Manual

Wheels, Axles & Chains

Removing the Front Axle (Avenger Model) 1.

Raise the vehicle off of the ground.

Remove the front tire.

Remove the firewall.Turn the quick release fastener located at the top of the firewall. Pull the top of the firewall rearward and into the drivers compartment.

Remove the front floor pan

WA-1

Remove the drive chain between front sprocket and idler shaft sprocket. Photo WA-1 Refer to Drive Chain Removal in the 673-04 Argo Service Guide.

Remove the inner axle fastener and washer located at the inner bearing on the axle end. Photo WA-2

For ease of removal, place the closed end of the wrench at the fastener head while turning the axle at the wheel hub on the outside of the vehicle. Photo WA-3

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Wheels, Axles & Chains 9.

Argo Service Manual

Remove set screws at the inner bearing collar.

10. Loosen off the inner bearing flange hardware. 11. Remove the (4) nuts that secure the outer bearing greaseable flange. Photo WA-4

WA-4

WA-5

WA-6

WA-7

WA-51A

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Argo Service Manual

Wheels, Axles & Chains

Installing the Front Axle (Avenger Models) 1.

Perform the servicing procedure, Installing the Axle Seals, in the Wheels, Axles & Chains section of the 673-04 Argo Service Guide.

Loosen off or remove the set screws from the new bearing before slipping it on to the axle.

WA-9

WA-8

Apply Blue LOCTITE to the set screws and secure to the axle shaft. Torque to specifications. Photo WA-8

Fill the inner grease cavity with axle grease (Lithium based, NLGI #2 or 3 mineral oil based), using a hand grease gun. Photo WA-9

Set the greasable flange to the bearing aligning the grease fitting with the small hole in the bearing. Photo WA-10 & 11

WA-10

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WA-11

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Wheels, Axles & Chains 6.

Argo Service Manual

Install a cork gasket at the front aluminum axle extension followed by a steel inner flange and second cork gasket. Photo WA-12

WA-12

WA-13

Apply some anti-seize compound to the spline area of the axle shaft. Photo WA-13

Slip the axle assembly into the front bearing extension. Photo WA-14 On the inside of the vehicle, prepare to install the front sprocket as the axle is pushed through to the inner bearing.

IMPORTANT

The front axle sprocket is a "floater" and requires no set screws. Orient the sprocket with the larger shoulder facing towards the inside of the vehicle. Photo WA15

WA-14 9.

WA-15

Align the mounting holes of the greasable flange with the studs of the aluminum bearing extension and place into position up tight against the cork gasket. Photo WA-16

10. Install flat washers to the studs. Photo WA-17

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WA-53A

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Argo Service Manual

Wheels, Axles & Chains

WA-16

WA-17

11. Secure with nylon locknuts and torque to specifications. Photo WA-18

WA-18

WA-19

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Argo Service Manual

WA-21

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WA-55A

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Argo Service Manual

Transmission

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TR-1

Transmission

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TR-2

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Transmission

SECTION TR

Supplement Pages

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Transmission

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Argo Service Manual

Transmission

Transmission Re & Re

34-100 Transmisson Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

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TR-1A

Transmission

Argo Service Manual

Argo Transmission Disassembly 1.

Drain oil and unthread the 4 fasteners securing the shifter lever assembly to top end of the transmission and remove the lever. Photo TR-1 & 2

TR-1

TR-2

3. 4.

Remove the oil seal from the input shaft. Photo TR-3 Remove the retaining ring from the input shaft. Photo TR-4

TR-4

TR-3 5.

Remove the retaining rings from both output shafts. There may or may not be shims below the retaining rings. Photo TR-5

Separating the Transmission 6.

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TR-2A

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Argo Service Manual

Transmission

Pull the housing halve, up and off from the input shaft side. Photo TR-7

TR-5

TR-6

TR-7

TR-8

Shift to top position.(High Gear) and remove roll pin from the shift block on the high/low shift shaft. Photos TR-8 & 9

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TR-3A

Transmission 9.

Argo Service Manual

Place shift shaft back into neutral. Photo TR-10

10. Place reverse shift shaft into reverse. Photo TR-11

TR-10

TR-11

11. Pull the output shaft from the transmission housing. Photo TR-12 12. Remove the spline shaft drive gear assembly. Photo TR-13 13. Remove the set screw securing the ball and spring within the housing at the hi/lo shift shaft assembly. Photo TR-14 14. Remove the spring and steel ball. Photo TR-15 & 16 15. Place the reverse shift shaft block back down against the housing (out of reverse). Photo TR-17 16. Remove the hi/lo shift shaft from the housing. Photo TR-18

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TR-4A

TR-12

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Argo Service Manual

Transmission

TR-15

TR-16

TR-17

TR-18

17. Using an arbor press, remove the smaller ball bearing from the end of the input shaft. Photo TR-19 18. Remove the retaining ring at the reverse gear. Photo TR-20

TR-19

TR-20

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TR-5A

Transmission

Argo Service Manual

TR-22

TR-21

TR-23

TR-24

TR-25 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-6A

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Argo Service Manual

Transmission TR-26

26. Press the differential from the housing at the arbor press. Photo TR-28

The use of wood blocks beneath the housing prevents damage to the sealing edge of the casting as well as provides height for removing the differential

TR-28

TR-29

27. Disassemble the reverse shift shaft block by removing the roll pin securing it to the shaft. Photo TR-29 & 30

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TR-7A

Transmission

Argo Service Manual

28. Remove the 3 steel balls located in the housing, between the hi/lo shift shaft and the reverse shift shaft. Photo TR-34

TR-35

TR-34

TR-36

TR-37

31. Pull the reverse shift shaft up and free from the housing. Photo TR-37 32. Remove the Steel Dowel Pin from the reverse shift shaft.

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TR-8A

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Argo Service Manual

Transmission

TR-38

TR-39

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TR-9A

Transmission

Argo Service Manual

Reassembling the Transmission 1. Lay out all components of the AVENGER Transmission on a clean work surface. See Photo below and following page.

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TR-10A

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Argo Service Manual

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Transmission

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TR-11A

Transmission

Argo Service Manual

Assembling the Idler Gear Bore Assembly

Install the 34-109 High Gear to the short side of the 34-112 Splined Shaft. Photo TR-41

IMPOR TANT IMPORT

Install the High Gear with the machined shoulder up. See Photo TR-41 2.

Press the 101-01 Bearing to the High Gear end of the Splined Shaft with the shielded side facing out. Photo TR-42

TR-41

TR-42 3.

TR-43

Install the 34-110 Low Gear to the opposite side of the Splined Shaft (long side). Photo TR-43

IMPOR TANT IMPORT Install the Low Gear with the machined shoulder up. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

TR-12A

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Argo Service Manual 4.

Transmission

Slip on the 34-111 Reverse Gear up against the previously installed Low gear. Photo TR-45

TR-44

IMPOR TANT IMPORT The 34-111 Reverse gear must be assembled to the Splined Shaft with the chamfered teeth side facing up. Photo TR-45 5.

Install the 34-123 Drive gear to the top of the previously installed Reverse Gear. Photo TR-46

TR-46 6.

TR-47

Press on the 101-01 bearing to the end of the shaft, shielded side up. Photo TR-47 See assembled component on the following page.

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TR-13A

Transmission

Argo Service Manual

Assembling the Input Shaft Assembly 1.

Install the 107-02 Retaining Ring to the 34-104 Input Shaft. Photo TR-48

IMPOR TANT IMPORT Remember to do the comparison check of this retaining ring as described on page TR-9 2.

Slip a 108-79 Thrust Washer on to the Input Shaft and up against the previously installed retaining ring. Photo TR-49

TR-48

TR-49 3.

Slip the 34-105 High Gear Pinion (with 4 dog teeth), or 34-128 High Gear Pinion (with 3 dog teeth), up against the Thrust Washer. Photo TR-50 See Note Regarding number of teeth on following page

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TR-14A

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Argo Service Manual

Transmission

Transmissions manufactured prior to serial #A2856 utilize 4 dog teeth and from #A2856, 3 dog teeth. Photo TR-50 Orient the the High Gear Pinion with the dog teeth facing up. 4.

Install the second Thrust Washer to the top of the High Gear Pinion. Photo TR-51

TR-50

TR-51

Install the 107-10 retaining ring to secure the second thrust washer. Photo TR-52

Slip the 34-103 Dog Clutch (4 Tooth, prior to serial #A2856)or 34-127 Dog Clutch (3 tooth, from serial #A2856),to the Input Shaft. Photo TR-53

TR-52

TR-53

Install the 34-106 Low Gear Pinion (4 Tooth, prior to serial #A2856) or 34-129 (3 tooth, from serial #A2856)with the dogs facing towards the previously installed Dog Clutch. Photo TR-54

Press the 34-107 Reverse Gear Pinion on to the Input Shaft and up against the Low

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TR-15A

Transmission

Argo Service Manual

Gear Pinion. Orient the Reverse Gear Pinion with the chamfered teeth facing up. Photo TR-55

TR-54 9.

TR-55

Secure the Reverse Gear Pinion with a 107-12 Retaining Ring. Photo TR-56

10. Press a 101-01 bearing to the end of the Input Shaft with the shielded side up. Photo TR-57

TR-56

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TR-16A

TR-57

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Argo Service Manual

Transmission

Assembling the Differential 1.

Install all 105-03 Oilite Bushings into both 34-122 cage and 34-124 Gear Plate. Photo TR-58 & 59

TR-59

TR-58 2.

Blow all foreign debris from the Cage and Gear Plate.

Install the 101-15 Bearing into both Cage and Gear plate. Photo TR-60 & 61

Wipe the 34-98 Output Shaft free of debris with a lint free rag. Install this Output Shaft into the Aluminum Cage. Photo TR-62 & 63 See Note following page.

TR-60

TR-61

TR-62

TR-63

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TR-17A

Transmission

Argo Service Manual

Use a specialized spacing tool to secure the previously installed 101-15 Bearing inside the Aluminum Cage while the Output Shaft is press into place. Photo TR-64 7.

Orient the 34-14 Sun Gear as in Photo TR-65 with the higher shoulder side facing up. Install it to the splined end of the Output Shaft. Photo TR-66 & 67

TR-64

Secure the Sun Gear with a 107-04 Snap Ring. Photo TR-68

TR-65

TR-66

TR-67

TR-68

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TR-18A

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Argo Service Manual

Transmission

TR-69

TR-70

10. Wipe down the 2nd 34-98 Output Shaft and assemble to the Gear Plate using the same method as described for the Aluminum Cage. Photo TR-71, 72 & 73

TR-71

TR-72

TR-73

TR-74

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TR-19A

Transmission

Argo Service Manual

TR-75

TR-76

TR-77

TR-78

12. Set the assembled 34-122 Aluminum Cage into an assembly stand. Photo TR-78 13. Install (3) 105-23 Hollow Dowl Pins into the mounting holes of the aluminum cage. Photo TR-79

TR-79

TR-80

14. Install (6) 34-13 Pinions into the Oilite Bushings of the Aluminum Cage alternating the Pinions in an up and down manner as shown in Photo TR-80 & 81

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TR-20A

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Argo Service Manual

Transmission

TR-81

TR-82

TR-83

TR-84

Apply Red 271 LOCTITE to each of the (3) 112-143 fasteners, Photo TR- 85, and tighten down to 35 FT/LBS. Photo TR-86

TR-85

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TR-86

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TR-21A

Transmission

Argo Service Manual

Assembling Transmission Components to Housing 1.

Apply some LOCTITE pipe sealant to the threads of the 103-02 drain plug and install into the housing. Photo TR-87 & 88

TR-87 2. 3.

TR-88

TR-89

TR-90

Install the 34-32 Spring into the machined hole of the 34-102 Right Hand Housing at the Reverse Shift Shaft location. Photo TR-92

Install the 109-05 Steel Ball to the top of the Spring. Photo TR-93

Push down on the Steel Ball using the access hole from the top of the Transmission Housing. While the ball is compressed, press the shaft over top of the ball. Photo TR-94

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TR-22A

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Argo Service Manual

Transmission

TR-91

TR-92

TR-93

TR-94

Continue to push the reverse shift shaft through the housing until the machined groove for the O-ring location is visible to the outside of the housing. Photo TR94A

Install the 113-16 O-ring to the groove and apply some oil lubrication. Photo TR94B

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TR-23A

Transmission

Argo Service Manual

iii

Push the reverse shift shaft back through the housing ensuring that you don't damage the O-ring as re-enters the housing.

Pull the Reverse Shift Shaft up until the lower retaining ring groove location is visible. shaft is Photo TR-95

Install the 107-11 Retaining Ring onto the Reverse Shift Shaft. Photo TR-96 & 97

TR-95

TR-96

10. Lower the Reverse Idler Gear and install the second 107-11 Retaining Ring to the machined groove at the top of the Reverse Idler Gear. Photo TR-98 & 99

TR-97

TR-98

11. Insert a tool, eg. an allen wrench, into the machined hole of the Reverse Shift Shaft and turn the shaft until the keyways of both shaft and transmission boss are aligned. Photo TR-100

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TR-24A

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Argo Service Manual

Transmission

TR-99 12.

TR-100

Install the 104-40 Dowel Pin to secure the Reverse Shift Shaft. Photo TR-101

13. Assemble the 34-115 Reverse Shift Block to the Reverse Shift Shaft by aligning the keyway with the previously installed Dowel Pin. Photo TR-102

TR-101

TR-102

14. Tap the Shift Block on until the machined hole in both the Reverse Shift Shaft and the Shift Block are aligned, then install the 104-39 Spring Pin. Photo TR-103, 104 & 105

Install the Roll Pin flush to the machine corner of the shift block as shown in Photo TR105

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TR-25A

Transmission

Argo Service Manual

TR-104

TR-103

TR-105

TR-106

15. Install a 106-03 Retaining Ring to top groove of the Housing. Photo TR-106 16. Press and install the 101-03 bearing into the Housing. Photo TR-107 & 108

TR-107

TR-108

TR-26A

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Argo Service Manual

Transmission

TR-109

TR-110

TR-111 TR-113

TR-114 www.odg.com

TR-27A

Transmission

Argo Service Manual

20. Install the 34-113 Hi/Low Shift Shaft into the Housing with the 3 machined gates facing to the outside of the housing and the 1 machined gate facing the Reverse Shift Shaft. Photo TR-115

TR-115

TR-116

21. Align one of the 3 gates in the Hi/Lo Shift Shaft with the access hole in the casting and install a 109-05 Steel Ball and 34-32 Spring. Photo TR-116, 117 & 118

TR-117

TR-118

TR-119

TR-28A

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Argo Service Manual

Transmission

TR-120

TR-121

TR-122

TR-123

25. Place the transmission into the neutral position. Photo TR-123 26. Secure the Hi/Lo Shift Fork to the Shift Shaft using a 104-39 Spring Pin. Photo TR-124

TR-124

TR-125

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TR-29A

Transmission

Argo Service Manual

TR-126

TR-127

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TR-129

TR-30A

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Argo Service Manual

Transmission TR-131

TR-132

TR-133

TR-134

TR-135

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TR-31A

Transmission

Argo Service Manual

38. Install a 101-05 Bearing to the Output Shaft. Photo TR-136 & 137

TR-136

TR-137

IMPOR TANT IMPORT Ensure that all retaining rings are seated properly

TR-138

TR-139

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Argo Service Manual

Transmission

TR-142

TR-143

44. Apply Blue LOCTITE to each of the 112-04 Fasteners and secure the Shift Lever assembly to transmission. Photo TR-144 & 145

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TR-33A

Transmission

Argo Service Manual

46. Install the CE-035 Dipstick. Photo TR-146 47. Fill the transmission with 1.1 L (38.7 oz of 80 W 90 Gear Lube HYPOY-C.

TR-146

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TR-34A

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Argo Service Manual

Fuel System

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FS-1

Fuel System

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FS-2

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Argo Service Manual

Fuel System

SECTION FS

Supplement Pages

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Fuel System

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Argo Service Manual

Fuel System

Removing the fuel Tank (Avenger) 1. Drain any fuel that may be present in the fuel tank. 2.

Remove the seat to expose the storage tray & battery.

Remove the battery.

Drill out the 11 rivets that secure the tool box to the seat frame and remove.

Disconnect the fuel line at the pickup tube on the fuel tank.

Undo the gear clamp securing the filler hose at the fuel tank neck and pull the filler neck assembly free of the tank. Photo FS 1

Remove the tank from the vehicle. The tank will come forward into the drivers compartment. Photo FS 1 & 2

Ensure that the vent tube does not pull out from the filler neck and that it is not kinked in any way when the filler neck assembly is reassembled to the new tank.

FS-1 9.

FS-2

Unthread the fuel pickup tube from the tank and discard.

Installing the Fuel Tank 1.

Thread the new pickup tube into the top of the fuel tank. Position the outlet facing towards the fuel neck side of the vehicle.

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FS-4A

Fuel System

Argo Service Manual

FS-3 2.

FS-4

Slip the new or cleaned tank into the vehicle from the drivers compartment, reconnecting the filler hose to the tank at the same time and secure it with the gear clamp.

IMPOR TANT IMPORT Be sure to reconnect the fuel vent hose at the filler neck and ensure that it is facing up and not kinked or pinched in any way. 3.

With the tank in place, reinstall the tool box and secure with rivets.

Replace the fuel filter with a new one.

Reinstall the battery

Place the front seat back into the vehicle.

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Argo Service Manual

Brake System

Insert the following pages (CS-19 through CS-26) in place of same pages in 67304 Argo Service Manual

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Argo Service Manual 4.

Clutch System

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CS-19

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Clutch System

Argo Service Manual

Removing the Driven Clutch 1.

Perform the servicing procedure, Removing the Firewall, in section VB

Perform the servicing procedure, Removing the Drive Belt.

Locate and remove the bolt, lock washer and flat washer securing the clutch to the input shaft of the transmission.

Slip the driven clutch from the transmission. Photo CS-44

Remove the driven clutch to a clean work area.

Driven Clutch Disassembly 1.

CS-44 CS-45

Depending on the age of the vehicle, the movable cam may be secured by 2 retaining rings and may also have spacers installed beneath the retaining ring. 2.

With the retaining ring removed, slowly release the arbor press off the cam until the cam is free of the fixed pulleyâ&#x20AC;&#x2122;s shaft and the spring has unwound . Photo CS-46

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CS-20

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Argo Service Manual

Clutch System The cam is under spring tension. Wear eye protection and keep fingers clear of the clutch. 3.Remove the cam and key from the keyway. Photo CS-47

CS-46

CS-47

Slide the movable face from the fixed pulley. Photo CS-48

Remove the retaining ring and spacer(s) from the shaft of the fixed pulley. Photo CS-49

The Oilite bushing of the 126-24 driven Clutch movable face is secured with a spring pin. Remove the spring pin and press the bushing from the movable face. Photo CS-50

CS-48

The 127-136 Avenger driven clutch does not utilize this oilite bushing in it's design. 7.

The Super Oilite Bushing used in the 127-129 Driven clutch is NOT secured with a spring pin, but uses a retaining style ring at the end to secure the bushing. Photo 50A

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CS-21

CS-49

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Clutch System

Argo Service Manual

CS-50 7.

To replace the nylon cam slider shoes, pry each out with a slot screwdriver or small chisel. You may need to use a small hammer applying quick blows to pop the slider shoes loose. Photo CS-51

CS-50A

CS-51

Press each new slider shoe back into the moveable face pulley. Ensure that they are pressed in completely and seated.

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CS-22

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Argo Service Manual

Clutch System

Driven Clutch Reassembly (126-24 & 127-129) 1.

Slip the movable face back on to the fixed pulley after installing all spacers and snap ring to the fixed face shaft. Slide the small key into the key way of the fixed shaft. Photo CS-52

There are 6 spring tension adjustment holes in the cam that are numbered 1 through 6. Insert the one end of the cam spring into the number 3 hole. Photo CS-53

CS-52

There is 1 hole within the movable face pulley. Insert the other end of the cam spring into this hole. Photo CS-54

CS-53

CS-54

Driven Clutch Reassembly (Avenger 127-136) i.

Slip the movable face back on to the fixed pulley after installing all spacers and snap ring to the fixed face shaft. Slide the small key into the key way of the fixed shaft.

ii.

Locate the # 10 marking on the moveable face. The cam spring will be inserted into the hole across from this number. Photo 53A

iii. Insert the other end of the clutch spring into th e # 2 hole of the cam. Photo 54A

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CS-23

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Clutch System

Argo Service Manual CS-54A

CS-53A

All Driven Clutches 5.

Install the cam and spring to the fixed face shaft aligning the key on the fixed shaft with the keyway in the cam. Photo CS-55

CS-56

CS-55

CS-24

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Argo Service Manual

Clutch System

Testing The Spring Load Of The Driven Clutch

CS-57

CS-58

Installing the Driven Clutch 1.

Apply anti-seize compound to the transmission input shaft.

Install the key to the keyway of the input shaft. Photo CS-58

Align the keyway of the driven clutch with that of the previously installed key on the input shaft and slip the clutch on and up to the machined shoulder.

Apply blue 242 LOCTITE to the threads of the fastener and install along with the lockwasher and flat washer. Torque to specifications.

Perform the servicing procedure, Installing the Drive Belt.

Perform the servicing procedure, Installing the Firewall, in section VB

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CS-25

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Clutch System

Argo Service Manual IMPORTANT

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CS-26

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Argo Service Manual

Brake System

STION BR Replace torque pages in section GI of 673-04 Argo Service Manual with the following torque pages

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Argo Service Manual

General Information

24.3Nm 47.5Nm 8.5Nm

23.2Nm 23.2Nm 23.2Nm 23.2Nm 23.2Nm

135.6Nm 67.8Nm 54.3Nm 67.8Nm 20.3Nm 9.6Nm

40.7Nm 32.6Nm 47.5Nm 101.7Nm 4.0Nm 10.7Nm 40.7Nm 27.1Nm 176.2Nm

61.0Nm 44.8Nm 23.2Nm 20.3Nm 24.6Nm

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GI-13

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General Information

Argo Service Manual

Argo Torque Specifications Brake Sprocket to Disc (Avenger)...................................15 FT. LBS 20.3Nm Master Cylinder Lid Screws........................................... Snug By Hand Upper Handle Bar Clamp Bolts (Avenger).....................12 Ft. LBS 16.3Nm Steering Shaft Nut................ .......................................Tighten snug. Back off until lower washer can be turned by hand. Ensure shaft can be turned with minimal end play Vehicle Body and Firewall Hood Hinge Mounting Bolts...........................................Snug By Hand Rear Seat Mounting Bolts............................................... Snug By Hand Trailer Hitch Mounting Bolts..........................................35 FT. LBS. Trailer Hitch Ball............................................................ 100 FT. LBS.

47.5Nm 135.6Nm

Frame and Drive System Wheel Nuts......................................................................45 FT. LBS. Bearing Extensions ........................................................ 30 FT. LBS. Bearing Extension Bolts................................................. 240 IN. LBS. Bearing Extension Flange Nuts (Avenger).....................30 FT. LBS Axle Flange Bolts........................................................... 30 FT. LBS. Battery Bracket to Frame................................................ 30 FT. LBS. Axle Sprocket Retaining Screws................................... 144 IN. LBS Axle Bearing Set Screws................................................ 96 IN. LBS Axle Retaining Bolt........................................................ 35 FT. LBS Wheel Stud Extensions................................................... 45 FT. LBS Power Frame Bolts to Vehicle Main Frame.................... 130Ft. LBS Fuel System and Seat Assembly

61.0Nm 40.7Nm 27.1Nm 40.7Nm 40.7Nm 40.7Nm 16.4Nm 10.7Nm 47.5Nm 61.0Nm 176.2Nm

Handrail Assembly to UpperbodyHand Tight Approx... 48 IN. LBS Backpad to Handrail Assembly....................................... 72 IN.LBS Angle Bracket to Seat Assembly..................................... 72 IN.LBS Seat Frame Assembly to Frame..................... ................72 IN.LBS Seat Frame Assembly to Body........................................ Snug By Hand

5.4Nm 8.1Nm 8.1Nm 8.1Nm

Electrical System Battery Retaining Bracket...............................................Snug By Hand Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421

GI-14

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ARGO TORQUE SPECIFICATIONS *Where Avenger differs from other models

Transmission Side Cover Bolts Differential Bolts *Shifter Plate Bolts (Avenger)

216 IN. LBS. 35 FT. LBS. 75 IN. LBS

24.3Nm 47.5Nm 8.5Nm

Intake & Exhaust Kawasaki Exhaust Manifold to Engine Kawasaki Muffler to Engine Briggs Muffler to Engine Briggs Exhaust Man. to Engine Kohler Exhaust Man. to Engine (Avenger)

204 IN. LBS. 204 IN. LBS. 204 IN. LBS. 204 IN. LBS. 204 IN. LBS

23.2Nm 23.2Nm 23.2Nm 23.2Nm 23.2Nm

Clutch System Driver Clutch Nut on Clutch Driver Clutch Bolt to Briggs Engine *Driver Clutch Bolt to Kohler Engine (Avenger) Driver Clutch Bolt to Kaw. Engine Driven Clutch Bolt to Input Shaft Spring Cover Cap Screws

100 FT. LBS. 50 FT. LBS. 40 FT. LBS 50 FT. LBS. 15 FT. LBS. 85IN. LBS

135.6Nm 67.8Nm 54.3Nm 67.8Nm 20.3Nm 9.6Nm

Powerpak Assembly Engine to Powerpak Frame (Kaw) Engine to Powerpak Frame (Briggs) *Engine to Powerpak Frame (Kohler) Transmission to Powerpak Frame Transmission to Power Pack Frame (HDi) Brake Cooling Air Duct to Frame Master Cylinder Mounting Bolts Belt Guard to Transmission Brake Bracket Mounting Bolts Power Pack Bolts to Main Vehicle Frame

30 FT. LBS. 24 FT. LBS. 35 FT. LBS 75 FT. LBS. 80 FT.LBS. 35 in.lbs. 96 IN. LBS. 30 FT. LBS. 240 IN. LBS. 80 FT. LBS

40.7Nm 32.6Nm 47.5Nm 101.7Nm 108.4Nm 4.0Nm 10.7Nm 40.7Nm 27.1Nm 108.4Nm

Vehicle Body and Firewall Hood Hinge Mounting Bolts Rear Seat Mounting Bolts Trailer Hitch Mounting Bolts Trailer Hitch Ball

Snug By Hand Snug By Hand 35 FT. LBS. 100 FT. LBS.

47.5Nm 135.6Nm

ARGO TORQUE SPECIFICATIONS Frame and Drive System Wheel Nuts Bearing Extensions Bearing Extension C/Bolts *Bearing Extension Flange Nuts (Avenger) *Bearing Extension Flange Bolts (2010 +) Axle Flange Bolts Battery Bracket to Frame Axle Sprocket Set Screws Axle Bearing Set Screws Idler Shaft Bearing Set Screws (outer) Axle Retaining Bolt Idler Shaft Coupler Bolts (HDi) Wheel Stud Extensions Brake System - Hydraulic Brake Caliper to Transmission Brake Caliper Assembly Bolts (M10) Brake Caliper Assembly Bolts (M8) *Avenger Brake Caliper Assembly Bolts *Brake Sprocket to Disc (Avenger) Service Brake Caliper Bolts (HDi) Parking Brake/Band Brake Mounting Bolts (HDi) Hydraulic Hose Bolts Master Cylinder Lid Screws *Upper Handle Bar Clamp Bolts (Avenger) *Steering Shaft Nut

Brake Disc to Output Shaft

45 FT. LBS. 30 FT. LBS. 240 IN. LBS. 30 FT. LBS. 30 FT. LBS. 30 FT. LBS. 30 FT. LBS. 144 IN. LBS. 10-15 IN. LBS. 10-15 IN.LBS. 35 FT. LBS. 22 FT.LBS. 45 FT. LBS.

61.0Nm 40.7Nm 27.1Nm 40.7Nm 40.7Nm 40.7Nm 40.7Nm 16.4Nm 1.12 - 1.16Nm 47.5Nm 30.0Nm 61.0Nm

45 FT. LBS. 61.0Nm 33 FT. LBS. 44.8Nm 17 FT. LBS. 23.2Nm 218 IN. LBS. 24.6Nm 15 FT. LBS. 20.3Nm 25 FT.LBS. 20.3Nm 22FT.LBS. 30.0Nm 180 IN. LBS. 20.3Nm Snug By Hand 12 Ft. LBS.+ 16.3Nm Tighten snug. Back off until lower washer can be turned by hand. Ensure shaft can be turned with minimal end play 30 FT.LBS

Fuel System and Seat Assembly Handrail Assembly to UpperbodyHand Tight Approx Backpad to Handrail Assembly Angle Bracket to Seat Assembly Seat Frame Assembly to Frame Seat Frame Assembly to Body

48 IN. LBS 72 IN.LBS 72 IN.LBS 72 IN.LBS Snug By Hand

Electrical System Battery Retaining Bracket

Snug By Hand

40.7Nm 5.4Nm 8.1Nm 8.1Nm 8.1Nm

OPERATORâ&#x20AC;&#x2122;S MANUAL MODELS - S, SN, BF, RB, CB from 1997 Ontario Drive & Gear Limited P.O. Box 280, 220 Bergey Court New Hamburg, Ontario N0B 2G0 Telephone: (519) 662-2840, Fax: (519) 662-2421 www.argoatv.com MANUAL NO. 671-04 Rev. 7

Printed in Canada

09/2001

A MESSAGE FROM THE PEOPLE WHO BUILT YOUR ARGO Thank you for selecting an ARGO amphibious, off-road utility vehicle! Ontario Drive & Gear Limited has been building ARGO vehicles since 1967. By listening carefully to our customers and responding to their needs, we have been constantly improving the ARGO and will continue to do so. Over twenty-five thousand ARGO vehicles have provided reliable service all over the world. From Britain to the Far East, Alaska to the Antarctic, and from the tropical forests of South America to the deserts of Saudi Arabia. We are proud to provide you with a vehicle that represents the ultimate in amphibious, all-terrain transportation. Your safety and the safety of all ARGO users is of the greatest concern to us. You will find numerous safety statements in this manual. Please read and follow them carefully. Always be safety conscious when you operate your ARGO and remember it is a motorized vehicle. The ARGO is easy to drive and you will soon be tempted to take on new challenges. Please take the time to develop your driving skills before doing so. Observe the recommendations outlined in this Operatorâ&#x20AC;&#x2122;s Manual and remember; some things are just impossible, even with an ARGO. WELCOME TO THE WORLD WIDE ARGO FAMILY!

673-25 Argo Service Video Ontario Drive & Gear has produced a video which provides the Argo owner with step-by-step instructions on how to perform general service procedures on your vehicle. Everything from removal and replacement of brake pads to rebuilding the transmission. Itâ&#x20AC;&#x2122;s all there. Removal and replacement of engines is included, however, engine overhaul is not. A separate overhaul manual is available for each engine from your Argo dealer. Order the Service Video from your selling dealer or from Ontario Drive & Gear directly (have your VISA card information ready). Cost of the 4 hour video is $33.00.

NOTE Read this manual before you operate your ARGO. It contains safe operating instructions and warns the user about potential hazards that can result in personal injury. Warnings are identified in the text by the following symbol:

WARNING The manual also contains operating cautions that can prevent damage to the vehicle. Cautions are identified in the text by the following symbol:

CAUTION This manual is based on the latest product information available at the time of printing. Ontario Drive & Gear Limited reserves the right to make changes at any time and without obligation. Reproduction of any part of this publication is prohibited without prior written permission. Une version francaise du manuel d’operation est disponsible sous le numero suivant 671-04FR. Les plaquettes d’avertissement et d’instructions qui apparaissent sur l’Argo sont aussi disponsibles en francais sous le numero suivant 126-73. © Ontario Drive & Gear Limited, 2000

PREFACE This manual describes the controls, operation and basic maintenance procedures for all VANGUARD, VANGUARD2, BIGFOOT, RESPONSE and CONQUEST models of the ARGO from date of printing. Please take the time to read this manual carefully, for your safety and that of others. By following these instructions, you will ensure extended, trouble free operation of your vehicle. For maintenance and adjustment of the engine, refer to the engine manufacturer’s operation and maintenance manual included in your vehicle’s information package. Before you drive your ARGO, make sure you understand how to use all controls, particularly the brakes and steering levers. Learn how to drive your vehicle in an open level area, away from buildings, trees and other obstacles, until you are completely familiar with its operating characteristics. Drive very slowly until your driving skills improve, and drive with caution and consideration at all times. The risk of accident or injury is greatest during the first weeks of use. Take special care during this period. ALWAYS RESPECT OUR ENVIRONMENT. CAUTION TO THE ARGO OWNER/OPERATOR • Make sure everyone who drives this vehicle receives proper operating instructions and reads this Operator’s Manual. • No one under the age of 16 should be allowed to operate the ARGO. • Never allow anyone under the influence of alcohol or any other intoxicating substance to drive or ride in the vehicle. • Wear an approved safety helmet and eye protection when driving or riding in the vehicle. • Special operating and safety procedures described in this manual must be observed before and during water operation as outlined in Section 5. • When operating your vehicle for extended periods of time, we recommend the use of approved hearing protection. • Equip your vehicle with a fire extinguisher and a first aid kit. • Equip your vehicle with basic tools for emergency repairs. • Before starting your engine, check for spilt gasoline and wipe any up immediately. Gasoline is a potentially explosive substance that can cause serious personal injury when ignited. • Keep the floor pans secured in place at all times. Fingers, feet, animal tails or paws can be injured in the drive components beneath the floor pans. The floor pans also help keep damaging debris out of the drive components. • Make sure all passengers remain seated while the vehicle is in motion. Advise your passengers to hold onto the vehicle at all times. • Never overload your vehicle. Trying to steer an overloaded vehicle can overheat the brakes. This will lead to brake fade which means loss of steering control and the ability to stop the vehicle. Overloading your vehicle can lead to premature brake system failures and costly damage to drive chains, axles or bearings. Follow the recommended load capacity for your vehicle listed in Section 1. • Do not drive the vehicle at high speeds over unfamiliar or rough terrain. Personal injury or vehicle damage may result. • Certain terrain and steep hills cannot be traversed safely with the Argo or any other vehicle. Do not attempt to drive over terrain that is questionable. • Do not drive your vehicle on asphalt or concrete roadways. When the vehicle turns, its tires skid on the driving surface. Asphalt or concrete causes extensive tire wear. • Use common sense at all times when driving your vehicle. • The Argo engine hood is designed to stay fastened in place while the vehicle is being driven. If the Argo is transported by truck or trailer, the hood should be removed and carried in the transport vehicle or secured in place on the Argo with rope or tie down straps. Wind or turbulence at road speeds could result in the loss of the hood. IMPORTANT Operate this vehicle with safety constantly in mind. Off-road vehicles face unpredictable and often hazardous terrain conditions. It is ultimately the operator’s responsibility to handle the vehicle safely within its limitations and to decide when and where to travel.

NOTES

III

NOTES

TABLE OF CONTENTS SECTION 1.0

2.0

3.0

4.0

5.0

PAGE

GENERAL INFORMATION 1.1 AMPHIBIOUS OPERATION ........................................................................... 1.2 MAINTENANCE PROCEDURES ................................................................... 1.3 WIND CHILL FACTOR ................................................................................... 1.4 MODEL IDENTIFICATION ............................................................................ 1.5 REAR SEATS - 8 WHEEL MODELS ............................................................. 1.6 IDENTIFICATION AND LOCATION OF CONTROLS ................................ 1.7 INFORMATION LABELS ...............................................................................

1 1 1 1 2 3 4

GENERAL OPERATING INSTRUCTIONS 2.1 NEW VEHICLE “BREAK-IN” PROCEDURE ............................................... 2.2 PRE-OPERATION CHECKS ........................................................................... 2.3 CARRYING PASSENGERS AND CARGO .................................................... 2.4 FUELING THE VEHICLE ............................................................................... 2.5 VENTED FUEL SYSTEM - ALL MODELS ..................................................

5 5 5 6 6

OPERATING INSTRUCTIONS 3.1 BRAKES AND STEERING ............................................................................. 3.2 HOLDING BRAKE SYSTEM - Vanguard2, Bigfoot, Response & Conquest 3.3 HOLDING BRAKE SYSTEM - Vanguard ...................................................... 3.4 THROTTLE CONTROL .................................................................................. 3.5 STARTING PROCEDURE ............................................................................... 3.6 STOPPING THE ENGINE ............................................................................... 3.7 MANUAL STARTING PROCEDURE ............................................................. 3.8 SELECTING AND CHANGING TRANSMISSION GEARS ........................ 3.8.1 Changing Transmission Gears ........................................................... 3.9 HEADLIGHTS ..................................................................................................

7 7 8 8 8 9 9 9 10 10

DRIVING PROCEDURES 4.1 DRIVING STRAIGHT AHEAD ...................................................................... 4.2 STOPPING THE VEHICLE ............................................................................. 4.3 TURNING THE VEHICLE .............................................................................. 4.3.1 Left Turn ............................................................................................. 4.3.2 Right Turn .......................................................................................... 4.4 BACKING THE VEHICLE UP ........................................................................ 4.4.1 Turning the Vehicle While Backing Up .............................................

11 11 11 11 11 11 11

DRIVING PROCEDURES DURING UNUSUAL CONDITIONS 5.1 REMOTE AREA USE ...................................................................................... 5.2 ANGLE OF OPERATION ................................................................................ 5.3 UPHILL OPERATION ...................................................................................... 5.4 DOWNHILL OPERATION .............................................................................. 5.5 SIDE SLOPE OPERATION ............................................................................. 5.6 AMPHIBIOUS OPERATION - GENERAL ..................................................... 5.6.1 Entering Water .................................................................................... 5.6.2 Driving Procedures in Water .............................................................. 5.6.3 Driving Out of Water .......................................................................... 5.6.4 Outboard Motor Bracket ..................................................................... 5.7 WINTER OPERATION .................................................................................... 5.7.1 Use on Ice Covered Bodies of Water ..................................................

13 13 13 13 14 14 15 15 15 15 16 16

TABLE OF CONTENTS SECTION 6.0

PAGE

OIL, FILTER AND LUBRICATION INFORMATION 6.1 ENGINE OIL INFORMATION 6.1.1 CHECKING THE ENGINE OIL LEVEL ........................................... 17 6.1.2 RECOMMENDED ENGINE OIL ....................................................... 17 6.1.3 CHANGING ENGINE OIL ................................................................. 18 Draining the Engine Oil ....................................................................... 18 Refilling the Engine ............................................................................. 18 6.2

TRANSMISSION OIL INFORMATION 6.2.1 CHECKING THE TRANSMISSION OIL LEVEL ............................. 18 6.2.2 CHANGING THE TRANSMISSION OIL .......................................... 18 Refilling the Transmission ................................................................... 19

6.3

FILTER INFORMATION 6.3.1 AIR FILTER ......................................................................................... 19 6.3.2 FUEL FILTER ...................................................................................... 19 6.3.3 OIL FILTER ......................................................................................... 19

6.4

LUBRICATION INFORMATION 6.4.1 GENERAL ............................................................................................ 19 6.4.2 DRIVEN CLUTCH LUBRICATION ................................................... 19 6.4.3 DRIVE CHAIN LUBRICATION ......................................................... 20 6.4.4 IDLER CHAIN LUBRICATION ......................................................... 20 6.4.5 OUTER AXLE FLANGE AND BEARING LUBRICATION ............. 21 6.4.6 IDLER SHAFT BEARING LUBRICATION - All Models ................. 21 6.4.7 INNER AXLE BEARING LUBRICATION ........................................ 21

7.0 MAINTENANCE INFORMATION 7.1 ELECTRICAL SYSTEM 7.1.1 GENERAL ............................................................................................ 22 7.1.2 BATTERY - Argo Part No. 127-54 ...................................................... 22 Checking Fluid Level ........................................................................... 22 Cleaning the Battery Terminals and Cable Connections ..................... 22 Cleaning the Battery ............................................................................. 23 7.1.3 ELECTRICAL SYSTEM FUSES ........................................................ 23 7.1.4 SPARK PLUGS .................................................................................... 23 7.1.5 SPARK ARRESTER ............................................................................ 23 7.2

DRIVE SYSTEM & TIRES 7.2.1 DRIVE BELT ....................................................................................... 23 Drive Belt Removal .............................................................................. 24 Drive Belt Installation .......................................................................... 24 7.2.2 CLUTCH MAINTENANCE ................................................................ 24 Clutch Inspection .................................................................................. 25 7.2.3 DRIVE CHAINS .................................................................................. 25 Drive Chain Removal ........................................................................... 25 Drive Chain Installation ....................................................................... 25 7.2.4 DRIVE CHAIN TAKE-UP SYSTEM .................................................. 26 Removal of Slider Blocks ..................................................................... 27 Replacement of Slider Blocks .............................................................. 27

TABLE OF CONTENTS SECTION

PAGE 7.2.5

7.2.6 7.2.7 7.2.8

IDLER CHAIN .................................................................................. 27 Idler Chain Adjustment ..................................................................... 28 Idler Chain Replacement ................................................................... 28 Removal of Idler Chains ................................................................... 28 Installation of Idler Chains ............................................................... 28 TIRE INFLATION ............................................................................ 29 TIRE REPAIR AND REPLACEMENT ........................................... 29 AXLE BEARING MOUNTING ....................................................... 29

7.3

MECHANICAL BRAKES - VANGUARD 7.3.1 GENERAL ......................................................................................... 29 Removal of Firewall .......................................................................... 29 Mechanical Brake Inspection Procedure .......................................... 30 7.3.2 BRAKE CALIPER ADJUSTMENT ................................................. 30 7.3.3 BRAKE PAD REPLACEMENT ....................................................... 30 Re-installation of Firewall ................................................................ 31 7.3.4 STEERING LEVER ADJUSTMENT ............................................... 31 7.3.5 HOLDING BRAKE ADJUSTMENT ............................................... 31

7.4

HYDRAULIC BRAKES - VANGUARD2, BIGFOOT, RESPONSE & CONQUEST 7.4.1 GENERAL ......................................................................................... 31 7.4.2 BRAKE FLUID LEVEL ................................................................... 31 7.4.3 CHANGING BRAKE FLUID ........................................................... 32 7.4.4 HYDRAULIC BRAKE PAD INSPECTION .................................... 32 Firewall Removal .............................................................................. 32 Brake Pad Inspection Procedure ....................................................... 32 Re-installation of Brake Pads ............................................................ 32 Re-installation of Firewall ................................................................ 33 7.4.5 HOLDING BRAKE ADJUSTMENT ............................................... 33 7.4.6 BRAKE COOLING SYSTEM .......................................................... 34 7.4.7 ENGINE COOLING & EXHAUST SYSTEM ................................. 34

7.5

MAINTENANCE SCHEDULE ...................................................................... 35

8.0

TROUBLESHOOTING ........................................................................................................... 36

9.0

CLEANING AND STORAGE 9.1 CLEANING THE VEHICLE .......................................................................... 38 9.2 STORING THE VEHICLE ............................................................................. 38 Cleaning the Vehicle ....................................................................................... 38 Drain the Fuel System ..................................................................................... 38 Prepare the Battery for Storage ....................................................................... 38 Protect the Electrical System ........................................................................... 38 Raise the Vehicle ............................................................................................. 38 Preparing the Engine for Storage .................................................................... 38

10.0

ACCESSORY 10.1 10.2 10.3

INFORMATION GENERAL ....................................................................................................... 39 CARGO TIE-DOWNS (PART NO. 614-06) .................................................. 39 ARGO TRACK SYSTEMS (STANDARD TRACK AND SUPER TRACK) 39

VII

TABLE OF CONTENTS SECTION

PAGE

10.4 10.5 10.6 10.7 10.8 10.9

10.10 10.11 10.12 10.13 10.14 10.15 10.16 10.17 10.18 10.19 10.20 10.21 10.22 10.23 10.24

10.3.1 Operating Precautions ................................................................................... 39 10.3.2 Standard Tracks ............................................................................................. 40 10.3.3 Super Tracks .................................................................................................. 40 ICE CLEAT KIT (PART NOS. 625-20 & 825-20) ..................................................... 40 OUTBOARD MOTOR BRACKET (PART NO. 617-00) ........................................... 40 OUTBOARD MOTOR SUPPORT (PART NO. 618-00) ............................................. 40 OUTBOARD MOTOR BRACKET - SIDE MOUNT (PART NO. 618-10) ............... 41 ARGO STORAGE COVERS (PART NOS. 621-10; 621-20; 821-10; 821-20 ........... 41 POWER WINCH (PART NOS. 622-40 & 622-70) ..................................................... 41 10.9.1 Rules for Safe Operation ................................................................................ 41 10.9.2 Tips for Extending the Life of Your Winch ................................................... 43 REAR MUD FLAP KIT (PART NO. 625-10) ............................................................. 43 TRAILER HITCH KIT (PART NO. 626-10) .............................................................. 43 BILGE PUMP KIT (PART NO. 638-25) ..................................................................... 43 HANDRAIL KITS (PART NO. 639-20 & 839-20) ..................................................... 44 TOW HOOK KIT (PART NO. 642-00) ....................................................................... 44 WINDSHIELD (PART NO. 648-75) ........................................................................... 44 CONVERTIBLE TOP (PART NOS. 649-33, 649-50 & 849-50) ................................ 44 ALTERNATOR KITS (PART NOS. 650-60, 850-60 & 850-40) ................................ 45 10.17.1 Alternator Kit for Conquest ............................................................. 45 SNOW PLOW KIT (PART NO. 657-00) .................................................................... 45 AMPHIBIOUS TRAILER (PART NO. 695-75) .......................................................... 45 10.19.1 Operating Precautions ...................................................................... 45 HEATER KIT - CONQUEST (Part No. 848-10) ........................................................ 46 ROLL OVER PROTECTIVE STRUCTURES (PART NOS. 848-40-2 & 848-40-4 .. 46 REAR BENCH SEAT (PART NO. 849-60) ................................................................ 46 DUMP BOX KIT (PART NOS. 835-00 & 835-01) ..................................................... 47 ROLL BAR KIT (PART NO. 648-15) ......................................................................... 47

APPENDIX 1

SPECIAL TOOLS VICE GRIP MODIFICATIONS .................................................................................. 48

VIII

SECTION 1 GENERAL INFORMATION 1.1 AMPHIBIOUS OPERATION

1.3 WIND CHILL FACTOR

All models of the ARGO are amphibious and capable of traversing calm water. Special operating procedures and safety precautions must be observed before entering the water and during amphibious operation. Do not drive your vehicle into water until you have read Section 5.6 Amphibious Operation.

Why does it feel much colder outdoors on a windy day than when there’s no wind, especially in winter?

1.2 MAINTENANCE PROCEDURES

Argo operators should be aware of the wind chill factor. Dress warmly and make sure exposed skin is protected. Pay particular attention that young passengers are properly “bundled up” with their hands and faces well protected.

The cooling effect of the wind makes it feel that it’s colder than it really is. This combined effect of wind and low temperature is known as the “wind chill factor”.

Maintenance procedures described in this manual can be carried out by the operator. These procedures include: 1. 2. 3. 4. 5.

WIND CHILL

checking fluid levels changing the engine and transmission oil cleaning and replacing filters preventative maintenance inspections, adjustments, repairs and trouble-shooting

Wind Speed km/h 8

Actual Temp.(C)

If you perform your own maintenance, carefully follow the lubrication and preventative maintenance schedule (Section 7.5). By following this schedule, you will receive trouble free, long term service from your vehicle. The following comprehensive ARGO service information is available: • • • • •

673-00 1977-1986 ARGO Service Manual 673-01 1987 ARGO Service Manual 673-02 1988 Supplement 673-10 Service Manual (673-01 & 02) 673-25 Argo Service Video

Your Argo dealer will perform regular maintenance and lubrication for a reasonable service charge.

-2

-8

-11

-14 -16

-17

-5

-7 -14

-18

-21 -23

-25

Gradually -19 -19 Increasing -26 -27 Danger

-10

-12 -20

-25

-28 -31

-33

-34 -35 Dangerous

-15

-18 -26

-32

-35 -38

-40

-42 -43

-20

-23 -32

-38

-43 -46

-48

-50 -51

-25

-28 -38

-45

-50 -53

-56

-30

-33 -45

-52

-57 -61

-63

-57 -59 Extremely -65 -67 Dangerous

-35

-39 -51

-59

-64 -68

-71

-73 -75

-40

-44 -57

-65

-71 -75

-79

-81 -83

-45

-49 -63

-72

-78 -83

-86

-89 -90

-50

-54 -69

-79

-85 -90

-94

-96 -98

1.4 MODEL IDENTIFICATION The vehicle identification plate is fastened to the dash. Reference Section 1.6 for the exact location. The model and serial numbers are stamped into it. Model identification starts with “V”, followed by five numbers. The four or five digit serial number begins with one of the following prefixes:

The trouble-shooting chart (Section 8) contains information for locating and correcting mechanical problems. In many cases, potential problems can be identified by unusual noises, sluggishness or vibration, before they result in a breakdown. Refer to the chart to identify these symptoms. Take immediate corrective action or take the vehicle to an Argo dealer for service.

S - 6x6 Vanguard (Mechanical Brakes) SN - 6x6 Vanguard2 (Hydraulic Brakes) BF - Bigfoot RB - 8x8 Response CB - Conquest

This manual does not provide detailed maintenance or servicing information for the engine. Refer to the engine manufacturer’s manual (supplied with each Argo) for important warranty, service and operating information.

Carefully observe the maximum load capacity for your vehicle on land and in water as listed in the following:

If the engine requires servicing, take the vehicle to an authorized engine service outlet.

SECTION 1 GENERAL INFORMATION ARGO 6 x 6 VANGUARD (S)

ARGO 6 x 6 VANGUARD2 (SN)

Serial Number: Engine:

S-6999 Briggs & Stratton Vanguard, 480 cc (16 h.p.) V-Twin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Mechanical, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 16 Amp magneto type charging system, electronic ignition Speed: Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) Water - 2 adults or 158 kg (350 lbs.) Maximum Rear Capacity: Land and Water - 63 kg (140 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 348 kg (765 lbs.)

Serial Number: Engine:

ARGO 6 x 6 BIGFOOT (BF)

ARGO 8 x 8 RESPONSE (RB)

Serial Number: Engine:

Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains: Electrical:

Speed: Load Capacity: Maximum Rear Capacity: Tires: Dry Weight:

BF-9212 Briggs & Stratton Vanguard, 570 cc (18 h.p.) V-Twin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Hydraulic, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain and single RC-60 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp magneto type charging system, electronic ignition Speed: Land - 39 km/h (24 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) Water - 2 adults or 158 kg (350 lbs.) Tires: 25x12.00-9NHS, 2 ply Dry Weight: 414 kg (910 lbs.)

Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains: Electrical:

Speed: Load Capacity: Tires: Dry Weight:

Land and Water - 63 kg (140 lbs.) 22x10.00-8NHS, 2 ply 348 kg (765 lbs.)

RB-12075 Briggs & Stratton Vanguard, 570 cc (18 h.p.) V-Twin, 4 cycle, air cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic, 9" disc with holding brake system Double RC-50 roller chain 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp magneto type charging system, electronic ignition Land - 30 km/h (20 mph) Water - 3 km/h (2 mph) Land - 6 persons or 454 kg (1000 lbs.) Water - 4 adults or 317 kg (700 lbs.) 22x10.00-8NHS, 2 ply 436 kg (960 lbs.)

1.5 REAR SEATS - 8 WHEEL MODELS

ARGO CONQUEST (CB) Serial Number: Engine: Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains: Electrical:

SN-7888 Briggs & Stratton Vanguard, 480 cc (16 h.p.) V-Twin, 4 cycle, air cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic, 9" disc with holding brake system Double RC-50 roller chain 12 volt D.C. battery, 435 cranking amps at 0 F; 16 Amp magneto type charging system, electronic ignition Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Land - 4 persons or 317 kg (700 lbs.) Water - 2 adults or 158 kg (350 lbs.)

CB-10847 Kawasaki 620 cc (20 h.p.) V-twin 4 cycle, liquid cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic Caliper, 9" disc with holding brake system Double RC-50 roller chains 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp charging system, battery ignition Land - 30 km/h (20 mph) Water - 3 km/h (2 mph) Land - 6 persons or 454 kg (1000 lbs.) Water - 4 adults or 317 kg (700 lbs.) 22x10.00-8NHS, 2 ply 465 kg (1025 lbs.)

Argo 8 wheel models are fitted with â&#x20AC;&#x153;quick-releaseâ&#x20AC;? rear seats. Removal 1. Grasp the inner edge of the rear seat at both ends. 2. Lift the inner edge of the rear seat upwards until both plastic bumpers are clear of the upper body. 3. Using an upward motion, pull the seat toward the centre of the rear compartment. 4. Remove the seat. Installation 1. Place the rear seat over the seat mounting holes in the upper body. Insert the large seat washers through the holes. 2. Using downward pressure, slide the seat towards the outside of the vehicle to lock it in place.

SECTION 1 GENERAL INFORMATION 1.6 IDENTIFICATION AND LOCATION OF CONTROLS

SECTION 1 GENERAL INFORMATION 1.7 INFORMATION LABELS There are labels on all models which indicate operating hazards and provide special operating instructions. Information about the use of the holding brake system, the use of the vehicle in water, correct fueling procedures and placement of the floorpans has been provided on distinctive coloured labels fastened to the various locations on the Argo.

Figure 1.1 Location of Information Labels - All Models

The label shown below is located behind the seat in the rear compartment of all 6-wheel models.

Figure 1.2 Rear Compartment Capacity Label - All 6x6 Models

SECTION 2 GENERAL OPERATING INFORMATION 2.1 NEW VEHICLE “BREAK-IN” PROCEDURE

2.2 PRE-OPERATION CHECKS

To obtain long term, trouble free service from your vehicle, observe the following break-in guidelines:

Carefully follow the engine manufacturer’s recommended pre-operation/daily checks as well as the following:

1. Vary the speed of the vehicle for the first tank of fuel. Avoid full throttle operation during break-in period.

1. Check the fuel level in the see-through tank located under the driver’s seat.

2. Check engine and transmission oil levels daily during break-in period.

2. Check the air pressure in all tires. NOTE: Improperly inflated tires can cause the vehicle to pull to one side, requiring constant steering correction. See Section 7.2.6 for tire pressure specifications.

3. Change the transmission oil after initial 20 hours of operation, or after 2 tanks of fuel have been used. Failure to do so can result in damage to the transmission bearings or gear surfaces. Refer to Section 6.2.2 for transmission oil changing instructions.

3. Test the operation of the twist grip throttle control by turning it to the fully open position and releasing it. The throttle must operate smoothly and return automatically to the fully closed position. Take the vehicle to an ARGO dealer if the twist grip requires adjustment.

4. Change the engine oil in the Vanguard engine after the first 8 hours of operation and in the Kawasaki after the first 20 hours. Refer to Section 6.1.3 of this manual and the oil change section of each engine owner’s manual for oil change information.

4. Check the steering lever travel by pulling both steering levers fully to the rear. See Section 7.3.4 for proper adjustment details.

5. Check the idler chain adjustment each day before driving the vehicle, and after the initial 2 hours of operation. Refer to Section 7.2.5 for idler chain inspection and adjustment information.

5. Check the engine intake and exhaust screen for obstructions. Clear any debris that has accumulated.

2.3 CARRYING PASSENGERS AND CARGO 6. Never overload your vehicle. Trying to steer an overloaded vehicle can overheat the brakes. This will lead to brake fade which means loss of steering control and the ability to stop the vehicle. Overloading the vehicle can lead to premature brake system failures and costly damage to drive chains, axles or bearings. Follow the recommended load capacity for the vehicle listed in Section 1.4.

1. Keep cargo as low as possible and evenly distributed. 2. Use extreme CAUTION when negotiating inclines with a loaded vehicle. Heavy loads and high loads decrease the stability of the vehicle and may cause it to roll. Be prepared to shift occupant weight and load forward or have passengers get out of the vehicle to climb an incline.

7. Do not allow the brakes to drag, particularly during the first 10 hours of operation. To maximize brake pad life, start by making several low speed turns to both sides. Allow the brakes to cool by driving in a straight line. Repeat the low speed turns. Allow the brakes to cool again. This procedure will properly seat the brake pad friction material to the brake disc. The steering levers should be fully forward, against the dash, during straight ahead operation. Dragging the brakes will cause overheating of the brake components and result in brake fade.

3. Secure cargo to prevent it from shifting while driving.

8. The axle flange gaskets and bearing extension gaskets have a tendency to settle on new machines which could result in a loosening of the flange and extension bolts. Check and if necessary re-torque the bolts to 30 ft. lbs. (360 in. lbs.) See Section 7.2.8.

SECTION 2 GENERAL OPERATING INFORMATION 4. Do not mount any heavy fixtures to the upper body without support to the vehicle frame. The added weight may cause body deformation that could result in the tires rubbing through the body.

The fuel filler neck and fuel cap are located on the right side of the vehicle behind the driver’s seat. Replace the fuel cap if fuel leakage occurs, or if moisture is detected in the fuel. Use ARGO Part No. 126-46 fuel cap.

WARNING

Never fill the tank to the point where the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vent.

The rear compartment capacity of all 6 wheel ARGO vehicles is 65 kg. (140 lbs.) MAXIMUM. Exceeding this weight limitation will decrease the stability of the vehicle on inclines and increase the possibility of rolling over backwards when climbing a grade. Do NOT exceed this weight in the rear compartment.

Portable fuel containers may contain contaminants (dirt, water, etc.) that will cause engine operating problems. Use only clean, approved gasoline containers. After filling the fuel tank, be sure the fuel cap is replaced securely. Do not drive the vehicle unless the fuel cap is properly in place.

Make sure all passengers riding in an ARGO equipped with tracks and ice cleats are informed to keep hands, feet and clothing inside the vehicle, well away from the tracks and ice cleats, while the ARGO is in motion. Serious injury or death could result from getting caught by the ice cleats.

WARNING Never use untreated gasoline that has been stored for more than 45 days. Stale gasoline can cause gum deposits to form in the fuel lines and carburetor. these deposits clog the fuel system and cause engine starting and operating problems.

2.4 FUELING THE VEHICLE

WARNING

When storing the ARGO for 45 days or more, use ARGO Part No. 125-85 Fuel Stabilizer to treat fuel in the fuel tank and fuel containers.

Gasoline is extremely flammable and can explode under certain conditions. Do not add fuel while the engine is running or hot. If fuel is spilt in, on or around the vehicle, wipe it up immediately. Flush out any fuel spilt in the vehicle with water and allow it to drain out through the drain plug holes. Do not smoke when filling the fuel tank.

2.5 VENTED FUEL SYSTEM - ALL MODELS All ARGO models have fuel systems that are vented through a special hose connected to the filler neck assembly that runs along the upper body to a fitting at the left rear.

Use clean, fresh, unleaded gasoline in all models of the ARGO. Minimum 87 octane fuel is recommended. Leaded gasoline can be used as a substitute fuel. However, if leaded gasoline is used, the engine will require more frequent servicing.

WARNING When installing the Handrail Kit, Convertible Top Kit or Outboard Motor Bracket; Since the fuel vent hose runs along the under side of the upper body, care must be taken when drilling mounting holes. The fuel vent hose could be pierced during the drilling process, resulting in a dangerous fuel leak into the vehicle and a costly repair procedure.

SECTION 3 OPERATING INSTRUCTIONS 3.1 BRAKES AND STEERING The right and left steering levers are used to turn and stop the vehicle when it is moving forward or in reverse. When the right steering lever is pulled back, the vehicle turns to the right (Figure 3-1). When the left steering lever is pulled back, the vehicle turns to the left (Figure 3-2). To stop the vehicle, pull both steering levers back evenly (Figure 3-3). The ARGO is a skid steer vehicle. During a turn, the rear of the vehicle swings outward as the vehicle pivots on the front tire on the inside of the turn. To make a right hand turn, the rear of the vehicle skids out to the left. To make a left hand turn, the rear of the vehicle skids out to the right.

Figure 3-3. Stopping the vehicle

3.2 HOLDING BRAKE SYSTEM VANGUARD2, BIGFOOT, RESPONSE & CONQUEST Models

WARNING

All VANGUARD2, BIGFOOT, RESPONSE & CONQUEST models have holding brake levers between the steering levers.

When turning, the back of the vehicle swings to the opposite direction of the turn. 8-wheel vehicles swing out further than 6-wheelers. Always take care to avoid hitting persons or objects with the rear of the vehicle! Serious injury or death can result!

WARNING The holding brake system is not a parking brake, and therefore is not designed to hold the vehicle in place for long periods of time. The holding brake is for short term use only. When parking on an incline, engage the holding brake levers, leave the vehicle in gear, turn the engine off and block the vehicleâ&#x20AC;&#x2122;s wheels. When in use, the holding brake system keeps the steering levers locked in the full braking position. To apply the holding brake system:

Figure 3-1. Making a right hand turn

1. Pull the steering levers back fully. 2. While holding the steering levers back, push each holding brake lever down until it rests against each steering lever holding brake stop. 3. Release the steering levers so that they rest against the holding brake adjuster screws. To release the holding brake system: 1. Pull the steering levers back. 2. The spring-loaded holding brake levers will release automatically. When not in use, the holding brake levers rest against the bottom edge of the dash.

Figure 3-2. Making a left hand turn

SECTION 3 OPERATING INSTRUCTIONS 3.3 HOLDING BRAKE SYSTEM - VANGUARD

3.5 STARTING PROCEDURE

The VANGUARD has a holding brake lever installed at the base of the left hand steering lever.

WARNING Never start or run the engine in a closed building or confined area. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odourless, colourless and can cause serious personal injury or death.

WARNING The holding brake is not a parking brake. When parking on an incline, engage the holding brake, leave the vehicle in gear, turn the engine off and block the vehicle’s wheels.

All ARGO models are equipped with key operated, electric start systems. Starting procedure is identical for all models. To start the vehicle, proceed as follows:

To apply the holding brake system:

1. Place the gearshift in the neutral (N) position.

1. Pull the left steering lever back.

2. Use the choke if the engine is cold. Briggs & Stratton engines are equipped with a spring loaded choke that will have to be held out. The Conquest choke is operated by flipping the choke lever up. Once the engine is started, flip it back down.

2. While holding the steering lever back, lift the holding brake lever up so it engages the steering lever holding brake pin. 3. Release the steering lever against the holding brake lever.

3. Open the accelerator twist grip control 1/8 turn.

To release the holding brake system:

4. Turn the key to the “START” position. (See Figure 3-5)

1. Pull the steering lever back.

Off Run

2. The spring-loaded holding brake lever will release automatically. When not in use, the holding brake lever will rest against the bottom of the steering lever.

Start

3.4 THROTTLE CONTROL Vehicle speed is controlled by the throttle twist grip. To increase vehicle speed, turn the twist grip as shown in Figure 3-4. To decrease vehicle speed, release the twist grip so the engine returns to idle.

Figure 3-5. Ignition Switch

CAUTION Do not operate the starter continuously for more than 5 seconds or the starter may overheat. Wait 30 seconds between each operation of the starter to let it cool and the battery power recover. Never attempt to restart the engine until the engine completely stops. Always remove key from switch when leaving vehicle unattended or when vehicle is not in use. Figure 3-4. Operation of the throttle twist grip

SECTION 3 OPERATING INSTRUCTIONS 5. Release the key as soon as the engine starts: the key will automatically return to the “RUN” position.

NOTE

6. Release the twist grip control and allow the engine to come to an idle.

NO MANUAL STARTING PROCEDURE IS AVAILABLE FOR THE CONQUEST.

7. Push the choke in halfway after the engine starts, and push it in all the way as the engine warms up.

3.8 SELECTING AND CHANGING TRANSMISSION GEARS

8. If the engine fails to start, refer to the trouble-shooting chart in Section 8 for corrective action.

All models for the ARGO are equipped with a four position transmission. The gearshift lever extends through the firewall and is moved to the right or left into one of four positions (See Figure 3-7):

3.6 STOPPING THE ENGINE Release the throttle twist grip. Let the engine speed return to idle and turn ignition switch to the “OFF” position. Always remove key from ignition switch when leaving the vehicle unattended.

* REV (Reverse) - for backing up the vehicle * N (Neutral) - for starting the engine or idling * LOW - for use when extra pulling power or very low speed is required in rough terrain. * HIGH - for general use at normal operating speeds.

3.7 MANUAL STARTING PROCEDURE VANGUARD, VANGUARD2, BIGFOOT & RESPONSE models can be manually started using the recoil starter on the Vanguard engine. 1. Turn the key to the “RUN” position. 2. Place the gearshift in the neutral (N) position. 3. Pull out the choke if the engine is cold. 4. Remove the engine compartment hood.

Figure 3-7. Direction of gearshift travel and gear positions

5. Grasp starter grip as illustrated and pull slowly until recoil engages (Figure 3-6).

To shift from N (neutral) position into the desired gear: 1. Apply the brakes by pulling back both steering levers.

6. Open the accelerator twist grip control 1/8 turn, then pull cord rapidly to overcome compression, prevent kickback and start engine. Repeat if necessary with choke pushed in slightly.

CAUTION

7. When engine starts, push choke in gradually.

Do not attempt to move the gearshift from the neutral (N) starting position until the engine idles down completely. The ARGO is equipped with an automatic clutch that is activated by engine speed. If the engine idle speed is too high, the transmission will grind during gear engagement. Figure 3-6. Recoil Starter - Vanguard Engine

SECTION 3 OPERATING INSTRUCTIONS 2. After the engine has idled down completely, lift up on the gear shift lever and move it with a quick movement to the selected gear.

3.9 HEADLIGHTS All ARGO vehicles are equipped with 2 headlights that are operated through the dash mounted light switch. To turn the lights on, pull the light switch out.

NOTE: You will find it easier to engage high gear if the gear shift is first moved to reverse (REV), then directly over to HIGH with one quick movement.

CAUTION

Do not leave the lights on for any length of time when the engine is not running. Leaving them on will drain the battery.

Always turn the ignition switch to the ‘OFF’ position when turning off the engine. On CONQUEST, RESPONSE & BIGFOOT models and optional on VANGUARD2 models, the brake cooling system remains operational in the ‘RUN’ position after the engine has been turned off.

3. Use the gear position decal only as a guide for finding the gear position. Make sure you feel the detent which indicates the selected gear is properly engaged.

Avoid frequent starting of the engine and extensive idling. Both will lead to a drain of the battery because the electrical draw is greater than the charging rate at engine idle.

3.8.1 Changing Transmission Gears DO NOT CHANGE TRANSMISSION GEARS WHILE THE VEHICLE IS MOVING. To change gears, bring the vehicle to a complete stop, let the engine idle down completely, and move the shift lever to the selected gear as described above.

SECTION 4 DRIVING PROCEDURES a series of short turns. Hold the steering lever against the dash between turns. Riding the brakes while making turns will result in excessive heat, brake fade and lead to premature brake wear.

4.1 DRIVING STRAIGHT AHEAD Shift the transmission into LOW or HIGH. Hold both steering levers straight ahead against the dash (See Figure 4-1). Turn the throttle twist grip slowly until the clutch system engages and the vehicle moves forward.

Figure 4-2. Correct method of making a wide turn

WARNING Sharp turns, especially at high speeds or when heavily loaded, may cause the vehicle to roll over. Slow the vehicle down before making a turn. Do not apply the brakes too suddenly.

Figure 4-1. Position of steering levers for straight ahead operation

4.3.1 Left Turn 4.2 STOPPING THE VEHICLE To make a left turn, pull back on the left steering lever to stop the wheels on the left side of the vehicle. When the turn has been completed, return the left steering lever forward against the dash.

Allow the throttle grip to return to the idle position. Pull back evenly on both steering levers.

4.3.2 Right Turn

WARNING

Pull the right steering lever back and return it to the dash when the turn has been completed.

Do not pull back abruptly on the steering levers. The brakes are very effective, and sudden braking may cause you or your passengers to be thrown from the vehicle. Never use excessive force on the steering levers to apply the brakes. This can cause tremendous pressure in the master cylinders and brake calipers, resulting in component failure.

4.4 BACKING THE VEHICLE UP With the engine at idle, shift the transmission into reverse. Hold the steering levers forward against the dash. Turn the throttle twist grip slowly until the clutch engages and the vehicle moves backwards. Increase speed by gradually turning the accelerator twist grip.

4.4.1 Turning The Vehicle While Backing Up Pull the left steering lever back to make a turn to the left. Pull the right steering lever back to make a turn to the right.

4.3 TURNING THE VEHICLE

When turning the vehicle while backing up, the rear of the vehicle swings in the direction of the turn. This is unusual for most people who are not familiar with skid steer vehicles. Carefully practice backing up and turning in an open area until you become accustomed to this procedure. Take precautions to avoid hitting persons or objects.

SECTION 4 DRIVING PROCEDURES

WARNING Do not push against the firewall with your knees. Damage to the firewall and serious personal injury can result from the driven clutch wearing through the firewall

SECTION 5 DRIVING PROCEDURES IN UNUSUAL CONDITIONS 5.1 REMOTE AREA USE

5.3 UPHILL OPERATION

When traveling in remote areas or when traveling long distances, the following items are essential:

• • • • • • • • • • •

WARNING

a first aid kit a complete survival kit protective clothing and footwear waterproof safety matches candles emergency flares communications equipment adequate fuel supply in approved, watertight containers fire extinguisher manual starting rope or back-up battery basic mechanic’s tools and Argo spare parts

Never accelerate or brake suddenly while driving up or down a hill. Sudden acceleration or braking can cause the vehicle to roll over, causing serious personal injury or death. The rear compartment capacity of all 6 wheel ARGO vehicles is 65 kg (140 lbs.) MAXIMUM. Exceeding this weight limitation will decrease the stability of the vehicle on inclines and increase the possibility of rolling over backwards when climbing a grade. Do NOT exceed this weight in the rear compartment. Never attempt to turn the vehicle around on a steep hill or grade. Turning the vehicle around on a hill can result in the vehicle rolling over.

Before venturing into remote areas, carry out all inspections, adjustments and lubrication checks detailed in this manual. Do not proceed unless your vehicle is in good working condition.

Approach the hill head on to minimize the possibility of sliding sideways or rolling over. Accelerate slowly to prevent loss of traction. When traction is lost, the vehicle may slide sideways or backwards. If this occurs, apply the brakes gently and evenly to stop the slide. Allow the vehicle to coast to the bottom of the hill by carefully releasing the brakes.

Inform someone of your departure and return plans and your route so that help can be dispatched if you do not return as scheduled. Do not travel into a remote area alone.

Try to avoid steep hills. When a steep hill can’t be avoided, be prepared to shift occupant weight forward, or have them get out of the vehicle to prevent the vehicle from rolling over. As a general rule, driving up a steep hill greatly increases the possibility of rolling over.

Choose your equipment and supplies to meet the climate and terrain conditions that you may encounter. Practice safe driving habits when traveling in remote areas. Avoid terrain that may be impassable.

5.4 DOWNHILL OPERATION 5.2 ANGLE OF OPERATION Always approach the hill head on to minimize the possibility of sliding sideways, or rolling over. Gently apply the brakes to control downward vehicle speed. Do not jam on the brakes while traveling downhill. Sudden braking can cause the vehicle to roll over frontwards.

When operating any Argo vehicle on an angle, (up and down hills or across uneven terrain that causes the vehicle to tilt in any direction) the engine oil level is affected. If the engine oil level falls below the oil pump intake, damage can occur because of inadequate lubrication. To avoid premature engine damage and costly repairs:

An alternative to applying the brakes while going down a gentle decline is to use engine braking. Select low range and keep the engine speed up just enough to keep the clutch engaged.

• Do not operate your engine continuously on angles or •

inclines that are greater than 30 degrees in any direction. Make sure the engine oil level is near the “full” mark (However, do not overfill.)

Avoid steep declines when possible. When a steep decline cannot be avoided, shift occupant weight to the rear of the vehicle to prevent the vehicle from rolling over. As a general rule, driving the vehicle down a steep decline greatly increases the possibility of rolling over.

SECTION 5 DRIVING PROCEDURES IN UNUSUAL CONDITIONS 5.5 SIDE SLOPE OPERATION

6. Care must be taken when encountering submerged obstacles that may upset the vehicle.

Do not drive your vehicle across the side of a hill. Side slope operation greatly increases the risk of rolling the vehicle over sideways.

Observe the following safety precautions BEFORE entering the water:

Prolonged side slope operation may cause engine damage. Observe the engine angle of operation limitations in Section 5.2.

1. All occupants must wear an approved personal flotation device (PFD) or life jacket while traveling in water. 2. Equip the vehicle with a paddle and bailing can. An optional bilge pump kit (ARGO Part No. 638-25) is available from your ARGO dealer and is recommended for water operation.

Operation on side slopes will require frequent use of the brakes for steering correction since the vehicle tends to head downhill. This may cause brake overheating or fade. 5.6 AMPHIBIOUS OPERATION - GENERAL

3. Lift the rear floor pan and make sure both drain plugs in the rear of the lower body (Figure 5-1) are in place and properly tightened. To install, seat the rubber portion of the drain plug properly in the lower body hole and push the lever down to lock plug in place (Figure 5-2). Check that the plug is firmly in place. To tighten the drainplug, lift the lever up and turn the lever clockwise until it is snug when the lever is pushed down. Replace worn or inoperative drain plugs with ARGO Part No. 100-18.

WARNING ARGO vehicles may sink if they fill with water. If water starts entering the vehicle, head to the nearest shore immediately. Be prepared to abandon the vehicle if it appears that the vehicle will fill with water before you reach the shore. Be especially cautious when operating a loaded vehicle (cargo and/or passengers) in water. Observe the capacity limits. All ARGO vehicles are self-propelled, amphibious vehicles, capable of navigating calm water, provided the following precautions are observed:

Figure 5-1. Location of rear drain plugs

1. Do not enter water if the vehicle is overloaded. Refer to Section 1.4 of this manual for recommended load capacity in water.

4. Visually check the lower body of the vehicle for cuts, punctures or holes that will allow water to enter the vehicle. 5. Make sure that any cargo in the rear of the vehicle is evenly distributed.

2. Do not use seat belts or any passenger restraining device while operating an ARGO in water. If an emergency arises, you and your passengers may have to leave the vehicle quickly.

6. Periodically inspect the outer bearing flange and gaskets of each axle (Figure 5-3) to ensure they are water tight. If there are signs of water leaking into the lower body, take corrective action before entering water again. Make sure there is sufficient grease in the bearing flange and that the grease seal is in good condition.

3. Do not attempt to cross large bodies of water. Stay close to the shore in case an emergency arises and you have to leave the water. 4. Do not attempt to navigate any body of water with a strong current. Avoid water operation under windy conditions. 5. Use extra caution when operating the ARGO in cold water. If the vehicle upsets or swamps, exposure in cold water significantly reduces the chance of survival.

SECTION 5 DRIVING PROCEDURES IN UNUSUAL CONDITIONS Be careful not to submerge the bumper as you enter the water. With the bumper submerged, water can enter through the openings in the upper body. 5.6.2 Driving Procedures in Water After the vehicle is floating evenly on the water, turn the throttle twist grip to increase speed. Use only part throttle when traveling through water. Full throttle only results in excessive turbulence, not higher speeds. The vehicle is steered by pulling the right or left steering levers back as on land. The turning radius is somewhat greater in water, and the vehicle does not respond to changes in direction as quickly as it does on land.

Figure 5-2. Tightening and locking the drain plugs

The vehicle is propelled forward through the water by the web of the tires as they rotate. To back up in water, release the throttle, shift the transmission into neutral, and use a paddle. Avoid rocks, stumps or other obstacles that are below the surface of the water. Striking these obstacles may damage the bottom or upset the vehicle. If your vehicle begins to fill with water, immediately head to the nearest shore. Get the vehicle out of the water and drain it by removing both rear drain plugs. Correct the leak before entering the water again.

Figure 5-3 Outer bearing flange sealing area

NOTE

CAUTION Always observe the recognized rules of boating while traveling in water.

Do not leave the vehicle in water for extended periods of time. Water could enter the axle seals and cause damage to the axle bearings.

5.6.1 Entering the Water

5.6.3 Driving Out of Water

The point of entry should be free of rocks, stumps and other obstacles. Enter the water from a firm, gradual slope whenever possible. With the wheels partially submerged but still in contact with the bottom, stop and check thoroughly for water entering the lower body.

When driving out of water, choose an area of the shore that is reasonably flat and free of rocks, stumps and other obstacles. Steer the vehicle so that both front wheels reach the shore at the same time. Accelerate slowly until the vehicle is out of the water.

If a leak is detected, drive back onto shore. Drain the vehicle and repair the leak before re-entering the water.

5.6.4 Outboard Motor Bracket If the body of water must be entered from a steep slope or uneven terrain, back the vehicle into the water. With the engine and transmission weight concentrated in the front of the vehicle, the rear is lighter and floats higher.

An optional outboard motor bracket (ARGO Part No. 61700) and support (ARGO Part No. 618-00 or 618-10 Outboard Motor Bracket - Side Mount) are available to mount an outboard motor up to 9.9 h.p. A long shaft outboard motor is preferred to prevent cavitation.

SECTION 5 DRIVING PROCEDURES IN UNUSUAL CONDITIONS Do not mount an outboard motor on the vehicle unless the special bracket is used. Damage to the vehicle will occur if an outboard motor is mounted directly on the vehicle body.

Before venturing out onto ice-covered bodies of water, it is extremely important to:

• Check the ice thickness and condition to be sure it will

WARNING

•

Gasoline is extremely flammable and can explode if ignited. Fill outboard motor fuel tanks outside of the vehicle. Wipe up any spilt fuel immediately. Do not carry or store fuel tanks in a vehicle equipped with a cab or convertible top unless adequate ventilation is provided.

support the vehicle. Take all precautions as in Section 5.6, particularly paragraph 3 referring to drain plugs.

If the vehicle breaks through the ice, it will float in the water, provided that there are no leaks in the body, the drain plugs are in place and vehicle is not taking on water through any body openings. However, there is a risk of the vehicle tipping, particularly if the load is unbalanced. Be prepared to shift occupants’ weight for balance.

5.7 WINTER OPERATION Getting back onto safe ice depends on various conditions and the expertise of the driver. Be especially careful to prevent water from entering the vehicle. • Balance the cargo and passenger load. • Keep openings, like air intakes/exhaust, etc. above the water line. • Keep the bilge pump running. • Winch the vehicle out. • Back onto ice, as the back end is lighter and floats higher in the water. • Avoid getting the wheels on only one side onto the ice surface as water could enter over the opposite side of the vehicle. • Avoid turning as the Argo is climbing out to avoid vehicle tip-over. • Break the thin ice around the vehicle with the paddle until there is firm ice for the vehicle to climb onto. • Be wary of currents which may pull the vehicle under the ice.

Follow these precautions when operating the ARGO in winter conditions:

• Equip the vehicle for remote area use, as listed in Section • • •

• • • •

5.1. Keep the battery fully charged and in good condition. Use the recommended winter grade of engine oil. Do not allow water or snow to accumulate in the vehicle. Snow may melt during operation of the vehicle, collect in the lower body and freeze around the chains and final drive components, immobilizing the vehicle. Store the vehicle indoors or under cover. Equip your vehicle with snow tracks for travel over deep snow. Steep, snow-covered or icy hills may be more difficult to ascend. Ice cleat kits (625-20 for 6 wheel or 825-20 for 8 wheel) are available for Super Track systems. Never travel alone into a remote area. Leave your route and arrival plans with someone who can send help if you fail to arrive as planned.

If you feel that you may not be able to get the vehicle back onto safe ice or land, you might consider staying put to await rescue. This may be safer than trying to leave the vehicle to walk over thin ice.

5.7.1 Use on Ice Covered Bodies of Water

WARNING Using the ARGO on ice-covered bodies of water is potentially hazardous. Use extreme caution. Exposure to cold water reduces a person’s chance of survival. Protective clothing, such as a marine survival suit will significantly decrease the effect of exposure in frigid water.

SECTION 6 OIL, FILTER AND LUBRICATION INFORMATION 6.1 ENGINE OIL INFORMATION 6.1.1 Checking the Engine Oil Level Check the engine oil level each day before operating the engine. To check the oil during an operating period, shut the engine off, let it cool down and allow the oil time to drain into the sump before checking the oil level. Position the vehicle so the engine is level. Figure 6-2. Dipstick “A” and oil filler “B” location KAWASAKI engine

The BRIGGS & STRATTON VANGUARD (Figure 6.1) and KAWASAKI engines (Figure 6-2) are equipped with a dipstick and a separate oil filler tube. To check the oil level, clean the area around the dipstick before removing. Remove the dipstick and wipe it with a clean cloth. Re-insert the dipstick and push it all the way into the tube. Remove the dipstick and check the oil level. The oil level should be between the marks. If the level has dropped, add oil to bring the level up to the FULL mark. DO NOT OVERFILL.

CAUTION Do not run the engine if the oil level is above the “H” mark or below the “L” mark. Premature engine damage or failure can occur when oil levels are not maintained. 6.1.2 Recommended Engine Oil Use a high quality detergent oil of API (American Petroleum Institute) service class as listed below. Choose the correct viscosity of oil for seasonal driving conditions. Briggs & Stratton API Service Class SE, SF or SG

Figure 6-1 Oil fill and level location BRIGGS & STRATTON engine

CAUTION Do not run the engine if the oil level is above the FULL mark or below the ADD mark. Premature engine damage or total engine failure can occur when the oil level is not properly maintained.

SECTION 6 OIL, FILTER AND LUBRICATION INFORMATION Kawasaki API Service Class SD, SE or SF

NOTE

Ambient Temperature -20 C -10 C 0 C 10 C 20 C 30 C 40 C SAE40

SAE30 SAE 10W-30/SAE 10 W-40 SAE 5W-20 -4 F -14 F 32 F 50 F

68 F

86 F 104 F

Some increase in oil consumption may be expected when a multi-grade engine oil is used. Check the oil level frequently.

CONQUEST

A ziploc plastic bag makes a convenient oil container. It conforms to the space available and can be closed securely when the oil is drained, then lifted neatly out of the engine compartment.

VANGUARD, VANGUARD2, BIGFOOT & RESPONSE

Oil Capacity

Kawasaki

Briggs & Stratton

3.2 IMP pints 1.8 litres

2.5 IMP pints 1.4 litres/1.6 litres with filter change

PLEASE DISPOSE OF WASTE OIL PROPERLY TO CONSERVE OUR ENVIRONMENT. 4. When all the oil has been drained from the engine, clean and replace the drain plug. MAKE SURE it is properly tightened before refilling the engine. 5. See Oil Filter Replacement in Section 6.3.3. Refilling the Engine

Figure 6-3 Oil Capacities

Refill the engine through the oil fill with the correct amount and grade of oil as indicated on chart, Figure 6-3, Section 6.1.2. As you add oil, frequently check the level with the dipstick. Do not overfill. Start engine. Check for leaks. Stop the engine. Check the oil level. Add oil only to the “Full” or “H” mark on the dipstick.

6.1.3 Changing Engine Oil During the initial engine break-in period, change the oil after the first 8 hours of operation for Briggs & Stratton and 20 hours of operation for the Kawasaki. After the break-in period, change the engine oil every 50 operating hours, or more frequently if the vehicle is operated in dusty or dirty conditions.

6.2 TRANSMISSION OIL INFORMATION

Draining the Engine Oil

6.2.1 Checking the Transmission Oil Level

Each engine is equipped with a drain plug for draining the oil. The drain plug location is shown in the engine owner’s manual. Drain the oil from the engine as follows:

Check the transmission oil level every 50 operating hours. All models of the ARGO are equipped with a transmission oil dipstick (Figure 6-4). Clean the area around the dipstick before removing. Remove the dipstick by pulling up.

1. Start and warm up the engine so the oil will drain easily. 2. Level the vehicle so the oil will drain completely. 3. Place a suitable container under oil drain of engine and remove drain plug with a wrench: a 7/16" open end wrench or 7/16" square socket for Briggs & Stratton engines or a 21mm socket for Kawasaki engines.

Figure 6-4. Transmission dipstick

The transmission oil level should be even with the mark on the dipstick as shown in Figure 6-4. Add 80 W 90 Gear Lube HYPOY-C through the transmission oil fill/dipstick hole until the transmission is filled to the correct level. DO NOT OVERFILL. Replace the dipstick securely.

SECTION 6 OIL, FILTER AND LUBRICATION INFORMATION 6.2.2 Changing the Transmission Oil

Replace the fuel filter after every 250 hours of operation or once a year. To replace the filter, loosen the gear clamps with a slot screw driver and pull the rubber fuel lines off of the filter. Install the new filter with the flow arrow pointing toward the engine. Tighten the clamps securely. Start the engine and check for fuel leaks.

Change the transmission oil after the first 20 hours of operation, or after using 2 tanks of fuel. After this, change the transmission oil every 100 operating hours. Remove firewall to access the drain plug located at the bottom of the transmission. Drain the transmission oil into a suitable container and dispose of the oil at a disposal site.

6.3.3 Oil Filter

While draining the transmission oil, be sure to clean off any metal particles that are on the magnet of the drain plug. These fine metal particles are a result of the transmission gears meshing during the initial break-in period. Re-install the plug and tighten it securely.

During the initial engine break-in period, change the oil filter (Part No. 126-95 for Briggs & Stratton engines and Part No. 127-68 for Kawasaki engines) when the oil is changed. After that, change the oil filter every 50 hours. Before installing the new filter, lubricate the rubber filter gasket with fresh engine oil. Screw the filter on by hand until the gasket contacts filter adapter. Tighten 1/2 to 3/4 turn more. Start and run engine to check for oil leaks. Stop engine and re-check oil level. Add oil if required.

Refilling the Transmission Refill the transmission through the oil fill/dipstick hole with 30 oz (.85L) of 80 W 90 Gear Lube HYPOY-C. As you refill the transmission, check the oil level with the dipstick. Check that the oil level is even with the mark on the dipstick, after it has been seated fully in the dipstick hole. DO NOT OVERFILL.

6.4 LUBRICATION INFORMATION 6.4.1 General

Overfilling may result in oil being forced out the breather hole that could contaminate the brake pads and lead to brake failure.

The following parts and components require regularly scheduled lubrication to prevent premature wear and replacement. 1. Driven Clutch 2. Drive Chains

6.3 FILTER INFORMATION 6.3.1 Air Filter

3. Idler Chains 4. Bearings

Use the recommended lubricants listed in this section and carefully observe the recommended lubrication intervals.

All ARGO engines are equipped with a foam precleaner and dry paper air filter element housed in an air cleaner assembly attached to the carburetor.

WARNING

Wash and oil the precleaner after every 25 hours of operation or more often under extremely dusty or dirty conditions.

Do not attempt to lubricate the driven clutch while the engine is running.

Check the paper air filter element every 100 hours of operation or more often under extremely dusty or dirty conditions.

6.4.2 Driven Clutch Lubrication

For instructions to remove, clean and replace the air filter components, refer to the air cleaner section of the engine ownerâ&#x20AC;&#x2122;s manual.

6.3.2 Fuel Filter All models of the ARGO are equipped with an in-line fuel filter (ARGO Part No. 125-64). The fuel filter is located in the fuel hose, next to the fuel tank.

SECTION 6 OIL, FILTER AND LUBRICATION INFORMATION Do NOT spray lubricant onto the drive belt, brake disc or clutch faces. Allow the lubricant to dry before using the vehicle. If the lubricant is not dry, use of the vehicle will attract dirt and cause damage to the clutch components.

Refer to Section 7.2.3 of this manual for drive chain removal and re-installation instructions.

A complete service of the clutch units is required after every 250 hours of operation. To perform this procedure, the clutches must be disassembled. Special tools are required to disassemble the clutch units. We recommend that you return your vehicle to an ARGO dealer to have the clutch units serviced.

Lubricate the idler chains after 10 hours of operation, and more frequently if the vehicle is operated in dirty or wet conditions (Figure 6-6). Use only ARGO Chain Lube (ARGO Part No. 125-86) to lubricate the idler chains.

6.4.4 Idler Chain Lubrication

When applying the chain lube, protect the brake discs with a rag or simple cardboard shield (Figure 6-7). DO NOT SPRAY CHAIN LUBE ON THE BRAKE DISCS OR PADS. Roll the vehicle so that all of the idler chain is accessible for lubrication.

Figure 6-5. Lubricating the driven clutch Figure 6-6. Location of the idler chains

6.4.3 Drive Chain Lubrication Your ARGO vehicle is equipped with roller chains to each axle. Lubricate the chains every 10 hours with Aerosol Chain Lube (ARGO Part No. 125-86), or more frequently in dirty or wet conditions. After every 100 hours of operation, remove all the drive chains from the vehicle and clean them thoroughly in a suitable solvent, i.e. degreaser.

WARNING Never use gasoline as a cleaning solvent. Gasoline is extremely flammable and can explode if ignited, causing serious personal injury. Allow the chains to dry thoroughly, re-lubricate generously with ARGO Chain Lube and re-install.

Figure 6-7. Lubricating the idler chain

SECTION 6 OIL, FILTER AND LUBRICATION INFORMATION The second or inner grease fitting of the outer axle flange supplies grease directly to the outer axle bearing. Since the bearing is well sealed and packed with grease when manufactured, it requires re-greasing only every 100 hours of operation or before the vehicle is taken out of service for any extended period. Use a pistol grip type grease gun to avoid dislocating the bearing seals due to excessive grease pressure.

Do not use regular oil or grease to lubricate the idler chains. Regular oil or grease will be thrown off the idler chains during normal operation, and contaminate the brake pads or discs. When these components become contaminated, brake efficiency is affected. After every 100 hours of operation, remove both idler chains from the vehicle and clean them thoroughly in a suitable solvent. Allow the idler chains to dry thoroughly, re-lubricate them generously with Argo chain lube and re-install. Refer to section 7.2.5 of this manual for idler chain removal and re-installation instructions.

CAUTION Do not use high pressure or excessive amounts of grease. Damage to the bearing seals could result.

6.4.5 Outer Axle Flange & Bearing Lubrication

CAUTION

DO NOT USE HIGH PRESSURE PNEUMATIC GREASING EQUIPMENT Each outer axle flange is equipped with two grease nipples. Grease the outer cavity through the outer nipple of each flange with Shell Alvania No. 2 grease or equivalent frequently, at least every 25 hours of operation, to flush dirt and water that may have entered the axle seal. Only a small amount of pressure should be required. Grease until any contamination has been forced out past the seal and fresh grease is visible. At the same time, inspect all the axle seals for damage (Figure 6-8). Vegetation wrapping around the axles can damage the rubber lip of the seal, allowing dirt and water into the outer cavity. Replace any damaged seals.

Figure 6-9 Idler shaft bearing grease nipples

6.4.7 Inner Axle Bearing Lubrication The inner axle flanges are equipped with a grease nipple. Lubricate the bearings with a small amount of Shell Alvania No. 2 grease or equivalent every 250 hours or before the vehicle is taken out of service for any extended period. Only a small amount of grease is required.

Figure 6-8. Outer Axle Flange

SECTION 7 MAINTENANCE INFORMATION 7.1 ELECTRICAL SYSTEM 7.1.1 General To prevent damage to the electrical system:

• Never weld on the vehicle without first disconnecting both • •

7.1.2 Battery- ARGO Part No. 127-54 - Exide Part No. 45-50

WARNING Figure 7-1. Battery fluid level

Charging the Battery If the battery loses its electrical charge, remove the battery from the ARGO and recharge it with a 12 volt battery charger at the rate of 10-12 amps maximum. The battery should remain on charge until the specific gravity reaches 1.265 on an hydrometer. Re-install the battery in the vehicle and try to start the engine. If the battery fails to perform properly, have it tested by a battery service dealer. Replace a defective battery with ARGO Part No. 127-54/Exide Part No. 45-50.

Batteries can explode and cause serious personal injury if exposed to flame or sparks. Never smoke while servicing the battery. All models are equipped with a 12 volt, wet cell type battery. The battery is located in the engine compartment, on the right side in front of the driver’s position.

WARNING

Checking Fluid Level Ventilate area when charging. Keep away from spark, heat, cigarettes or open flame.

Check the fluid level every 50 hours of operation. Remove the pod vents and make sure each cell is filled to the fluid level as shown in Figure 7-1. If the fluid has dropped below the fill well, add distilled water until the cell is filled to correct level. DO NOT OVERFILL.

Cleaning the Battery Terminals and Cable Connections Clean the battery terminals and cable connections every 100 hours. Remove the black NEGATIVE (-) cables first. Make sure you reconnect the NEGATIVE (-) cables to the NEGATIVE (-) post and the red POSITIVE (+) cables to the POSITIVE (+) posts. Damage to the electrical system will occur if the cables are reversed.

SECTION 7 MAINTENANCE INFORMATION Cleaning the Battery

springs from the muffler attached to the tail pipe.

Clean the top of the battery every 250 hours with a mixture of baking soda and water. Before cleaning the battery, remove it from the vehicle and make sure the pod vents are in place. Soak a cloth in the soda/water mixture and scrub the top of the battery. After the foaming has stopped, flush with clean water and dry with a clean cloth.

3. The screen-type spark arrester assembly is located inside the tail pipe. It is fastened with one (1) slotted washerhead hex screw. Find the screw on the side of the outlet tube.

7.1.3 ELECTRICAL SYSTEM FUSES

5. Take off the screen-type spark arrester assembly.

All models of the ARGO are equipped with push-in type automotive fuses. The fuses protect the electrical circuits of the vehicle. They are located in the fuse block, inside the engine compartment, just in front of the steering levers. Replace any blown fuses. Return your vehicle to an ARGO dealer for inspection of the electrical circuit if a fuse blows repeatedly.

6. Shake loose particles out of the screen assembly.

NOTE:

4. Remove the screw and save it for step 9.

7. Clean the screen with a wire brush. (Soak it in oil solvent if necessary.) 8. If any breaks in the screen or weldments are discovered, replace the assembly with Part No. 807-67.

On the Vanguard, Vanguard2, Bigfoot and Response one of the center fuses in the fuse block is a spare and can be used for accessory equipment.

9. Return the screen assembly to the outlet tube and refasten it with the screw from Step 4. 7.2 DRIVE SYSTEM & TIRES

7.1.4 SPARK PLUGS

WARNING

Remove and inspect the spark plugs after every 100 hours of operation. Clean the plugs and reset the gap as detailed in the engine owner’s manual.

Do not attempt to adjust, repair or replace the drive belt, clutches or any moving part while the engine is running. Before servicing the vehicle, disconnect the battery to prevent accidentally starting the engine.

Replace the spark plugs if the electrodes are corroded or damaged or if the insulator is cracked. Use the correct plug for the engine as detailed in the engine owner’s manual.

Keep the engine compartment hood, clutch guard and firewall securely in place when the engine is running. Severe injury can result if the drive belt, clutch components or other moving parts come loose.

Re-install the spark plugs carefully, taking care to start the threads properly. Torque the plugs to 10 - 15 ft. lbs (14 to 20 N·m). Do not over tighten.

If engine compartment inspection is necessary while the engine is running, use EXTREME CAUTION! Keep engine RPM low. Avoid standing directly in line with moving components. Use a mirror to view the components.

7.1.5 SPARK ARRESTER Cleaning the Spark Arrester (only for Argo’s equipped with one)

7.2.1 DRIVE BELT

CAUTION

The drive belt transmits power from the driver clutch (on the engine) to the driven clutch (on the transmission). These components are located on the left side of the engine compartment. (Figure 7-2)

After operating the engine, do not touch any part of the exhaust system until it has had sufficient time to cool! 1. Keep a record of the number of hours of engine use. The spark arrester should be removed, cleaned and inspected every 50 hours of operation. 2. Remove the tail pipe assembly by disconnecting the

SECTION 7 MAINTENANCE INFORMATION

Figure 7-2. Location of drive clutches and drive belt Figure 7-3. Removing the drive belt

Check the drive belt after every 25 hours of operation, or whenever there is a noticeable reduction in clutch performance. Replace the belt when:

To install the Drive Belt:

CAUTION

• the top width of the belt has worn to 1-5/16" (33mm) • cracks , fraying or shredding is apparent • it becomes contaminated with oil or some other fluid

If this procedure is not carried out as described, the edge of the fixed face may cut or damage the drive belt.

Refer to the ARGO Parts Manual for correct drive belt part number.

1. Position the belt around the driver clutch first.

To Remove the Drive Belt

2. Ease the belt over the edge of the fixed face on the driven clutch and at the same time, turn the inside, movable face clockwise.

1. Make sure ignition is turned off. 2. Remove the engine access hood.

Drive Belt alignment and tension are pre-set at the factory and are not adjustable. They are critical for proper operation of the drive system. Return the vehicle to an ARGO dealer if rapid belt wear occurs.

3. Remove the firewall. 4. Place the transmission in N (neutral).

7.2.2 CLUTCH MAINTENANCE 5. Ease the belt over the fixed half pulley of the driven clutch starting from the bottom of the clutch, while turning the clutch counterclockwise until the belt is off. (Figure 7-3).

Disassembly and repair of the driver and driven clutch requires special tools. Return the vehicle to an ARGO dealer if the clutch units need servicing. The following indicates that clutch service is required:

6. Remove the belt from the driver clutch.

• • • • • • • 24

a drop in vehicle performance the clutch does not shift smoothly the clutch sticks during vehicle operation the drive belt wears rapidly the vehicle vibrates severely during operation the vehicle does not accelerate when the engine speed is increased with the transmission in gear transmission will not shift smoothly into gear at engine idle.

SECTION 7 MAINTENANCE INFORMATION 4. Roll the vehicle until the connecting link on one of the chains is visible. 5. Remove the spring clip from the connecting link as shown in Figure 7-7. Remove the outside plate and tap out the connecting link. The inside plates will be released when the connecting link is removed (Figure 7-8). 6. Remove the chain from the vehicle. 7. Repeat steps 4 to 6 until all drive chains are removed.

Figure 7-4. Location of the sliders

Clutch Inspection Inspect the nylon sliders every 50 hours. The nylon sliders are mounted in the driven clutch moveable pulley. (Figure 74). When the clutch shifts, the cam moves on the nylon sliders. Replace the nylon sliders before there is aluminum to aluminum contact between the cam and the movable pulley. Driven clutch disassembly is required to replace the nylon sliders properly. Return the vehicle to an ARGO dealer for service.

Figure 7-6. Securing tensioner cam

To install the Drive Chains:

7.2.3 DRIVE CHAINS

1. Position the drive chain over the slider block and around the drive sprockets.

Roller chain “stretch” results from wear to the chain pins and bushings because of the loss of lubricant.

2. Pull the ends of the chain together and insert the connecting link as shown in Figure 7-8 and 7-9. When connecting the RC50-2 chain, insert the inside plates before tapping the connecting link into position.

To prevent sprocket damage and unnecessary breakdowns, replace the chains when:

• • • •

the chain tensioner can no longer take up the chain slack. the chain is rubbing on a frame cross member. the chain is seized due to rust and lack of lubrication. the chain climbs the sprocket teeth, especially noticeable when turning.

NOTE Use a pair of modified 7R Vice Grips to hold the ends of the chain together while inserting the connecting link. Some drive chains have no slack, and replacement of the connecting link is difficult without this tool. Modified Vice Grips can be ordered from your ARGO dealer (ARGO Part No. 658-08) or refer to Appendix 1 for modification information.

To remove the Drive Chains: 1. Place the gearshift in the N (neutral) position. 2. Remove the floor pans.

3. Replace the outside plate and spring clip. The open end of the clip must face rearward when it is on top of the chain.

3. Turn the tensioner cam assembly in the direction which winds up the torsion spring and push the assembly down as close as possible to the cam follower block in the bottom of the frame. Secure it in this position with a ViceGrip 10CR as illustrated in Figure 7-6.

4. Remove the vice-grips, securing the cam assembly in its lowest position.

5. Repeat steps 1 to 4 until all chains are replaced.

SECTION 7 MAINTENANCE INFORMATION

Figure 7-7. Removal of the spring clip

Figure 7-10. Wear groove on the slider block

The chain tensioning system consists of a torsion spring loaded cam assembly with a slider block which takes up the slack on the bottom side of all but the front final drive chains. As the chain wears, the chain tensioning mechanism adjusts semi-automatically. Under most conditions, the tensioner cam assembly will move to the next step of adjustment simply due to normal drive system dynamics. Sometimes, however, the cam assembly can bind due to debris caught in the area. IT IS VERY IMPORTANT TO CHECK THAT THE CAM ASSEMBLY IS PROGRESSING PROPERLY. CHECK FOR PROPER CHAIN TENSIONER OPERATION AFTER THE FIRST TWO HOURS OF USE AND THEN EVERY 10 HOURS OF VEHICLE OPERATION, WHEN THE DRIVE CHAINS ARE BEING LUBRICATED. Each step of the cam takes up about 2.5 inches of chain slack (see Fig. 7-11). 2.5â&#x20AC;?

measure at midpoint between sprockets

Figure 7-8. Chain connection link components

7.2.4 DRIVE CHAIN TAKE-UP SYSTEM Figure 7-11. Chain slack required before the tensioner will progress to the next step.

CAUTION Check for proper chain tensioner operation every 10 hours of vehicle operation. Figure 7-9. Installing the connecting link

SECTION 7 MAINTENANCE INFORMATION Each chain tensioner has a single nylon slider block. Inspect the nylon slider blocks for wear after the first 100 hours and every 50 hours thereafter. Replace the blocks (ARGO Part No. 603-61) when the wear groove, as shown in Figure 7-10, measures 1/4" (6mm). To Replace a Slider Block: 1. Remove the floor pans. 2. Turn the tensioner cam assembly in the direction which winds up the torsion spring and push the assembly down as close as possible to the cam follower block across the bottom of the frame channels. Clamp it in this position with a Vice-Grip 10CR or similar plier as illustrated in Figure 7-6. Figure 7-14 Hammering Slider Block into place

3. With pliers, pry the slider block off the cam assembly as illustrated in Figure 7-13.

7.2.5 IDLER CHAIN All ARGO vehicles are equipped with 2 idler chains to transfer power from the output shafts of the transmission to the drive chains through a series of sprockets. They are located on each side of the transmission.

4. Place a new slider block over the shaft of the cam assembly. 5. Using a piece of wood (or similar material) pressed against the top of the slider block, carefully hammer the piece of wood so the slider block snaps onto the cam assembly shaft as shown in Figure 7-14.

A loose or improperly adjusted idler chain can result in damage to the chain or sprockets. During the new vehicle breakin period, check the idler chain adjustment before operating the vehicle and after the first 2 hours of operation. After the initial break-in period, check the idler chain adjustment every 50 hours. An indication of loose idler chains is a loud banging noise when the vehicle is turned.

6. Remove the locking pliers securing the cam assembly in its lowest position. 7. Pull up on the cam assembly to allow it to take up as much chain slack as possible. 8. Replace the floor pans.

Figure 7-13 Prying the Slider Block off the Cam Assembly

Figure 7-15. Measuring idler chain deflection

SECTION 7 MAINTENANCE INFORMATION To check the idler chain adjustment, push the slack side of the chain and measure the amount of chain deflection (Figure 7-15). Adjust the idler chain tension if deflection is more than 3mm (1/8").

1. Place the gearshift in neutral and roll the vehicle until the connecting link of one of the idler chains is positioned as shown in Figure 7-17. 2. Remove the spring clip from the connecting link. Remove the outside plate and tap out the connecting link. As the connecting link is removed, the inside plates will be released (refer to Figure 7-7).

Idler Chain Adjustment 1. Remove the firewall from the vehicle as detailed in Section 7.3.1 for the Vanguard and Section 7.4.4 for the Vanguard2, Bigfoot, Response and Conquest.

3. Remove the idler chain from the vehicle. 4. Repeat steps 1 to 3 to remove the other idler chain.

2. Loosen the 2 left side clamping nuts and 1 front pivot shaft nut with a 15/16" sprocket wrench (figure 7-16). Loosen the 3/8" hex nut (117-15) securing the adjustment support (602-27), just above the transmission, to the hood frame assembly. (Refer to Section 6.0 of the Parts Manual.) 3. Turn the vertical adjustment bolts counter-clockwise to raise the power pack and tighten the idler chains. The idler chains are properly adjusted when the deflection measures 3 mm (1/8"), (Figure 7-15). 4. Tighten the 2 left side clamping nuts and 1 pivot shaft nut securely. Tighten the adjustable support fasteners with the rubber bumper (126-88) pressed down firmly onto the top of the transmission.

Figure 7-17. Position of idler chain link for removal

To Install the Idler Chains: 1. Install the chain over the brake disc sprocket and the idler shaft sprocket. 2. Pull the ends of the chains together and insert the connecting link. Insert the inside plates before pushing the connecting link into position. NOTE: Use a pair of modified 7R Vice Grips to hold the ends of the chain together while inserting the connecting link. There may be no slack in the idler chain, making installation of the connecting link difficult without this tool. Modified Vice Grips can be ordered from your ARGO dealer (ARGO Part No. 658-08) or refer to Appendix 1 for modification information.

Figure 7-16. Location of power pack clamping nuts and adjusting bolts

Idler Chain Replacement Replacement of the idler chains is required if the adjustment bolt is fully extended and idler chain deflection still exceeds 3 mm (1/8").

3. Replace the outside plate and spring clip as shown in Figure 7-7.

To Remove the Idler Chains: 4. Repeat steps 1 to 3 to replace the other idler chain. Loosen the power pack clamping nuts and adjusting bolts as shown in Figure 7-16 and proceed as follows:

SECTION 7 MAINTENANCE INFORMATION 7.2.6 TIRE INFLATION Improperly inflated tires can cause the vehicle to pull to one side, requiring constant steering correction. Suggested inflation for the Runamuk 22x10.00-8, Rawhide III 22x11.008 and Rawhide III 25x12.00-9 is between 2.5 to 3.5 psi (17 to 24 kPa). Maximum operating pressure is 5 psi (34 kPa). A special low pressure tire gauge (ARGO Part No. 619-10) is available from your ARGO dealer. 7.2.7 TIRE REPAIR AND REPLACEMENT Repair a flat tire by removing the tire completely from the rim. Proper tire changing equipment is necessary to remove and remount the tire. Apply a radial tire patch on the inside of the tire over the puncture or hole.

Figure 7-18. Bearing Flange and Cork Gasket

Remount the tire on the rim using ONLY WATER as a bead lubricant. Spoon the tire onto the rim to prevent tire bead area damage. THE TIRE MAY EXPLODE IF OVER-INFLATED. Place the tire and rim assembly in a protective cage to inflate and to seat the beads. Never inflate over 32 psi (220 kPa) to seat the bead. Once both beads are seated, deflate to 2.5 to 3.5 psi (17 to 24 kPa), 5 psi (34 kPa) maximum operating pressure. A special, low pressure tire gauge (ARGO Part No. 619-10) is available from your ARGO dealer. Replace badly worn or damaged tires with original equipment Goodyear tires. Consult your ARGO dealer if in doubt. Any other tires (size, type or tread pattern), will affect the skid steering characteristics of the vehicle. Figure 7-19 Re-tightening bolts.

ARGO track systems are designed for use ONLY with original equipment Goodyear Runamuk tires.

7.3 MECHANICAL BRAKES - 6x6 VANGUARD

7.2.8 AXLE BEARING MOUNTING

7.3.1 GENERAL

The axles are mounted to the Argo using special cork gaskets between the flanged bearings and the outside surface of the lower body (see Figure 7-18). During the initial run-in period, the gasket material may relax causing the nuts to loosen slightly. These should be checked and re-tightened after initial 8 hours of use and then after every 100 hours. See Figure 7-19.

Periodic inspection and adjustment of the mechanical brake system is required to maintain optimum vehicle performance. Inspect the brake pads after every 25 hours of use. Badly worn pads can lead to brake disc damage. To inspect the pads, first remove the firewall: To remove the firewall: 1. Remove the front floor pan. 2. Remove the left and right brake adjustment nuts with a 1/2" deep socket and ratchet (refer to Section 1.6). 3. Pull both steering levers back, away from the dash and against the seat.

SECTION 7 MAINTENANCE INFORMATION 4. Remove the gearshift knob. 5. Remove the 2 firewall retaining bolts with a 3/8" wrench (refer to Section 1.6) 6. Pull the bottom of the firewall back and lift it out of the vehicle.

2. Use another 1/2" open wrench to tighten the outer lock nut to the inner one. 3. Tighten the adjustment lock nut with a 1/2" wrench so it is snug but the bolt can still be turned freely with fingers. 4. Adjust the other brake caliper assembly by repeating steps 1 to 3.

Mechanical brake inspection procedure With the firewall removed, inspect both brake caliper assemblies.

Figure 7-21. Tightening the lock nut

7.3.3 BRAKE PAD REPLACEMENT During the inspection of all 4 brake pads, if they are: • worn to 3 mm (1/8") thickness as shown in Figure 7-22; • glazed and brake efficiency is affected; or • contaminated with lubricant and brake performance is affected; • they are no longer serviceable and must be replaced. Figure 7-20. Mechanical brake assemblies

7.3.2 BRAKE CALIPER ADJUSTMENT Adjust the calipers when:

• the brake adjustment nuts are tightened all the way but •

the steering lever travel still exceeds 7" or the total clearance between the brake pads and the brake disc exceeds .010".

To adjust the brake calipers: Figure 7-22. Measuring the distance between the brake disc and brake pad.

1. Tighten the lock nut with a 1/2" open end wrench, no wider than the thickness of the lock nut (Figure 7-21). As the lock nut is tightened, measure the clearance between the brake disc and pad as shown in Figure 7-22, using a .010" feeler gauge. .010" is the correct clearance between the left brake pad and the brake disc when the right pad is pressed against the disc.

To replace the brake pads: Use an electric drill and 1/4" drill bit to remove the heads of the rivets holding the old pads to the calipers. Clear the remainder of the rivets from the calipers and install each 100-56 brake pad set (2 pads) using 8 of 120-09 rivets and a

SECTION 7 MAINTENANCE INFORMATION pop riveting tool to fasten the pad in place. An ARGO dealer will replace brake pads for you.

WARNING The use of an improperly adjusted holding brake is a serious safety hazard, and could lead to vehicle damage or personal injury. 1. Pull the left steering lever back. 2. While holding the lever, lift the spring loaded brake lever until it contacts the pin in the steering lever. 3. Release the steering lever, allowing the holding brake lever to lock the left brake on. 4. If the steering lever grip is approximately 18 cm (7") from the dash, the holding brake system is correctly adjusted.

Figure 7-23. Brake pad wear, mechanical brakes

5. If the distance from the dash is greater, refer to Section 7.3.4 STEERING LEVER ADJUSTMENT to properly set the left lever.

To reinstall the firewall: 1. Place the firewall in the vehicle and secure it with the 2 retaining bolts. 2. Replace the gearshift knob. 3. Rest the steering levers against the dash. Insert the brake adjusting rods into the brake rod clamps. Replace the brake adjusting nuts. 4. Proceed with steering lever adjustment as follows:

7.4 HYDRAULIC BRAKES - VANGUARD2, BIGFOOT, RESPONSE and CONQUEST 7.4.1 GENERAL Although the hydraulic brake system is self adjusting, the following require periodic attention:

7.3.4 STEERING LEVER ADJUSTMENT

7.4.2 BRAKE FLUID LEVEL Adjust the steering levers when: • steering levers travel more than 18 cm (7") from the dash to apply the brakes; • the levers are not parallel when the brakes are applied; or • the brake adjustment nuts have been removed during the removal of the firewall.

After every 50 hours of operation, check the brake fluid level through the side mounted view window in each master cylinder (Figure 7-24). The fluid level must be above the top of the view window. If the brake fluid is below this level:

1. Thoroughly clean the master cylinder cover and surrounding area. 2. Remove the two screws, lift off the cover and the gasket.

7.3.5 HOLDING BRAKE ADJUSTMENT 3. Add only fresh clean SILICONE - DOT 5 BRAKE FLUID (ARGO Part No. 126-19) to the correct level.

Although the holding brake system has been factory adjusted, it should be checked after every 25 operating hours to ensure the correct adjustment.

4. Replace the cover on each master cylinder, making sure the rubber gaskets are properly seated before tightening the cover screws.

SECTION 7 MAINTENANCE INFORMATION To remove the firewall: 1. Turn the firewall release catch (located at the bottom of the firewall) counter-clockwise 1/4 turn. 2. Using the finger holes, pull the bottom of the firewall back until the top of the firewall is clear of the vehicle dash. 3. Lift the firewall clear of the driving compartment. Brake Pad Inspection Procedure With the firewall removed, both hydraulic brake calipers are visible. Each caliper has 2 brake pads which are secured by cotter pins (Figure 7-27). Inspect all 4 brake pads. Replace the pads when:

• the brake lining material molded to each metal backing Figure 7-24. Hydraulic brake cylinder and fluid level

• •

CAUTION

plate is worn to 0.10" thickness. (Figure 7-26) the pads are glazed and brake performance is affected. the pads are contaminated with lubricant, and brake performance is affected.

To replace the brake pads:

Do not overfill the brake master cylinders. Fluid level must be at the top of the view window. Overfilling can cause seal damage. Use only SILICONE - DOT5 BRAKE FLUID. Other brake fluid may not be compatible with ARGO brake components and operating temperatures. Use of other fluids will void the warranty.

Remove both cotter pins from each brake caliper. Remove each brake caliper from the transmission using a 5/16" hex driver to remove the two 103-41 SHCS mounting bolts accessible through the brake disc holes as shown in Figure 725. Without disturbing the connection of the hydraulic hose assembly, swing the caliper away from the brake disc to allow the removal of the brake pads as shown in Figure 7-27. Install the brake pads into the caliper assembly. Remount the caliper to the transmission, using #242 Loctite or equivalent removable compound on the threads of the 103-41 SHCS mounting bolts and tighten securely. Insert two new cotter pins and bend the ends over to secure the pads in position.

7.4.3 CHANGING BRAKE FLUID The inherent stability of Silicone DOT 5 Brake Fluid reduces the need for frequent brake fluid replacement. Inspect the fluid for degradation (discolouration or particles) during normal fluid level inspections. If discolouration has occurred, the brake fluid system should be drained, flushed and refilled with fresh brake fluid. If particles are evident in the fluid, drain the system, overhaul the master cylinder and the brake caliper before flushing and refilling. An ARGO dealer will preform these operations for you.

Pump the steering levers a few times to build up proper pressure and to locate the pads in the caliper assembly. Check the steering lever travel and adjust if required.

7.4.4 HYDRAULIC BRAKE PAD INSPECTION Inspect the brake pads after every 25 hours of operation. Worn, glazed or contaminated brake pads affect the efficiency of the brake system. To inspect the pads, first remove the firewall.

SECTION 7 MAINTENANCE INFORMATION To replace the firewall: 1. Position the firewall in the driving compartment. 2. Insert the top of the firewall under the vehicle dash into the cavity of the dash brace. 3. Slide the bottom of the firewall forward. Make sure that the side bracket supports mounted on the dashboard stay behind the firewall. 4. Line up the firewall release catch with the mounting clasp on the frame and turn clockwise 1/4 turn to lock.

WARNING Do NOT operate the ARGO with the firewall removed. 7.4.5 HOLDING BRAKE ADJUSTMENT The holding brake system has been factory adjusted to ensure proper braking effectiveness. However, before the vehicle is used for the first time, and after every 25 hours of operation, the adjustment of the holding brake must be inspected.

Figure 7-25. Hydraulic brake assemblies

WARNING The use of an improperly adjusted holding brake is a serious hazard, and could lead to vehicle damage or personal injury. 1. Pull each steering lever back until you feel resistance. 2. While holding the levers back, push each holding brake handle down until it rests against the brake lever stop. 3. Check the distance between the holding brake stop on each steering lever and the holding brake adjusting screw. 4. If the distance is approximately 1/16" (1.6mm) the holding brake system is correctly adjusted. 5. If not, turn the holding brake adjuster screw in the direction required for correct distance.

Figure 7-26. Brake pad wear, hydraulic brakes

CAUTION If the holding brake system is too tight, excessive pressure in the brake system will damage the seals.

Figure 7-27. Removing the brake pads from the brake caliper

SECTION 7 MAINTENANCE INFORMATION 7.4.6 BRAKE COOLING SYSTEM Eight wheel vehicles with hydraulic brakes have a 12 volt fan forcing cool air from outside the engine compartment onto the brake components to protect the system from overheating. Overheating can damage the hydraulic brake components. Make sure the brake cooling fan is operating when the vehicle is being driven. The fan operates when the ignition switch is in the “run” position. Keep the brake cooling system in good working order by: • cleaning debris from the air intake screen and ducts. • keeping electrical connections tight and components securely mounted. 7.4.7 ENGINE COOLING & EXHAUST SYSTEM Engine cooling air is drawn in on the right side of the engine compartment and expelled with the exhaust on the left side. Keep all ducting and screening in place.

WARNING If the vehicle is equipped with an enclosed cab of any sort, make sure there is plenty of ventilation to avoid exposure to exhaust and engine fumes. Engine exhaust contains carbon monoxide, and odourless, colourless toxic gas that will cause serious personal injury or death. Inspect the exhaust system periodically for worn or damaged components. Listen for a change in exhaust or engine noise that may indicate a dangerous exhaust leak. If a leak is detected, have the exhaust system repaired immediately before further use. Check the area around the exhaust system periodically for accumulated debris, particularly when traveling through dry vegetation. Failure to inspect and clean the exhaust system on a regular basis may create a fire hazard. The tail pipe exiting through the left side of the upper body becomes very hot when the vehicle is operated. DO NOT ALLOW ANYONE TO TOUCH THE EXHAUST COMPONENTS. A SEVERE BURN CAN RESULT.

NOTE An annual complete check over of your ARGO vehicle is recommended once a year. This will reduce maintenance costs over the life of your vehicle and ensure it will function properly during use periods.

SECTION 7 MAINTENANCE INFORMATION BEFORE EACH USE

CHECK COOLANT LEVEL (CONQUEST) CHECK FAN BELT TENSION (CONQUEST) CHECK FUEL LEVEL CHECK TIRE INFLATION CHECK TWIST GRIP THROTTLE OPER. CHECK STEERING LEVER TRAVEL CHECK ENGINE INTAKE/EXH. FOR OBSTR. CHECK THAT DRAIN PLUGS ARE IN PLACE CHECK ENGINE OIL LEVEL CHANGE ENGINE OIL & OIL FILTER - KAWASAKI - BRIGGS & STRATTON CHECK TRANSMISSION OIL LEVEL CHANGE TRANSMISSION OIL CLEAN AIR PRE-CLEANER CHECK CLEAN/REPLACE AIR FILTER REPLACE FUEL FILTER LUBRICATE DRIVEN CLUTCH SERVICE DRIVER & DRIVEN CLUTCH LUBRICATE DRIVE CHAINS REMOVE, CLEAN & LUBE. DRIVE CHAINS LUBRICATE IDLER CHAINS REMOVE, CLEAN & LUBE. IDLER CHAINS LUBRICATE AXLE FLANGE - OUTER CAVITY LUBRICATE AXLE FLANGE - INNER CAVITY LUBRICATE INNER AXLE BEARINGS LUBRICATE IDLER BEARINGS LUBRICATE STEERING LEVERS CHECK BATTERY FLUID LEVEL & CAPS CLEAN BATTERY TERMINALS & CONNEC. CLEAN BATTERY CLEAN, ADJUST/REPLACE SPARK PLUGS CHECK THE DRIVE BELT CHECK NYLON SLIDERS - DRIVEN CLUTCH CHECK SLIDERS - CHAIN TAKE-UP SYSTEM CHECK & ADJUST IDLER CHAINS SERVICE THE CLUTCH UNITS INSPECT BRAKE PADS ADJUST HOLDING BRAKE CHECK HYD. BRAKE FLUID LEVEL/COND. CHECK FUEL TANK CONNECTIONS/LINES INSPECT WIRING HARNESS TIGHTEN BEARING EXT. BOLTS CLEAN OUT SPARK ARRESTER

AFTER INITIAL EVERY SECTION 2 Hrs. 8 Hrs. 20 Hrs. 10 Hrs. 25 Hrs. 50 Hrs. 100 Hrs. 250 Hrs. REF.

X X X X X X X X X

2.2 7.2.6 2.2 2.2 2.2 5.6 6.1.1

X X X

X X X X X X X X X X X X X X

6.1.3 6.1.3 6.2.1 6.2.2 6.3.1 6.3.1 6.3.2 6.4.2 6.4.2 6.4.3 6.4.3 6.4.4 6.4.4 6.4.5 6.4.5 6.4.7 6.4.6

X X X X X X X X

X X X

X X X X X X X

X X

7.1.2 7.1.2 7.1.2 7.1.4 7.2.1 7.2.2 7.2.4 7.2.5 6.4.2 7.3.1 7.3.5 7.4.2

7.2.8 7.1.5

The intervals shown on the schedule are based on average operating conditions. Vehicles which are subject to more severe use, wet or dusty conditions, will require more frequent servicing. Use only Argo replacement parts to ensure safe operation of the vehicle to comply with the warranty coverage. We strongly recommend that an Argo Dealer perform a complete check-over of your vehicle after the initial 20 hours of operation, then once each year. This will reduce maintenance costs over the life of your vehicle.

SECTION 8 TROUBLE SHOOTING MALFUNCTION (SYMPTOM)

PROBABLE CAUSE

CORRECTIVE ACTION

Electric starter inoperative

1. Loose electrical connections

1. Clean and re-tighten electrical connections 2. Recharge battery or replace as necessary 3. Return the vehicle to an Argo dealer for servicing

2. Battery charge low or dead 3. Faulty starter motor

Engine turns over but will not start

Engine will not run Vehicle will not move or turn

Vehicle pulls to right

1. Right tire pressure too low 2. Left tire pressure too high 3. Right brake engaged

4. Right side drive chain broken Vehicle pulls to left

1. Pull out the choke and try to start again 2. Refill tank 3. Remove obstruction or replace filter as necessary 4. Adjust as detailed in the engine manufacturer’s manual 5. Clean and re-gap or replace 6. Have unit serviced by a properly trained and equipped mechanic 7. Take the vehicle to a factory authorized engine repair outlet 8. Check that electric fuel pump is operating. Make sure fuel shut off solenoid is activated to allow fuel into carburetor.

1. See “Vehicle pulls to right” substitute right with left

1. Place gear shift properly in gear 2. Replace belt if worn excessively 3. Return the vehicle to an Argo dealer for servicing 4. Same as 3. above 5. Adjust caliper or replace brake pads 6. Repair or replace 7. Have vehicle serviced by an Argo dealer 1. Inflate all tires to the correct pressure 2. Same as above 3. Make sure the steering lever is held forward against the dash. Adjust brake assembly if required. 4. Repair or replace

SECTION 8 TROUBLE SHOOTING MALFUNCTION (SYMPTOM)

PROBABLE CAUSE

CORRECTIVE ACTION

Severe vibration when vehicle is operated

1. Engine loose on mounts

1. Take vehicle to an Argo dealer for service. 2. Same as above.

2. Driver or driven clutch or engine defective 3. Axle bent 4. Wheel rim bent 5. Worn or damaged drive belt

Water leaks into lower body

Tire leaks air

2. Tire is not properly seated on bead

3. Position of air leak is not obvious

4. Defective valve Hydraulic brakes are spongy, or there is excessive steering lever travel

1. Air in hydraulic system 2. Leak in system

3. Loose brakes Brakes ineffective

1. Pads have overheated and glazed 2. Pads worn beyond 0.10" 3. Pads are contaminated with lubricant

There is a loud bang when the vehicle is turned right or left

1. Idler chains worn/loose 2. Drive chains worn/loose

3. Remove and straighten or replace. 4. Replace. 5. Replace. Clutch service may be required. 1. Replace the bearing flange gaskets. 2. Replace the bearing flange seal. 3. Caulk under 103-81 bolt heads with silicone sealer. 4. Repair or replace vehicle lower body 5. Secure drain plugs. 1. Remove tire from rim and repair the hole with a radial tire patch or install a tube in the tire. 2. Deflate tire and carefully push tire bead off the rim. Clean the rim bead area to remove dirt and foreign matter. Re-inflate tire. 3. Submerge tire and rim in a water tank. Air may be escaping through the rim halves or the valve stem. Repair as required. 4. Replace defective valve. 1. Have an Argo dealer bleed the brake system and add fluid. 2. Have an Argo dealer check all fittings, hoses, calipers and seals for loose connections or leakage. Refill as needed. 3. Adjust or tighten. 1. Have the pads cleaned by an Argo dealer or replace. 2. Replace. 3. Have the pads cleaned by an Argo dealer or replace pads. 1. Adjust/replace idler chains as required 2. Adjust/replace drive chains as required

SECTION 9 CLEANING AND STORAGE 9.1 CLEANING THE VEHICLE

Prepare the Battery for Storage

Wash the vehicle body with a household detergent and rinse with water. Flush dirt out of the lower body by using a high pressure sprayer or garden hose after removing the drain plugs. After the bottom of the vehicle is dry, lubricate the drive chains with ARGO chain Lube. Make sure the drain plugs are replaced.

Remove the battery from the vehicle. Clean it and charge it with a battery charger. Coat the battery terminals with a multi-purpose grease to prevent corrosion. Store the battery in a cool dry place.

WARNING

9.2 STORING THE VEHICLE When the vehicle is stored for an extended period, the following preparation is required:

Do not store the battery near flames, sparks or any source of fire. Batteries can explode if exposed to flames or sparks, causing serious personal injury.

Clean the Vehicle

Recharge the battery monthly.

Remove all dirt and water from the vehicle body as directed above.

Protect the Electrical System

Remove the drain plugs if the vehicle is not fully sheltered from the elements.

Spray the wiring harnesses and all the electrical connections with a silicone based lubricant (WD40 or equivalent) to prevent corrosion.

CAUTION

Carefully inspect the wiring for loose connections, bare wires or corrosion. Repair as necessary.

Any water accumulation in the vehicle will, over time, destroy chains, sprockets and bearings. Grease all bearings and flanges (refer to Section 6.4.5).

Raise the Vehicle Place blocks under the front and rear of the vehicle to raise the tires off the ground. The blocks must be placed under the frame members to prevent body damage (Figure 9-1).

NOTE Bearing corrosion due to inadequate preparation for storage is the leading cause of premature bearing failure. Drain the Fuel System

Figure 9-1 Correct placement of blocks

Insert a siphon hose into the gas tank through the filler neck and drain the gasoline. Start the engine and run it until all fuel in the system is consumed.

Preparing the Engine for Storage Read the engine operatorâ&#x20AC;&#x2122;s manual and carry out all recommended storage procedures.

OR Add fuel stabilizer (ARGO Part No. 125-85) to the fuel tank and fill with fresh gasoline. Run the engine for a few minutes to allow the treated fuel to reach the carburetor.

SECTION 10 ACCESSORY INFORMATION 10.1 GENERAL

CAUTION

This section deals with accessories that have been specifically designed for the ARGO and can be purchased separately from your dealer. Special operating procedures and safety precautions must be observed before operating or using certain accessories.

Only use track segments that show the Argo trademark. Other track systems may fail and damage axles, bearings and the final drive system. Track segments will wear prematurely if used over pavement, gravel, rock or on any abrasive surface.

10.2 CARGO TIE DOWNS (Part No. 614-06)

Temperature changes will cause the segments to expand or contract and will also change the tire pressure. In order to maintain suitable tension on the track system, observe the following precautions:

Cargo tie downs are intended to assist in securing a load in the rear compartment of any Argo. Use rope or elastic cords, laced over the load and through the tie down rings, to hold the load in place.

• If the track-equipped vehicle is stored in a warm area,

CAUTION

•

Never attempt to raise the vehicle by using the tie down rings as lifting points.

•

WARNING Never exceed gross vehicle weight. Never exceed the maximum rear compartment weight for 6-wheelers (65 kg/140 lbs.).

always allow the tires and tracks to reach the outdoor temperature and re-check tire inflation before use. Do not over-inflate tires (3 p.s.i. max.). Damage to the lower body could result from the track segments rubbing against the lower body. Pay special attention to the tracks during the first few hours of use. If the tracks become loose or slack, start touching the lower body or the tires begin to slip inside the tracks, DO NOT INCREASE TIRE PRESSURE OVER 3.0 psi. REMOVE THE STEEL HALF SEGMENT FROM EACH TRACK.

CAUTION

10.3 ARGO TRACK SYSTEMS (Standard Track - Part Nos. 615-25 & 815-25, Super Track - Part Nos. 625-00, 625-35 & 825-00)

Over-inflating the tires will cause excessive and premature wear of the tires and the Argo track system. Over-inflation may also cause axle and/or bearing damage. Under-inflation of the tires may allow them to slip in the tracks or may lead to the unseating of the tire bead from the wheel rim. The tires may climb out of the track system during a turn or on side slope operation. Check that all tires are correctly inflated. Avoid sharp, high speed turns when the Argo is heavily loaded.

There are two different types of track systems available for use with the Argo, the standard track system and Super Track. Standards tracks and Super Tracks are similar in basic design and use the same pins and lock collars to join the segments together. However, Super Tracks are wider than standard tracks. The track systems spread the weight of the vehicle over a larger area than the tires, thereby reducing the ground pressure and allowing the vehicle to stay on top rather than sinking into soft terrain.

10.3.1 Operating Precautions An Argo equipped with tracks has a reduced carrying capacity in water. Tracked 6 wheel models have a 120 kg/264 lbs. capacity. Tracked 8 wheel models have a 270 kg/589 lbs. capacity. Refer to Section 5.6 of this manual for additional information on safe operation in water.

The segmented track design allows the replacement of only those segments that may have become damaged or worn with use.

SECTION 10 ACCESSORY INFORMATION 10.4 ICE CLEAT KIT (Part Nos. 625-20 & 825-20)

CAUTION

ARGO ice cleats are stamped steel cleats that bolt to the outer edges of the Super Track segments to grip on hard pack snow and ice to improve traction and stopping.

CAUTION should be observed when operating in winter conditions and a drop in temperature occurs. Snow and slush accumulation in the track could freeze, resulting in damage to the track system. Slush, snow and ice accumulation should be cleared from the axles and track periodically to prevent build-up.

WARNING

CAUTION should be observed when using any track system on an Argo. Make sure the steel connecting pins are properly secured in each track segment. Failure to secure the track pins in the segment can result in lower body damage if the track pin moves out of the segment, toward the lower body.

Make sure all passengers riding in an Argo equipped with ice cleats are informed to keep hands, feet and clothing inside the vehicle, well away from the tracks and ice cleats while the Argo is in motion. Serious injury or death could result from getting caught by the ice cleats.

WARNING

CAUTION

EXTREME CAUTION must be observed when using the track systems on icy surfaces. Steering and braking effectiveness will be reduced. Reduce speed.

EXTREME CAUTION must be observed when crossing ice-covered water. The vehicle may sink if it breaks through the ice surface and fills with water. Make sure drain plugs are securely in place and do not overload the vehicle. Should the vehicle break through the ice, attempt to back the vehicle out, taking care that water does not enter the engine compartment. Refer to section 5.7.1 of this manual for additional information on safe operation on ice-covered water.

10.5 OUTBOARD MOTOR BRACKET (Part No. 617-00) The outboard motor bracket accepts gasoline or electric outboard motors of up to 9.9 horsepower. Long shaft models are recommended to avoid cavitation during operation. When selecting an outboard specifically for the Argo, consider a light-weight 4 to 5 h.p. model for ease of handling, installation and adequate propulsion. When traveling on land it is recommended that the outboard motor be transported safely in the rear compartment of the Argo.

10.3.2 Standard Tracks Standard Tracks are intended to extend the use of the Argo so that it can be driven over softer terrain conditions such as mud, swamp, muskeg and snow. The standard track system is well suited for a wide variety of terrain conditions. However, for deep snow conditions, the Super Track system will outperform the standard track system.

CAUTION Deformation of the body components adjacent to the outboard motor bracket may occur when outboard motors are left installed in hot temperatures. Caution should be observed when turning an outboard motor equipped Argo on land. Since the rear of an Argo swings sideways during a turn, the motor could strike a person or object causing injury or damage.

10.3.3 Super Tracks Super Tracks provide the maximum â&#x20AC;&#x153;flotationâ&#x20AC;? available for the Argo. They are very effective in deep snow, swamp and muskeg. Care must be used while traveling over uneven ground conditions. The extra width of the segments can lead to the segments tipping to one side on the tire to such an extent that the tire guide forces the tire bead off the rim. In an extreme case, the tire guide may be bent in when run over by a tire and puncture the side wall of another tire, destroying it. SUPER TRACKS ARE NOT RECOMMENDED FOR TRAVEL OVER LOGS, STUMPS OR ROCKS.

SECTION 10 ACCESSORY INFORMATION 10.6 OUTBOARD MOTOR SUPPORT (Part No. 618-00)

CAUTION

The 618-00 outboard motor support mounts in place of the trailer coupler ball to provide support for the tail shaft of any gasoline outboard motor. The 616-16 receiver style trailer hitch is required to accept the 618-00 bracket. If an Argo amphibious trailer must be towed in water, use 618-10 side mount outboard motor bracket instead of 617-00/618-00 combination.

Damage may result to the cover if the vehicle is transported at highway speeds with the cover in place. If the cover must be used while transporting the vehicle, damage may be minimized by placing padding over sharp corners such as the tail pipe or the winch and tying the cover securely in place against the Argo body. 10.9 POWER WINCH (Part No. 622-40 & 622-70 )

10.7 OUTBOARD MOTOR BRACKET - SIDE MOUNT (Part No. 618-10 )

The power winch mounts to the front of the Argo and can be used for self-recovery and to raise and lower the snowplow blade (Part No. 657-00). The winch has a free-wheeling feature that allows the cable to be pulled off the winch drum without using the winch’s 12 volt electric motor.

The side mount outboard motor bracket attaches to the right rear of any Argo model. It allows the attachment of a gasoline or electric outboard motor of 9.9 horsepower maximum. When traveling on land it is recommended that the outboard motor be transported in the rear compartment of the Argo.

The electrical components and the wiring design of the winch kits prevent the use of the winch motor unless the ignition key is turned to the ‘on’ position. This is a safety feature that prevents the unauthorized use of the winch when the vehicle is parked.

WARNING Use caution when turning in confined spaces or close to bystanders. Personal injury or damage may result.

After the installation of the winch kit is completed, test the electrical connections by moving the toggle switch control from side to side with the ignition switch removed. If the winch DOES NOT operate the connections are correct. If the winch starts during this test have the installer correct the wiring connections immediately.

CAUTION 10.9.1 Rules For Safe Operation 1. The X2 winch is rated at 3,000 pounds (single-line) capacity. DO NOT OVERLOAD. DO NOT ATTEMPT PROLONGED PULLS AT HEAVY LOADS. DO NOT MAINTAIN POWER TO THE WINCH IF THE MOTOR STALLS. Overloads can damage the winch and/or the wire rope and create unsafe operating conditions. For heavy loads, we recommend the use of the optional pulley block and hook assembly (Superwinch Part No. 1503) to double line the wire rope. (Figure 10-2) This reduces the load on the winch and the strain on the wire rope by approximately 50%.

Figure 10.1 Warning Label 618-21

10.8 ARGO STORAGE COVERS (Part Nos. 621-10; 621-20; 821-10 & 821-20 ) The Argo storage covers prevent debris, rain water or snow from accumulating in the Argo. Secure the cover by pulling it down over the bumper and tying the cord tightly in place. A cord or tie strap through the side grommets and under the vehicle lower body securely holds the cover in place in windy conditions.

SECTION 10 ACCESSORY INFORMATION

Figure 10-2 Double Line

2. Periodically check the winch installation to assure that all bolts are tight.

Figure 10.4 Incorrect and correct hook-up

9. 3. DO NOT “move” your vehicle to assist the winch in pulling a load. The combination of the winch and vehicle pulling together could overload the wire rope and the winch itself.

It is a good idea to lay a heavy blanket or jacket over the wire rope near the hook end when pulling heavy loads (Figure 10.5). If a wire rope failure should occur, the cloth will act as a damper and help prevent the rope from whipping.

4. KEEP WINCHING AREA CLEAR. Do not allow people to remain in the area during winching operations. Do not step over a taut wire rope or allow anyone else to do so. Do not stand between the winch and the load. 5. INSPECT WIRE ROPE AND EQUIPMENT FREQUENTLY. A frayed wire rope with broken strands should be replaced immediately. Always replace wire rope with the manufacturer’s identical replacement part, Superwinch Part No. 1513.

Figure 10-5 Using a cloth damper

10. Your winch is not designed or intended for overhead hoisting operations. Never use your winch for lifting or moving people.

6. USE HEAVY LEATHER GLOVES when handling wire rope. Do not let wire rope slide through your hands. A broken strand could seriously injure your hands.

11. Avoid continuous pulls from extreme angles as this will cause the wire rope to pile up at one end of the drum (Figure 10-6). This can jam the wire rope in the winch causing damage to the wire rope or the winch itself.

7. Keep clear of winch wire rope and hook when operating winch. Never put your fingers through the hook when reeling in the last few feet of line. If your finger should become trapped in the hook, you could lose your finger. Use the HANDSAVER BAR (Figure 10.3) to guide the hook within the last few feet. Never guide a wire rope onto the drum with your hand.

Figure 10-6 Correct and incorrect positioning for continuous pulls.

Figure 10.3 Using the Handsaver Bar

12. Always operate the winch with an unobstructed view of the winching operation.

8. NEVER HOOK THE WIRE ROPE BACK ONTO ITSELF. Use a nylon sling. Hooking the wire rope onto itself can damage the rope (Figure 10.4).

13. Do not operate the winch when under the influence of drugs, alcohol or medication. 14. Never work on or around the fairlead or winch drum when the winch is under load.

SECTION 10 ACCESSORY INFORMATION 15. When using your winch to move a load, place the vehicle transmission in neutral, set vehicle parking brake, chock all wheels, and keep the engine running.

(1)

This is the start of a kink. At this time, the wire rope should be straightened.

(2)

The wire rope was pulled and the loop has tightened to a kink. The wire rope is now permanently damaged and must be replaced.

(3)

The result of kinking is that each strand pulls a different amount, causing the strands under greatest tension to break and reduce load capacity of the wire rope. The wire rope must be replaced.

16. Do not use the winch to hold the Argo in place during transportation. Use tie-down straps. 17. Maintain at least five turns of wire rope around wire rope drum to prevent the wire rope from pulling off under load. 18. Never run winch without circuit breakers in place. Dangerous overloads to mechanical and electrical components can result. 10.9.2 Tips for Extending the Life of Your Winch 1.

Keep a tightly and evenly wound wire rope drum. Do not allow the wire rope to become loosely wound. A loosely-wound spool allows a wire rope under load to work its way down into the layers of wire rope on the drum. When this happens, the wire rope may become wedged within the body of the windings damaging the wire rope. To prevent this problem, keep the wire rope tightly and evenly wound on the drum at all times. During winching, periodically check to see that the wire rope is winding on evenly. A good practice is to rewind the wire rope under tension after each use. One way to do this is to attach the hook to a stationary object at the top of a small hill or incline and winch your vehicle up the incline.

10.10 REAR MUD FLAP KIT

Argo mud flaps are made of black polyethylene sheet cut to conform to the curve of the rear corners of the lower body. They are recommended for use with either track system to block the mud and snow thrown up during higher speed travel.

Do not allow motor to overheat. Remember, the winch is only for intermittent use. During long or heavy pulls the motor will get hot. The internal parts will be hotter than the case. To check the motor temperature, stop winching and carefully touch the end of the motor. If the motor is uncomfortably warm, allow the motor to cool before continuing â&#x20AC;&#x201D; keep the engine running to recharge the battery during this break.

10.11 TRAILER HITCH KIT (Part No. 626-10) The trailer hitch kit is optional for the Vanguard models and is standard on all other models. It mounts at the rear of the Argo and includes 1 7/8" dia. coupler ball. Maximum tongue weight is 100 lbs./45 kgs. Maximum pull weight is 800 lbs./ 364 kgs.

Use a pulley block for heavy loads. To maximize winch and wire rope life, use a pulley block (Superwinch Part No. 1503) to double line heavier loads.

The pull required to start a load moving is often much greater than the pull required to keep it moving. Avoid frequent stopping and starting during a pull.

Prevent kinks before they occur.

(Part No. 625-10)

10.12 BILGE PUMP KIT (Part No. 638-25) The bilge pump kit features a 12 volt, 500 gallon per hour pump to empty water from the lower body. Operated by a dash mounted push/pull switch, the bilge pump is recommended for any amphibious use of an Argo.

SECTION 10 ACCESSORY INFORMATION DO NOT transport the Argo at highway speeds with the windshield upright. For transportation at highway speeds, it is recommended that the vehicle be reversed on the truck or trailer so that the front of the Argo faces to the rear. The windshield should be folded down and secured in place using a rope or a tie down strap.

CAUTION The pump is not designed to run dry. Use only when water has collected in the lower body.

CAUTION

10.13 HANDRAIL KITS (Part Nos. 639-20 & 839-20) Handrails mount to the top of the upper body around the rear compartment, providing a convenient passenger hand hold or cargo tie down point.

Operating the Argo for extended periods in high ambient temperatures with the windshield in the folded down position may restrict hot air flow from the engine compartment which could lead to engine overheating and heat build-up in the windshield frame and glass. Use caution when operating the vehicle with the windshield folded down to avoid overheating in warm temperatures.

CAUTION Do not attempt to lift the vehicle by using the handrails.

The following decal should be attached to the inside of the windshield:

10.14 TOW HOOK KIT (Part No. 642-00) The tow hook kit is a steel fabrication that bolts securely through the bumper and both body halves at the front or rear of the vehicle.

CAUTION The tow hook is not intended to secure an Argo to a trailer or truck bed. Body deformation could result from a downward pull. 10.15 WINDSHIELD (Part No. 648-75) If this decal is not attached to the windshield, contact your Argo retailer for a free-of-charge replacement. The part number is 126-84.

The windshield features an anodized aluminum frame with rubber mounted 24" high x 48" wide laminated safety glass. It mounts to the top of the dash area of any Argo model, folds down and secures in place over the hood and is required for the convertible top.

10.16 CONVERTIBLE TOP (Part No. 649-33, 649-50 & 849-50)

CAUTION

The convertible top provides protection from the elements for the occupants and offers the option of rolling up or removing the side doors, rear door and rear side panels while leaving the overhead portion in place.

When the windshield is raised in the upright position, it must be supported by the two side support arms. Attach both support arms to the windshield frame brackets using the quick pins supplied. Do not attempt to fasten the front of a convertible top to the windshield until the support arms are in place.

CAUTION Never fold the clear plastic windows; always roll them up to store them in place on the top assembly or remove them.

SECTION 10 ACCESSORY INFORMATION To fold the convertible top for storage, unzip the side and rear doors and the side panels, lay them aside and unsnap the domes along the front of the roof panel from the windshield frame. Fold the aluminum top frames together and roll the overhead panel around the frames loosely. Then, roll the window panels around the top material so the boot will cover the complete assembly for protection.

There is a red charge indicator light installed in the dash, to the right of the ignition switch. If the red light comes on, the alternator is not sending a charge to the battery. This may simply be a result of low engine idle speed. If the light stays on at vehicle operating speeds, have your Argo retailer service the system soon. 10.17.1 Alternator Kit for Conquest (Part No. 850-40)

CAUTION

Check the V-belt tension frequently to be sure belt deflection is no more than 1/8" or 3 mm with approximately 6 lbs. or 3 kgs of force applied to the belt, halfway between the pulleys. Adjust the belt tension as necessary. Failure to do so will reduce the charge rate and lead to battery failure.

The convertible top assembly is not designed to withstand the turbulence created while transporting the vehicle with the top assembled in the ‘up’ position. Fold the top down and secure it properly to the vehicle body or remove it from the vehicle for high speed transportation.

10.18 SNOW PLOW KIT (Part No. 657-00) The snow plow assembly attaches to the front of the Argo at two mounting brackets that bolt to the front axle bearing extension housings. The plow blade is raised and lowered by operating the power winch in and out.

WARNING Hearing protection is strongly advised when operating the vehicle equipped with any convertible top assembly.

WARNING

The following decal should be attached to the inside of the windshield:

DO NOT STAND BETWEEN THE PLOW BLADE AND THE FRONT OF THE ARGO. Injury could result if the blade is raised. The vehicle operator must observe caution when operating the vehicle and snow plow in the presence of others. Injury could result if a bystander is struck when the vehicle swings to turn or the blade is lowered onto someone’s foot. Always be aware of the area being plowed. Although there is a blade trip mechanism feature of the blade, damage or operator injury could result from hitting rocks, stakes or curbs hidden under the snow being plowed. 10.19 AMPHIBIOUS TRAILER (Part No. 695-75) The Argo four wheel amphibious trailer is designed as an additional cargo carrier for any Argo model. It is not intended for the transportation of people. Trailer load capacity is 600 lbs or 270 kgs at a recommended tire pressure of 4 psi.

If this decal is not attached to the windshield, contact your Argo retailer for a free-of-charge replacement. The part number is 126-84. 10.17 ALTERNATOR KITS (Part No. 650-60 & 850-60 for the Vanguard, Vanguard2, Bigfoot & Response/Part No. 850-40 for the Conquest)

10.19.1 Operating Precautions Keep cargo low and centered in the trailer, especially if used in the water. Secure the load in place to keep it from shifting when traveling in uneven terrain. Avoid sudden stops when towing the trailer downhill to prevent the trailer from colliding with or passing the Argo.

The externally mounted, belt driven, 40 amp alternator is recommended when electrical accessories such as a winch are added to the vehicle.

SECTION 10 ACCESSORY INFORMATION Do not step on or place loads on the edge of the body over the trailer wheels. This area of the trailer body is intended only as a mud guard.

The ROPS has been designed to meet the requirements of the Occupational Health and Safety Act - Regulation 856 ‘Roll-Over Protection Structures’ for the Province of Ontario, Canada.

Follow the instructions listed in Section 6.4.5 of this manual to service the axle bearings. Do not allow water and debris to accumulate in the bottom of trailer body to avoid premature bearing failure.

WARNING

The heater kit includes a conventional automotive style hot coolant heater core with 2 speed fan to circulate the warm air through the ducts to the right side of the driver’s compartment and the windshield. In some operating conditions, ie. high humidity or full passenger load, defrosting the windshield and side panel windows may not be effective.

Seat belts must be properly adjusted and worn by all occupants at all times EXCEPT when operating in water. Never carry more people in the vehicle than there are seat belts for. Articles must not be placed on top of the ROPS. Use caution when traveling on uneven ground; the ROPS reduces vehicle stability. No part of the ROPS shall be drilled, welded or altered in any way without the manufacturer’s authorization. Do not exceed maximum gross vehicle weight of 907 kg (2000 lbs.) Use caution when traveling tree-lined trails. Branches could be knocked down, causing injury to the vehicle occupants. FAILURE TO COMPLY WITH THE ABOVE COULD RESULT IN PERSONAL INJURY OR DEATH.

When the heater is not required, the heater valve should be closed, diverting all of the coolant through the engine radiator.

CAUTION

In extremely cold weather and operating at low load, the heater may perform like a second radiator and keep the engine from reaching proper operating temperature. Under these conditions, a piece of cardboard or similar material should be used to partially cover the engine radiator.

DO NOT use the ROPS as an attachment point for towing or winching the Argo. Check fastener tightness annually. Inspect for and replace any damaged or worn parts of the ROPS and the seat belts.

WARNING Keep fingers clear of tongue swiveling components. 10.20 HEATER KIT - Conquest (Part No. 848-10)

10.22 REAR BENCH SEAT (Part No. 849-60)

The 850-40 Alternator is essential to provide the electrical power to operate the heater fan and maintain the battery charge rate.

This bench seat assembly is similar to the front bench seat design, providing a back rest and more comfort for two persons riding in the rear compartment of any current Argo 8 x 8 model. The seat cushion and back rest are easily removed to use the rear compartment for cargo.

10.21 ROLL OVER PROTECTIVE STRUCTURES (Part Nos. 848-40-2, 848-40-4 & 648-40) Roll Over Protective Structures (ROPS) are designed for use on all Argo models. Part No. 848-40-2 provides roll over protection and lap belts for the driver and front seat passenger of all Argo 8 x 8 models. Part No. 848-40-4 provides roll over protection and lap belts for driver, front seat passenger and two passengers in the optional rear bench seat (Part No. 849-60). Part No. 648-40 provides roll over protection and lap belts for driver and front seat passenger of all Argo 6 x 6 models.

CAUTION Always ensure that the spring loaded pull pin (Part No. 849-72) on each side is fully engaged after installing the seat. Pull the seat hard to ensure that it is secured properly. Never attach a tow line to the handrail of the seat back rest. When a roll over protection structure (ROPS) is installed, seat belts must be installed for rear bench seat passengers and used properly.

The ROPS design provides reasonable protection from injury in the event of a rollover. DO NOT rely on it to protect the occupants from irresponsible driving.

SECTION 10 ACCESSORY INFORMATION Maximum total vehicle weight must not exceed 1465 lbs. or 665 kg. which means 2 people and 100 lbs. or 46 kg. of cargo in the vehicle. Never attach anything to the Roll Bar other than Ontario Drive & Gear 648-15 Roll Bar specific accessories. The Roll Bar reduces vehicle stability. Always use common sense when traveling over rough terrain. The Roll Bar is designed to reduce the chance of injury. DO NOT rely on it to protect the vehicle occupants from irresponsible driving. The Roll Bar could come in contact with tree branches. Falling branches or vehicle upset could occur. Use extreme caution when traveling on narrow tree lined trails. DO NOT use the Roll Bar as an attachment point for towing or winching. Check the torque of the Roll Bar nuts and bolts annually and replace any parts that are damaged. When the Roll Bar is installed, never carry more than two people in the Argo. Replace worn or damaged seat belt straps and buckles.

10.23 DUMP BOX KIT (Part Nos. 835-00 & 835-01) The dump box kit can be installed on any Argo 8 x 8. It improves the load carrying versatility of the Argo.

WARNING Keep hands and arms clear when lowering box. No riders in box; riders can fall off and be killed Installation of dump box reduces vehicle capacity; On land: 408kg (900lbs) On water: 227kg (500lbs) (Capacity includes: occupants, cargo and fuel) Tie loads down. Spread loads evenly. Operators should use caution when turning in confined spaces and close to bystanders. The dump box decreases the rear clearance of the Argo. Never operate dump while moving. Operate dump on level ground only. The dump box decreases the vehicle stability. Operate the vehicle with extra precautions when on uneven terrain and in water.

Failure to comply with the above could result in personal injury or death.

Note: Frequent use of the powered dump box will result in battery drain. The installation of an alternator kit is strongly suggested. 10.23.1 Dump Box Operating Guidelines 1. 2. 3.

For quick removal of the box disconnect the actuator or springs then disconnect the rear hinge pins 104-32. The rear side seats can still be used if you remove the dump box and undercarriage. A rear bench seat kit 849-60 can be used when the dump box is removed. The undercarriage frame support plates are in the same location as the rear bench seat frame support plates. So the seat can quickly be attached without any additional mounting.

10.24 ROLL BAR KIT (Part No. 648-15) The roll bar is designed for use on all Argo 6 x 6 models. The roll bar provides some roll over protection and lap belts for the driver and front seat passenger.

WARNING When the Roll Bar Kit is installed, ALWAYS wear seat belts when operating the vehicle on land. REMOVE seat belts when entering water.

APPENDIX 1 SPECIAL TOOLS 7R VICE GRIP MODIFICATION As detailed in Section 7, a pair of modified 7R Vice Grips is required to hold the ends of the drive chain together while inserting the connecting link. This tool can also be used to hold the ends of the idler chain together while inserting the connecting link. Grind the undercut and sides of the vice grip jaw to fit over 2 chain rollers. The undercut is approximately 1/4" radius as shown.

misuse, accident, theft or fire use of improper or insufficient fuel, fluids or lubricants use of parts other than genuine ARGO replacement parts modifications, alteration, tampering or improper repair performed by parties other than an authorised ARGO dealer or distributor any device or accessories installed by parties other than an authorised ARGO dealer or distributor

6. Batteries that fail due to improper charging or installation; broken container, cover or terminal sulphation or dehydration; damage caused by fire, excessive heat, wreckage, explosion, freezing, the addition of any chemical or solution other than the battery grade sulphuric acid. This shall constitute the complete and only warranty given by Ontario Drive & Gear Limited, and, except as specifically set forth in the foregoing, Ontario Drive & Gear Limited shall not, in any event, be liable for any losses, damages or costs, whether special, incidental, consequential or otherwise, in any way related to any vehicle or its sale. No warranty, expressed, implied or statutory, as to merchantability, fitness for a particular purpose, description, quality or any other matter is given in connection with any ARGO vehicle or its sale and no agent, employee or other person has any authority to vary any of the foregoing provisions. Provided, however, that this clause shall be severable where voided by application of the Consumer Protection Act.

ARGO RETAILER... Please complete this page at the time of sale to the new owner so your customer has all pertinent information that may be required.

ARGO MODEL __________________________________________________ ARGO SERIAL NO. ______________________________________________ ENGINE SERIAL NO. _____________________________________________ TRANSMISSION SERIAL NO. ______________________________________

SOLD TO: ______________________________________________________ STREET ADDRESS: _____________________________________________ CITY OR TOWN:_______________________PROV/STATE: _____________ POSTAL/ZIP: ___________________________________________________

DATE OF SALE: _________________________________________________ WARRANTY PERIOD EXPIRES: ____________________________________

DEALER NAME: _________________________________________________ PHONE: _______________________________________________________ ADDRESS: _____________________________________________________ CITY/TOWN:__________________________PROV/STATE: _____________

ARGO PRODUCTS MANUFACTURED BY: Ontario Drive & Gear Limited P.O. Box 280, 220 Bergey Court New Hamburg, Ontario N0B 2G0 Canada Phone: (519) 662-2840 Fax: (519) 662-2421 www.argoatv.com

OPERATORâ&#x20AC;&#x2122;S MANUAL MODELS - S, SN, BF, RB, C, CB from 1997

this cle. e v o ehi m v e ot r m this n Do l fro nua ma MANUAL NO. 671-04 Rev. 9

Printed in Canada

09/2002

Read this manual before you operate your ARGO. It contains safe operating instructions and warns the user about potential hazards that can result in personal injury.

Warnings are identified in the text by the following symbol:

Warning text warns the user about potential hazards that can result in personal injury or death.

Cautions are identified in the text by the following symbol:

Caution text contains cautions that can prevent damage to the vehicle.

This manual is based on the latest product information available at the time of printing. Ontario Drive & Gear Limited reserves the right to make changes at any time and without obligation. Reproduction of any part of this publication is prohibited without prior written permission. Une version francaise du manuel d’operation est disponsible sous le numero suivant 671-04FR. Les plaquettes d’avertissement et d’instructions qui apparaissent sur l’Argo sont aussi disponsibles en francais sous le numero suivant 126-73. © Ontario Drive & Gear Limited, 2000

PREFACE This manual describes the controls, operation and basic maintenance procedures for all VANGUARD, VANGUARD2, BIGFOOT, RESPONSE and CONQUEST models of the ARGO from date of printing. Please take the time to read this manual carefully, for your safety and that of others. By following these instructions, you will ensure extended, trouble free operation of your vehicle. For maintenance and adjustment of the engine, refer to the engine manufacturer’s operation and maintenance manual included in your vehicle’s information package. Before you drive your ARGO, make sure you understand how to use all controls, particularly the brakes and steering levers. Learn how to drive your vehicle in an open level area, away from buildings, trees and other obstacles, until you are completely familiar with its operating characteristics. Drive very slowly until your driving skills improve, and drive with caution and consideration at all times. The risk of accident or injury is greatest during the first weeks of use. Take special care during this period. ALWAYS RESPECT OUR ENVIRONMENT. CAUTION TO THE ARGO OWNER/OPERATOR • Make sure everyone who drives this vehicle receives proper operating instructions and reads this Operator’s Manual. • No one under the age of 16 should be allowed to operate the ARGO. Children under the age of 16 may not have the skills, abilities or judgement needed to operate the Argo safely and may be involved in an accident causing severe injury or death. • Never allow anyone under the influence of alcohol or any other intoxicating substance to drive or ride in the vehicle. • Wear an approved safety helmet and eye protection when driving or riding in the vehicle. • Special operating and safety procedures described in this manual must be observed before and during water operation as outlined in Section 5. • When operating your vehicle for extended periods of time, we recommend the use of approved hearing protection. • Equip your vehicle with a fire extinguisher and a first aid kit. • Equip your vehicle with basic tools for emergency repairs. • Before starting your engine, check for spilled gasoline and wipe any up immediately. Gasoline is a potentially explosive substance that can cause serious personal injury when ignited. • Keep the floor pans secured in place at all times. Fingers, feet, animal tails or paws can be injured in the drive components beneath the floor pans. The floor pans also help keep damaging debris out of the drive components. • Make sure all passengers remain seated while the vehicle is in motion. Advise your passengers to hold onto the vehicle at all times. • Never overload your vehicle. Trying to steer an overloaded vehicle can overheat the brakes. This will lead to brake fade which means loss of steering control and the ability to stop the vehicle. Overloading your vehicle can lead to premature brake system failures and costly damage to drive chains, axles or bearings. Follow the recommended load capacity for your vehicle listed in Section 1. • Do not drive the vehicle at high speeds over unfamiliar or rough terrain. Personal injury or vehicle damage may result. • Certain terrain and steep hills cannot be traversed safely with the Argo or any other vehicle. Do not attempt to drive over terrain that is questionable. • Do not drive your vehicle on asphalt or concrete roadways. When the vehicle turns, its tires skid on the driving surface. Asphalt or concrete causes extensive tire wear. • Use common sense at all times when driving your vehicle. • The Argo engine hood is designed to stay fastened in place while the vehicle is being driven. If the Argo is transported by truck or trailer, the hood should be removed and carried in the transport vehicle or secured in place on the Argo with rope or tie down straps. Wind or turbulence at road speeds could result in the loss of the hood. IMPORTANT Operate this vehicle with safety constantly in mind. Off-road vehicles face unpredictable and often hazardous terrain conditions. It is ultimately the operator’s responsibility to handle the vehicle safely within its limitations and to decide when and where to travel.

NOTES

III

NOTES

TABLE OF CONTENTS SECTION 1.0

2.0

3.0

4.0

5.0

PAGE

GENERAL INFORMATION 1.1 AMPHIBIOUS OPERATION .......................................................................................... 1.2 MAINTENANCE PROCEDURES .................................................................................. 1.3 WIND CHILL FACTOR .................................................................................................. 1.4 MODEL IDENTIFICATION ............................................................................................ 1.4.1 Argo Vehicle Capacity ........................................................................................ 1.5 REAR SEATS - 8 WHEEL MODELS ............................................................................. 1.6 IDENTIFICATION AND LOCATION OF CONTROLS ................................................ 1.7 INFORMATION LABELS ...............................................................................................

1 1 1 1 3 3 4 5

GENERAL OPERATING INSTRUCTIONS 2.1 NEW VEHICLE “BREAK-IN” PROCEDURE ............................................................... 2.2 PRE-OPERATION CHECKS ........................................................................................... 2.3 CARRYING PASSENGERS AND CARGO .................................................................... 2.4 FUELING THE VEHICLE .............................................................................................. 2.5 VENTED FUEL SYSTEM - ALL MODELS ..................................................................

6 6 6 7 7

OPERATING INSTRUCTIONS 3.1 BRAKES AND STEERING ............................................................................................. 3.2 HOLDING BRAKE SYSTEM - Vanguard2, Bigfoot, Response & Conquest ................. 3.3 HOLDING BRAKE SYSTEM - Vanguard ...................................................................... 3.4 THROTTLE CONTROL .................................................................................................. 3.5 STARTING PROCEDURE .............................................................................................. 3.6 STOPPING THE ENGINE .............................................................................................. 3.7 MANUAL STARTING PROCEDURE ............................................................................ 3.8 SELECTING AND CHANGING TRANSMISSION GEARS ........................................ 3.8.1 Changing Transmission Gears ............................................................................ 3.9 HEADLIGHTS .................................................................................................................

8 8 9 9 9 10 10 10 11 11

DRIVING PROCEDURES 4.1 DRIVING STRAIGHT AHEAD ...................................................................................... 4.2 STOPPING THE VEHICLE ............................................................................................ 4.3 TURNING THE VEHICLE ............................................................................................. 4.3.1 Left Turn ............................................................................................................. 4.3.2 Right Turn ........................................................................................................... 4.4 BACKING THE VEHICLE UP ....................................................................................... 4.4.1 Turning the Vehicle While Backing Up ..............................................................

12 12 12 12 12 12 12

DRIVING PROCEDURES DURING UNUSUAL CONDITIONS 5.1 REMOTE AREA USE ...................................................................................................... 5.2 ANGLE OF OPERATION ................................................................................................ 5.3 UPHILL OPERATION ..................................................................................................... 5.4 DOWNHILL OPERATION .............................................................................................. 5.5 SIDE SLOPE OPERATION ............................................................................................. 5.6 AMPHIBIOUS OPERATION - GENERAL .................................................................... 5.6.1 Entering Water .................................................................................................... 5.6.2 Driving Procedures in Water .............................................................................. 5.6.3 Driving Out of Water .......................................................................................... 5.6.4 Outboard Motor Bracket .................................................................................... 5.7 WINTER OPERATION ................................................................................................... 5.7.1 Use on Ice Covered Bodies of Water .................................................................

13 13 13 13 14 14 15 15 15 15 16 16

TABLE OF CONTENTS SECTION 6.0

7.0

PAGE

OIL, FILTER AND LUBRICATION INFORMATION 6.1 ENGINE OIL INFORMATION ......................................................................................... 17 6.1.1 CHECKING THE ENGINE OIL LEVEL .......................................................... 17 6.1.2 RECOMMENDED ENGINE OIL ...................................................................... 17 6.1.3 CHANGING ENGINE OIL ................................................................................ 18 Draining the Engine Oil ....................................................................................... 18 Refilling the Engine ............................................................................................. 18 6.2

TRANSMISSION OIL INFORMATION .......................................................................... 18 6.2.1 CHECKING THE TRANSMISSION OIL LEVEL ............................................ 18 6.2.2 CHANGING THE TRANSMISSION OIL ......................................................... 19 Refilling the Transmission ................................................................................... 19

6.3

FILTER INFORMATION .................................................................................................. 19 6.3.1 AIR FILTER ........................................................................................................ 19 6.3.2 FUEL FILTER ..................................................................................................... 19 6.3.3 OIL FILTER ........................................................................................................ 19

6.4

LUBRICATION INFORMATION .................................................................................... 19 6.4.1 GENERAL .......................................................................................................... 19 6.4.2 DRIVEN CLUTCH LUBRICATION ................................................................. 19 6.4.3 DRIVE CHAIN LUBRICATION ........................................................................ 20 6.4.4 IDLER CHAIN LUBRICATION ........................................................................ 20 6.4.5 OUTER AXLE FLANGE AND BEARING LUBRICATION ........................... 21 6.4.6 IDLER SHAFT BEARING LUBRICATION - All Models ................................ 21 6.4.7 INNER AXLE BEARING LUBRICATION ....................................................... 21

MAINTENANCE INFORMATION 7.1 ELECTRICAL SYSTEM .................................................................................................. 22 7.1.1 GENERAL .......................................................................................................... 22 7.1.2 BATTERY - Argo Part No. 127-54 ..................................................................... 22 Checking Fluid Level .......................................................................................... 22 Cleaning the Battery Terminals and Cable Connections ..................................... 22 Cleaning the Battery ............................................................................................ 23 7.1.3 ELECTRICAL SYSTEM FUSES ....................................................................... 23 7.1.4 SPARK PLUGS ................................................................................................... 23 7.1.5 SPARK ARRESTER ........................................................................................... 23 7.2

DRIVE SYSTEM & TIRES .............................................................................................. 23 7.2.1 DRIVE BELT ...................................................................................................... 23 Drive Belt Removal ............................................................................................. 24 Drive Belt Installation ......................................................................................... 24 7.2.2 CLUTCH MAINTENANCE ............................................................................... 24 Clutch Inspection ................................................................................................. 25 7.2.3 DRIVE CHAINS ................................................................................................. 25 Drive Chain Removal .......................................................................................... 25 Drive Chain Installation....................................................................................... 25 7.2.4 DRIVE CHAIN TAKE-UP SYSTEM ................................................................. 26 Removal of Slider Blocks .................................................................................... 27 Replacement of Slider Blocks ............................................................................. 27

TABLE OF CONTENTS SECTION

PAGE 7.2.5

IDLER CHAIN .................................................................................................. Idler Chain Adjustment ...................................................................................... Idler Chain Replacement .................................................................................... Removal of Idler Chains .................................................................................... Installation of Idler Chains ................................................................................. TIRE INFLATION ............................................................................................. TIRE REPAIR AND REPLACEMENT ............................................................ AXLE BEARING MOUNTING .......................................................................

27 28 28 28 28 29 29 29

7.3

MECHANICAL BRAKES - VANGUARD ..................................................................... 7.3.1 GENERAL ......................................................................................................... Removal of Firewall ........................................................................................... Mechanical Brake Inspection Procedure ........................................................... 7.3.2 BRAKE CALIPER ADJUSTMENT ................................................................. 7.3.3 BRAKE PAD REPLACEMENT ....................................................................... 7.3.4 STEERING LEVER ADJUSTMENT ............................................................... 7.3.5 HOLDING BRAKE ADJUSTMENT ............................................................... Re-installation of Firewall .................................................................................

29 29 29 30 30 30 31 31 31

7.4

HYDRAULIC BRAKES - VANGUARD2, BIGFOOT, RESPONSE & CONQUEST ... 7.4.1 GENERAL ......................................................................................................... 7.4.2 BRAKE FLUID LEVEL .................................................................................... 7.4.3 CHANGING BRAKE FLUID ........................................................................... 7.4.4 HYDRAULIC BRAKE PAD INSPECTION .................................................... Firewall Removal ............................................................................................... Brake Pad Inspection Procedure ........................................................................ Re-installation of Brake Pads ............................................................................. Re-installation of Firewall ................................................................................. 7.4.5 HOLDING BRAKE ADJUSTMENT ............................................................... 7.4.6 BRAKE COOLING SYSTEM .......................................................................... 7.4.7 ENGINE COOLING & EXHAUST SYSTEM .................................................

31 31 31 32 32 32 32 32 33 33 34 34

7.5

MAINTENANCE SCHEDULE ....................................................................................... 35

7.2.6 7.2.7 7.2.8

8.0

TROUBLESHOOTING ............................................................................................................. 36

9.0

CLEANING AND STORAGE .................................................................................................... 9.1 CLEANING THE VEHICLE ........................................................................................... 9.2 STORING THE VEHICLE .............................................................................................. Cleaning the Vehicle ......................................................................................................... Drain the Fuel System ...................................................................................................... Prepare the Battery for Storage ........................................................................................ Protect the Electrical System ............................................................................................ Raise the Vehicle ............................................................................................................. Preparing the Engine for Storage .....................................................................................

10.0

POTENTIAL HAZARDS ............................................................................................................ 39

11.0

ACCESSORY INFORMATION 11.1 GENERAL ............................................................................................................. 43 11.2 CARGO TIE-DOWNS (PART NO. 614-06) ................................................................... 43

VII

38 38 38 38 38 38 38 38 38

TABLE OF CONTENTS SECTION 11.3

11.4 11.5 11.6 11.7 11.8 11.9

11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20 11.21 11.22 11.23 11.24 11.25

PAGE ARGO TRACK SYSTEMS (STANDARD TRACK AND SUPER TRACK) .......................... 43 11.3.1 Operating Precautions .................................................................................................. 43 11.3.2 Standard Tracks ............................................................................................................ 44 11.3.3 Super Tracks ................................................................................................................. 44 ICE CLEAT KIT (PART NOS. 625-20 & 825-20) .................................................................... 44 OUTBOARD MOTOR BRACKET (PART NO. 617-00) ......................................................... 44 OUTBOARD MOTOR SUPPORT (PART NO. 618-00) ........................................................... 45 OUTBOARD MOTOR BRACKET - SIDE MOUNT (PART NO. 618-10) .............................. 45 ARGO STORAGE COVERS (PART NOS. 621-10; 621-20; 821-10; 821-20 .......................... 45 POWER WINCH (PART NOS. 622-40 & 622-70) ................................................................... 45 11.9.1 Rules for Safe Operation .............................................................................................. 45 11.9.2 Tips for Extending the Life of Your Winch .................................................................. 47 REAR MUD FLAP KIT (PART NO. 625-10) ........................................................................... 47 TRAILER HITCH KIT (PART NO. 626-10) ............................................................................. 47 BILGE PUMP KIT (PART NO. 638-25) ................................................................................... 47 HANDRAIL KITS (PART NO. 639-20 & 839-20) ................................................................... 48 TOW HOOK KIT (PART NO. 642-00) ..................................................................................... 48 WINDSHIELD (PART NO. 648-75) .......................................................................................... 48 CONVERTIBLE TOP (PART NOS. 649-33, 649-50 & 849-50) .............................................. 48 ALTERNATOR KITS (PART NOS. 650-60, 850-60 & 850-40) ............................................... 49 11.17.1 Alternator Kit for Conquest ........................................................................................... 49 SNOW PLOW KIT (PART NO. 657-13) ................................................................................... 49 AMPHIBIOUS TRAILER (PART NO. 695-75) ........................................................................ 49 11.19.1 Operating Precautions .................................................................................................... 49 HEATER KIT - CONQUEST (Part No. 848-10) ....................................................................... 50 ROLL OVER PROTECTIVE STRUCTURES (PART NOS. 848-40-2 & 848-40-4 ................ 50 REAR BENCH SEAT (PART NO. 849-60) ............................................................................... 50 DUMP BOX KIT (PART NOS. 835-00 & 835-01) ................................................................... 51 11.23.1 Dump Box Operating Guidelines ................................................................................. 51 ROLL BAR KIT (PART NO. 648-15) ....................................................................................... 51 12V ACCESSORY OUTLET KIT (PART NO. 633-25) ........................................................... 51

APPENDIX 1

SPECIAL TOOLS VICE GRIP MODIFICATIONS ................................................................................................. 52

VIII

SECTION 1 GENERAL INFORMATION 1.1 AMPHIBIOUS OPERATION

1.3 WIND CHILL FACTOR

Why does it feel much colder outdoors on a windy day than when there’s no wind, especially in winter? The cooling effect of the wind makes it feel that it’s colder than it really is. This combined effect of wind and low temperature is known as the “wind chill factor”.

1.2 MAINTENANCE PROCEDURES Argo operators should be aware of the wind chill factor. Dress warmly and make sure exposed skin is protected. Pay particular attention that young passengers are properly “bundled up” with their hands and faces well protected.

Maintenance procedures described in this manual can be carried out by the operator. These procedures include: 1. 2. 3. 4. 5.

checking fluid levels changing the engine and transmission oil cleaning and replacing filters preventative maintenance inspections, adjustments, repairs and trouble-shooting

673-00 1977-1986 ARGO Service Manual 673-01 1987 ARGO Service Manual 673-02 1988 Supplement 673-10 Service Manual (673-01 & 02) 673-25 Argo Service Video

Your Argo dealer will perform regular maintenance and lubrication for a reasonable service charge. 1.4 MODEL IDENTIFICATION

The vehicle identification plate is fastened to the dash. Reference Section 1.6 for the exact location. The model and serial numbers are stamped into it. Model identification starts with “V”, followed by five numbers. The four or five digit serial number begins with one of the following prefixes: S - 6x6 Vanguard (Mechanical Brakes) SN - 6x6 Vanguard2 (Hydraulic Brakes) BF - Bigfoot RB - 8x8 Response C - Conquest 6x6 CB - Conquest 8x8

Carefully observe the maximum load capacity for your vehicle on land and in water as listed in the following:

SECTION 1 GENERAL INFORMATION ARGO 6 x 6 VANGUARD (S)

ARGO 6 x 6 VANGUARD2 (SN)

Serial Number: Engine:

S-6999 Briggs & Stratton Vanguard, 480 cc (16 h.p.) V-Twin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Mechanical, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 16 Amp magneto type charging system, electronic ignition Speed: Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) SEE SECT.1.4.1 Water - 2 adults or 158 kg (350 lbs.) Maximum Rear Capacity: Land and Water - 63 kg (140 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 348 kg (765 lbs.)

Serial Number: Engine:

ARGO 6 x 6 BIGFOOT (BF)

ARGO 8 x 8 RESPONSE (RB)

Serial Number: Engine:

BF-9212 Briggs & Stratton Vanguard, 570 cc (18 h.p.) V-Twin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Hydraulic, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain and single RC-60 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp magneto type charging system, electronic ignition Speed: Land - 39 km/h (24 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) SEE SECT.1.4.1 Water - 2 adults or 158 kg (350 lbs.) Tires: 25x12.00-9NHS, 2 ply Dry Weight: 414 kg (910 lbs.)

Serial Number: Engine:

ARGO 6 x 6 CONQUEST (C)

ARGO CONQUEST (CB)

Serial Number: Engine: Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains:

Serial Number: Engine: Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains: Electrical:

SN-7888 Briggs & Stratton Vanguard, 480 cc (16 h.p.) V-Twin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Hydraulic, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 16 Amp magneto type charging system, electronic ignition Speed: Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) SEE SECT.1.4.1 Water - 2 adults or 158 kg (350 lbs.) Maximum Rear Capacity: Land and Water - 63 kg (140 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 348 kg (765 lbs.)

RB-12075 Briggs & Stratton Vanguard, 570 cc (18 h.p.) V-Twin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Hydraulic, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp magneto type charging system, electronic ignition Speed: Land - 30 km/h (20 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 6 persons or 454 kg (1000 lbs.) SEE SECT.1.4.1 Water - 4 adults or 317 kg (700 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 436 kg (960 lbs.)

CB-10847 Kawasaki 620 cc (20 h.p.) V-twin 4 cycle, liquid cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic Caliper, 9" disc with holding brake system Double RC-50 roller chains 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp charging system, battery ignition Speed: Land - 30 km/h (20 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 6 persons or 454 kg (1000 lbs.) SEE SECT.1.4.1 Water - 4 adults or 317 kg (700 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 465 kg (1025 lbs.)

C-12747 Kawasaki 620 cc (20 h.p.) V-twin 4 cycle, liquid cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic, 9" disc with holding brake system Double RC-50 roller chain and single RC-60 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp charging system, battery ignition Speed: Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 2 persons or 317 kg (700 lbs.) SEE SECT.1.4.1 Water - 2 adults or 158 kg (350 lbs.) Tires: 25x12.00-9NHS, 2 ply Dry Weight: 450 kg (990 lbs.)

SECTION 1 GENERAL INFORMATION 1.4.1 Argo Vehicle Capacity

1.5 REAR SEATS - 8 WHEEL MODELS Argo 8 wheel models are fitted with “quick-release” rear seats. Removal 1. Grasp the inner edge of the rear seat at both ends. 2. Lift the inner edge of the rear seat upwards until both plastic bumpers are clear of the upper body. 3. Using an upward motion, pull the seat toward the centre of the rear compartment. 4. Remove the seat.

Vehicle capacity includes occupants, cargo, fuel, and all accessories. Capacity for occupants and cargo is reduced by the weight of accessories as shown in the chart below. Available vehicle capacity must be reduced if your vehicle is equipped with any accessories. Reduce the available capacity by the total weight of accessories fitted to your vehicle.

Accessory On Vehicle Regular Tracks 6x6 Regular Tracks 8x8 Supertracks 6x6 Supertracks 8x8 Winch Kit Brush Guard Windshield Roll Bar 6x6 ROPS 6x6 ROPS 8x8 Half Top Full Top 8x8 Full Top 6x6 Snow Plow Dump Box Rear Bench Seat

Reduce By On Land 135 lbs. (60 kg) 175 (80) 145 (65) 210 (95) 50 (23) 11 (5) 33 (15) 50 (23) 130 (60) 140 (64) 16 (7) 27 (12) 22 (10) 190 (85) 100 (45) 34 (15)

Installation 1. Place the rear seat over the seat mounting holes in the upper body. Insert the large seat washers through the holes. 2. Using downward pressure, slide the seat towards the outside of the vehicle to lock it in place.

On Water 85 lbs. (40 kg) 110 (50) 90 (40) 135 (60) 50 (23) 11 (5) 33 (15) 50 (23) SEE WARNING 140 (64) 16 (7) 27 (12) 22 (10) SEE WARNING 500 (225) 34 (15)

SECTION 1 GENERAL INFORMATION 1.6 IDENTIFICATION AND LOCATION OF CONTROLS

Figure 1.1 Location of Information Labels - All Models

The label shown below is located behind the seat in the rear compartment of all 6-wheel models.

Figure 1.2 Rear Compartment Capacity Label - All 6x6 Models

SECTION 2 GENERAL OPERATING INFORMATION 2.1 NEW VEHICLE “BREAK-IN” PROCEDURE

2.2 PRE-OPERATION CHECKS

To obtain long term, trouble free service from your vehicle, observe the following break-in guidelines:

Carefully follow the engine manufacturer’s recommended preoperation/daily checks as well as the following:

1. Vary the speed of the vehicle for the first tank of fuel. Avoid full throttle operation during break-in period.

1. Check the fuel level in the see-through tank located under the driver’s seat.

2. Check engine and transmission oil levels daily during break-in period.

4. Check the steering lever travel by pulling both steering levers fully to the rear. See Section 7.3.4 for proper adjustment details.

5. Check the idler chain adjustment each day before driving the vehicle, and after the initial 2 hours of operation. Refer to Section 7.2.5 for idler chain inspection and adjustment information.

5. Check the engine intake and exhaust screen for obstructions. Clear any debris that has accumulated.

3. Secure cargo to prevent it from shifting while driving. 4. Do not mount any heavy fixtures to the upper body without support to the vehicle frame. The added weight may cause body deformation that could result in the tires rubbing through the body.

SECTION 2 GENERAL OPERATING INFORMATION Make sure all passengers riding in an ARGO equipped with tracks and ice cleats are informed to keep hands, feet and clothing inside the vehicle, well away from the tracks and ice cleats, while the ARGO is in motion. Serious injury or death could result from getting caught by the ice cleats.

After filling the fuel tank, be sure the fuel cap is replaced securely. Do not drive the vehicle unless the fuel cap is properly in place.

2.4 FUELING THE VEHICLE

When storing the ARGO for 45 days or more, use ARGO Part No. 125-85 Fuel Stabilizer to treat fuel in the fuel tank and fuel containers. 2.5 VENTED FUEL SYSTEM - ALL MODELS All ARGO models have fuel systems that are vented through a special hose connected to the filler neck assembly that runs along the upper body to a fitting at the left rear.

When installing the Handrail Kit, Convertible Top Kit or Outboard Motor Bracket; Since the fuel vent hose runs along the under side of the upper body, care must be taken when drilling mounting holes. The fuel vent hose could be pierced during the drilling process, resulting in a dangerous fuel leak into the vehicle and a costly repair procedure.

Never use gasoline containing methanol or white gas since engine or fuel system damage could occur. All models of the ARGO are equipped with a 32 litre (7.0 Imp. Gal., 8.4 U.S. Gal.) “see-thru” polyethelene fuel tank located underneath the driver’s seat. depending on loading and driving conditions, an ARGO can be driven for 7 to 12 hours on one tank of fuel. Verify your vehicle’s actual fuel consumption before attempting any long trips. Never travel in remote areas or set out on long trips without a full tank of fuel and adequate spare fuel stored in approved watertight fuel containers. The fuel filler neck and fuel cap are located on the right side of the vehicle behind the driver’s seat. Replace the fuel cap if fuel leakage occurs, or if moisture is detected in the fuel. Use ARGO Part No. 126-46 fuel cap. Never fill the tank to the point where the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vent. Portable fuel containers may contain contaminants (dirt, water, etc.) that will cause engine operating problems. Use only clean, approved gasoline containers.

Figure 3-3. Stopping the vehicle

3.2 HOLDING BRAKE SYSTEM VANGUARD2, BIGFOOT, RESPONSE & CONQUEST Models All VANGUARD2, BIGFOOT, RESPONSE & CONQUEST models have holding brake levers between the steering levers.

The holding brake system is not a parking brake, and therefore is not designed to hold the vehicle in place for long periods of time. The holding brake is for short term use only. When parking on an incline, engage the holding brake levers, leave the vehicle in gear, turn the engine off and block the vehicleâ&#x20AC;&#x2122;s wheels. When in use, the holding brake system keeps the steering levers locked in the full braking position. To apply the holding brake system: Figure 3-1. Making a right hand turn

1. Pull the steering levers back. 2. The spring-loaded holding brake levers will release automatically. When not in use, the holding brake levers rest against the bottom edge of the dash.

SECTION 3 OPERATING INSTRUCTIONS 3.3 HOLDING BRAKE SYSTEM - VANGUARD

3.5 STARTING PROCEDURE

The VANGUARD has a holding brake lever installed at the base of the left hand steering lever. Never start or run the engine in a closed building or confined area. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odourless, colourless and can cause serious personal injury or death.

The holding brake is not a parking brake. When parking on an incline, engage the holding brake, leave the vehicle in gear, turn the engine off and block the vehicle’s wheels. To apply the holding brake system:

All ARGO models are equipped with key operated, electric start systems. Starting procedure is identical for all models. To start the vehicle, proceed as follows:

1. Pull the left steering lever back.

1. Place the gearshift in the neutral (N) position.

2. While holding the steering lever back, lift the holding brake lever up so it engages the steering lever holding brake pin.

3. Release the steering lever against the holding brake lever. To release the holding brake system:

3. Open the accelerator twist grip control 1/8 turn. 1. Pull the steering lever back. 4. Turn the key to the “START” position. (See Figure 3-5) 2. The spring-loaded holding brake lever will release automatically. When not in use, the holding brake lever will rest against the bottom of the steering lever.

Off Run

3.4 THROTTLE CONTROL Start

Vehicle speed is controlled by the throttle twist grip. To increase vehicle speed, turn the twist grip as shown in Figure 34. To decrease vehicle speed, release the twist grip so the engine returns to idle. Figure 3-5. Ignition Switch

Figure 3-4. Operation of the throttle twist grip

SECTION 3 OPERATING INSTRUCTIONS 5. Release the key as soon as the engine starts: the key will automatically return to the “RUN” position. NO MANUAL STARTING PROCEDURE IS AVAILABLE FOR THE CONQUEST.

6. Release the twist grip control and allow the engine to come to an idle.

3.8 SELECTING AND CHANGING TRANSMISSION GEARS

7. Push the choke in halfway after the engine starts, and push it in all the way as the engine warms up.

All models for the ARGO are equipped with a four position transmission. The gearshift lever extends through the firewall and is moved to the right or left into one of four positions (See Figure 3-7):

8. If the engine fails to start, refer to the trouble-shooting chart in Section 8 for corrective action.

3.6 STOPPING THE ENGINE

Release the throttle twist grip. Let the engine speed return to idle and turn ignition switch to the “OFF” position. Always remove key from ignition switch when leaving the vehicle unattended. 3.7 MANUAL STARTING PROCEDURE VANGUARD, VANGUARD2, BIGFOOT & RESPONSE models can be manually started using the recoil starter on the Vanguard engine. 1. Turn the key to the “RUN” position. 2. Place the gearshift in the neutral (N) position. 3. Pull out the choke if the engine is cold.

Figure 3-7. Direction of gearshift travel and gear positions

4. Remove the engine compartment hood.

To shift from N (neutral) position into the desired gear:

5. Grasp starter grip as illustrated and pull slowly until recoil engages (Figure 3-6).

1. Apply the brakes by pulling back both steering levers.

6. Open the accelerator twist grip control 1/8 turn, then pull cord rapidly to overcome compression, prevent kickback and start engine. Repeat if necessary with choke pushed in slightly.

7. When engine starts, push choke in gradually.

Figure 3-6. Recoil Starter - Vanguard Engine

SECTION 3 OPERATING INSTRUCTIONS 2. After the engine has idled down completely, lift up on the gear shift lever and move it with a quick movement to the selected gear.

3.9 HEADLIGHTS All ARGO vehicles are equipped with 2 headlights that are operated through the dash mounted light switch. To turn the lights on, pull the light switch out.

NOTE: You will find it easier to engage high gear if the gear shift is first moved to reverse (REV), then directly over to HIGH with one quick movement.

Do not leave the lights on for any length of time when the engine is not running. Leaving them on will drain the battery.

3. Use the gear position decal only as a guide for finding the gear position. Make sure you feel the detent which indicates the selected gear is properly engaged.

Avoid frequent starting of the engine and extensive idling. Both will lead to a drain of the battery because the electrical draw is greater than the charging rate at engine idle.

SECTION 4 DRIVING PROCEDURES 4.1 DRIVING STRAIGHT AHEAD Shift the transmission into LOW or HIGH. Hold both steering levers straight ahead against the dash (See Figure 4-1). Turn the throttle twist grip slowly until the clutch system engages and the vehicle moves forward. Figure 4-2. Correct method of making a wide turn

Sharp turns, especially at high speeds or when heavily loaded, may cause the vehicle to roll over. Slow the vehicle down before making a turn. Do not apply the brakes too suddenly. 4.3.1 Left Turn Figure 4-1. Position of steering levers for straight ahead operation

To make a left turn, pull back on the left steering lever to stop the wheels on the left side of the vehicle. When the turn has been completed, return the left steering lever forward against the dash.

4.2 STOPPING THE VEHICLE Allow the throttle grip to return to the idle position. Pull back evenly on both steering levers.

4.3.2 Right Turn Pull the right steering lever back and return it to the dash when the turn has been completed.

4.4.1 Turning The Vehicle While Backing Up Pull the left steering lever back to make a turn to the left. Pull the right steering lever back to make a turn to the right. When turning the vehicle while backing up, the rear of the vehicle swings in the direction of the turn. This is unusual for most people who are not familiar with skid steer vehicles. Carefully practice backing up and turning in an open area until you become accustomed to this procedure. Take precautions to avoid hitting persons or objects.

4.3 TURNING THE VEHICLE The ARGO is a skid steer vehicle. The rear of the vehicle swings outward during a turn. Always take precautions when making turns to avoid hitting persons or objects. The proper way to make a wide turn is illustrated in Figure 4-2. Make a series of short turns. Hold the steering lever against the dash between turns. Riding the brakes while making turns will result in excessive heat, brake fade and lead to premature brake wear.

Do not push against the firewall with your knees. Damage to the firewall and serious personal injury can result from the driven clutch wearing through the firewall.

SECTION 5 DRIVING PROCEDURES IN UNUSUAL CONDITIONS 5.1 REMOTE AREA USE

5.3 UPHILL OPERATION

When traveling in remote areas or when traveling long distances, the following items are essential:

• • • • • • • • • • •

Never accelerate or brake suddenly while driving up or down a hill. Sudden acceleration or braking can cause the vehicle to roll over, causing serious personal injury or death.

The rear compartment capacity of all 6 wheel ARGO vehicles is 65 kg (140 lbs.) MAXIMUM. Exceeding this weight limitation will decrease the stability of the vehicle on inclines and increase the possibility of rolling over backwards when climbing a grade. Do NOT exceed this weight in the rear compartment. Never attempt to turn the vehicle around on a steep hill or grade. Turning the vehicle around on a hill can result in the vehicle rolling over. Approach the hill head on to minimize the possibility of sliding sideways or rolling over. Accelerate slowly to prevent loss of traction. When traction is lost, the vehicle may slide sideways or backwards. If this occurs, apply the brakes gently and evenly to stop the slide. Allow the vehicle to coast to the bottom of the hill by carefully releasing the brakes.

Before venturing into remote areas, carry out all inspections, adjustments and lubrication checks detailed in this manual. Do not proceed unless your vehicle is in good working condition. Inform someone of your departure and return plans and your route so that help can be dispatched if you do not return as scheduled. Do not travel into a remote area alone.

5.4 DOWNHILL OPERATION Always approach the hill head on to minimize the possibility of sliding sideways, or rolling over. Gently apply the brakes to control downward vehicle speed. Do not jam on the brakes while traveling downhill. Sudden braking can cause the vehicle to roll over frontwards.

5.2 ANGLE OF OPERATION When operating any Argo vehicle on an angle, (up and down hills or across uneven terrain that causes the vehicle to tilt in any direction) the engine oil level is affected. If the engine oil level falls below the oil pump intake, damage can occur because of inadequate lubrication. To avoid premature engine damage and costly repairs:

An alternative to applying the brakes while going down a gentle decline is to use engine braking. Select low range and keep the engine speed up just enough to keep the clutch engaged.

• Do not operate your engine continuously on angles or in•

clines that are greater than 30 degrees in any direction. Make sure the engine oil level is near the “full” mark (However, do not overfill.)

SECTION 5 DRIVING PROCEDURES IN UNUSUAL CONDITIONS 6. Be prepared to adjust the position of cargo and passengers so the vehicle floats level.

5.5 SIDE SLOPE OPERATION Do not drive your vehicle across the side of a hill. Side slope operation greatly increases the risk of rolling the vehicle over sideways.

7. Care must be taken when encountering submerged obstacles that may upset the vehicle. Observe the following safety precautions BEFORE entering the water:

Prolonged side slope operation may cause engine damage. Observe the engine angle of operation limitations in Section 5.2.

1. All occupants must wear an approved personal flotation device (PFD) or life jacket while traveling in water.

Operation on side slopes will require frequent use of the brakes for steering correction since the vehicle tends to head downhill. This may cause brake overheating or fade.

2. Equip the vehicle with a paddle and bailing can. An optional bilge pump kit (ARGO Part No. 638-25) is available from your ARGO dealer and is recommended for water operation.

5.6 AMPHIBIOUS OPERATION - GENERAL

ARGO vehicles may sink if they fill with water. If water starts entering the vehicle, head to the nearest shore immediately. Be prepared to abandon the vehicle if it appears that the vehicle will fill with water before you reach the shore. Be especially cautious when operating a loaded vehicle (cargo and/or passengers) in water. Observe the capacity limits. All ARGO vehicles are self-propelled, amphibious vehicles, capable of navigating calm water, provided the following precautions are observed: 1. Do not enter water if the vehicle is overloaded. Refer to Section 1.4 of this manual for recommended load capacity in water.

Figure 5-1. Location of rear drain plugs

2. Do not use seat belts or any passenger restraining device while operating an ARGO in water. If an emergency arises, you and your passengers may have to leave the vehicle quickly.

4. Visually check the lower body of the vehicle for cuts, punctures or holes that will allow water to enter the vehicle. 5. Make sure that any cargo in the rear of the vehicle is evenly distributed.

3. Do not attempt to cross large bodies of water. Stay close to the shore in case an emergency arises and you have to leave the water.

4. Do not attempt to navigate any body of water with a strong current. Avoid water operation under windy conditions. 5. Use extra caution when operating the ARGO in cold water. If the vehicle upsets or swamps, exposure in cold water significantly reduces the chance of survival.

SECTION 5 DRIVING PROCEDURES IN UNUSUAL CONDITIONS 5.6.2 Driving Procedures in Water After the vehicle is floating evenly on the water, turn the throttle twist grip to increase speed. Use only part throttle when traveling through water. Full throttle only results in excessive turbulence, not higher speeds. The vehicle is steered by pulling the right or left steering levers back as on land. The turning radius is somewhat greater in water, and the vehicle does not respond to changes in direction as quickly as it does on land. The vehicle is propelled forward through the water by the web of the tires as they rotate. To back up in water, release the throttle, shift the transmission into neutral, and use a paddle.

Figure 5-2. Tightening and locking the drain plugs

Avoid rocks, stumps or other obstacles that are below the surface of the water. Striking these obstacles may damage the bottom or upset the vehicle. If your vehicle begins to fill with water, immediately head to the nearest shore. Get the vehicle out of the water and drain it by removing both rear drain plugs. Correct the leak before entering the water again.

Figure 5-3 Outer bearing flange sealing area

Do not leave the vehicle in water for extended periods of time. Water could enter the axle seals and cause damage to the axle bearings.

Always observe the recognized rules of boating while traveling in water.

5.6.3 Driving Out of Water

5.6.1 Entering the Water

5.6.4 Outboard Motor Bracket

If a leak is detected, drive back onto shore. Drain the vehicle and repair the leak before re-entering the water.

Do not mount an outboard motor on the vehicle unless the special bracket is used. Damage to the vehicle will occur if an outboard motor is mounted directly on the vehicle body.

Be careful not to submerge the bumper as you enter the water. With the bumper submerged, water can enter through the openings in the upper body.

SECTION 5 DRIVING PROCEDURES IN UNUSUAL CONDITIONS If the vehicle breaks through the ice, it will float in the water, provided that there are no leaks in the body, the drain plugs are in place and vehicle is not taking on water through any body openings. However, there is a risk of the vehicle tipping, particularly if the load is unbalanced. Be prepared to shift occupants’ weight for balance.

Gasoline is extremely flammable and can explode if ignited. Fill outboard motor fuel tanks outside of the vehicle. Wipe up any spilled fuel immediately. Do not carry or store fuel tanks in a vehicle equipped with a cab or convertible top unless adequate ventilation is provided.

Getting back onto safe ice depends on various conditions and the expertise of the driver. Be especially careful to prevent water from entering the vehicle. • Balance the cargo and passenger load. • Keep openings, like air intakes/exhaust, etc. above the water line. • Keep the bilge pump running. • Winch the vehicle out. • Back onto ice, as the back end is lighter and floats higher in the water. • Avoid getting the wheels on only one side onto the ice surface as water could enter over the opposite side of the vehicle. • Avoid turning as the Argo is climbing out to avoid vehicle tip-over. • Break the thin ice around the vehicle with the paddle until there is firm ice for the vehicle to climb onto. • Be wary of currents which may pull the vehicle under the ice.

5.7 WINTER OPERATION Follow these precautions when operating the ARGO in winter conditions:

• Equip the vehicle for remote area use, as listed in Section 5.1.

• Keep the battery fully charged and in good condition. • Use the recommended winter grade of engine oil. • Do not allow water or snow to accumulate in the vehicle.

• • • •

Snow may melt during operation of the vehicle, collect in the lower body and freeze around the chains and final drive components, immobilizing the vehicle. Store the vehicle indoors or under cover. Equip your vehicle with snow tracks for travel over deep snow. Steep, snow-covered or icy hills may be more difficult to ascend. Ice cleat kits (625-20 for 6 wheel or 825-20 for 8 wheel) are available for Super Track systems. Never travel alone into a remote area. Leave your route and arrival plans with someone who can send help if you fail to arrive as planned.

5.7.1 Use on Ice Covered Bodies of Water

Using the ARGO on ice-covered bodies of water is potentially hazardous. Use extreme caution. Exposure to cold water reduces a person’s chance of survival. Protective clothing, such as a marine survival suit will significantly decrease the effect of exposure in frigid water. Before venturing out onto ice-covered bodies of water, it is extremely important to:

• Check the ice thickness and condition to be sure it will •

support the vehicle. Take all precautions as in Section 5.6, particularly paragraph 3 referring to drain plugs.

SECTION 6 OIL, FILTER AND LUBRICATION INFORMATION 6.1 ENGINE OIL INFORMATION Do not run the engine if the oil level is above the FULL mark or below the ADD mark. Premature engine damage or total engine failure can occur when the oil level is not properly maintained.

Detailed information on standard workshop and safety procedures and general installation practices is not included here. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any procedure performed, including those procedures outlined here. Before performing any procedure, an individual must have determined to his/ her satisfaction that personal injury or vehicle damage will not result from the procedure, working environment or tools selected. 6.1.1 Checking the Engine Oil Level Check the engine oil level each day before operating the engine. To check the oil during an operating period, shut the engine off, let it cool down and allow the oil time to drain into the sump before checking the oil level. Position the vehicle so the engine is level.

Figure 6-2. Dipstick “A” and oil filler “B” location KAWASAKI engine

Do not run the engine if the oil level is above the “H” mark or below the “L” mark. Premature engine damage or failure can occur when oil levels are not maintained. 6.1.2 Recommended Engine Oil Use a high quality detergent oil of API (American Petroleum Institute) service class as listed below. Choose the correct viscosity of oil for seasonal driving conditions.

Figure 6-1 Oil fill and level location BRIGGS & STRATTON engine

SECTION 6 OIL, FILTER AND LUBRICATION INFORMATION Briggs & Stratton API Service Class SE, SF or SG

There is limited space between the engine and power pack frame. Cut down an empty plastic container to the correct height so it will fit under the engine oil drain. Make sure the container will hold the amount of oil in the engine. A ziploc plastic bag makes a convenient oil container. It conforms to the space available and can be closed securely when the oil is drained, then lifted neatly out of the engine compartment. PLEASE DISPOSE OF WASTE OIL PROPERLY TO CONSERVE OUR ENVIRONMENT. 4. When all the oil has been drained from the engine, clean and replace the drain plug. MAKE SURE it is properly tightened before refilling the engine. 5. See Oil Filter Replacement in Section 6.3.3. Refilling the Engine Refill the engine through the oil fill port with the correct amount of oil (Figure 6-3). Make sure the appropriate grade of oil is used (Section 6.1.2). As you add oil, frequently check the level with the dipstick. Do not overfill. Start engine. Check for leaks. Stop the engine. Check the oil level. Add oil only to the “Full” or “H” mark on the dipstick. 6.2 TRANSMISSION OIL INFORMATION Figure 6-3 Oil Capacities

6.2.1 Checking the Transmission Oil Level

6.1.3 Changing Engine Oil

During the initial engine break-in period, change the oil after the first 8 hours of operation for Briggs & Stratton and 20 hours of operation for the Kawasaki. After the break-in period, change the engine oil every 50 operating hours, or more frequently if the vehicle is operated in dusty or dirty conditions. Draining the Engine Oil Each engine is equipped with a drain plug for draining the oil. The drain plug location is shown in the engine owner’s manual. Drain the oil from the engine as follows:

Figure 6-4. Transmission dipstick

SECTION 6 OIL, FILTER AND LUBRICATION INFORMATION The transmission oil level should be even with the mark on the dipstick as shown in Figure 6-4. Add 80 W 90 Gear Lube HYPOY-C through the transmission oil fill/dipstick hole until the transmission is filled to the correct level. DO NOT OVERFILL. Replace the dipstick securely.

6.3.2 Fuel Filter

6.2.2 Changing the Transmission Oil

All models of the ARGO are equipped with an in-line fuel filter (replacement fuel filter is ARGO Part No. 125-64). On Conquest models the fuel filter is located in the fuel hose, next to the fuel tank. On all other Argo models the fuel filter is located at the engine.

6.3.3 Oil Filter During the initial engine break-in period, change the oil filter (Part No. 126-95 for Briggs & Stratton engines and Part No. 127-68 for Kawasaki engines) when the oil is changed. After that, change the oil filter every 50 hours.

Refilling the Transmission Before installing the new filter, lubricate the rubber filter gasket with fresh engine oil. Screw the filter on by hand until the gasket contacts filter adapter. Tighten 1/2 to 3/4 turn more. Start and run engine to check for oil leaks. Stop engine and recheck oil level. Add oil if required.

Refill the transmission through the oil fill/dipstick hole with 30 oz (.85L) of 80 W 90 Gear Lube HYPOY-C. As you refill the transmission, check the oil level with the dipstick. Check that the oil level is even with the mark on the dipstick, after it has been seated fully in the dipstick hole. DO NOT OVERFILL.

6.4 LUBRICATION INFORMATION

Overfilling may result in oil being forced out the breather hole that could contaminate the brake pads and lead to brake failure.

6.4.1 General The following parts and components require regularly scheduled lubrication to prevent premature wear and replacement.

6.3 FILTER INFORMATION 1. Driven Clutch 2. Drive Chains

6.3.1 Air Filter All ARGO engines are equipped with a foam precleaner and dry paper air filter element housed in an air cleaner assembly attached to the carburetor.

3. Idler Chains 4. Bearings

Use the recommended lubricants listed in this section and carefully observe the recommended lubrication intervals.

Wash and oil the precleaner after every 25 hours of operation or more often under extremely dusty or dirty conditions.

Do not attempt to lubricate the driven clutch while the engine is running.

Check the paper air filter element every 100 hours of operation or more often under extremely dusty or dirty conditions.

6.4.2 Driven Clutch Lubrication

For instructions to remove, clean and replace the air filter components, refer to the air cleaner section of the engine ownerâ&#x20AC;&#x2122;s manual.

6.4.4 Idler Chain Lubrication Lubricate the idler chains after 10 hours of operation, and more frequently if the vehicle is operated in dirty or wet conditions (Figure 6-6). Use only ARGO Chain Lube (ARGO Part No. 125-86) to lubricate the idler chains.

Figure 6-6. Location of the idler chains

Figure 6-5. Lubricating the driven clutch

Never use gasoline as a cleaning solvent. Gasoline is extremely flammable and can explode if ignited, causing serious personal injury. Figure 6-7. Lubricating the idler chain

Allow the chains to dry thoroughly, re-lubricate generously with ARGO Chain Lube and re-install.

Refer to Section 7.2.3 of this manual for drive chain removal and re-installation instructions.

SECTION 6 OIL, FILTER AND LUBRICATION INFORMATION After every 100 hours of operation, remove both idler chains from the vehicle and clean them thoroughly in a suitable solvent. Allow the idler chains to dry thoroughly, re-lubricate them generously with Argo chain lube and re-install. Refer to section 7.2.5 of this manual for idler chain removal and reinstallation instructions.

dislocating the bearing seals due to excessive grease pressure.

Do not use high pressure or excessive amounts of grease. Damage to the bearing seals could result.

6.4.5 Outer Axle Flange & Bearing Lubrication

6.4.6 Idler Shaft Bearing Lubrication - All Models The idler shaft bearing flanges are fitted with grease nipples. These bearings should be greased with a small amount of Shell Alvania No. 2 grease or equivalent at 250 hours of operation or whenever major maintenance is performed on the vehicle. The grease fittings become more accessible when the idler chains are removed. Alternatively, ARGO Part# 658-16 Right Angle Coupler, can be used to access these fittings (also sold at automotive supply stores as a Right Angle Grease Coupler, Thexton part no. 418).

Figure 6-9 Idler shaft bearing grease nipples

Figure 6-8. Outer Axle Flange

The second or inner grease fitting of the outer axle flange supplies grease directly to the outer axle bearing. Since the bearing is well sealed and packed with grease when manufactured, it requires re-greasing only every 100 hours of operation or before the vehicle is taken out of service for any extended period. Use a pistol grip type grease gun to avoid

SECTION 7 MAINTENANCE INFORMATION 7.1 ELECTRICAL SYSTEM

• Never weld on the vehicle without first disconnecting both • •

Figure 7-1. Battery fluid level

Charging the Battery If the battery loses its electrical charge, remove the battery from the ARGO and recharge it with a 12 volt battery charger at the rate of 10-12 amps maximum. The battery should remain on charge until the specific gravity reaches 1.265 on a hydrometer. Re-install the battery in the vehicle and try to start the engine. If the battery fails to perform properly, have it tested by a battery service dealer. Replace a defective battery with ARGO Part No. 127-54/Exide Part No. 45-50.

7.1.2 Battery- ARGO Part No. 127-54 - Exide Part No. 45-50

Ventilate area when charging. Keep away from spark, heat, cigarettes or open flame.

Batteries can explode and cause serious personal injury if exposed to flame or sparks. Never smoke while servicing the battery.

All models are equipped with a 12 volt, wet cell type battery. The battery is located in the engine compartment, on the right side in front of the driver’s position. Checking Fluid Level Check the fluid level every 50 hours of operation. Remove the pod vents and make sure each cell is filled to the fluid level as shown in Figure 7-1. If the fluid has dropped below the fill well, add distilled water until the cell is filled to correct level. DO NOT OVERFILL.

SECTION 7 MAINTENANCE INFORMATION Cleaning the Battery

the tail pipe. It is fastened with one (1) slotted washerhead hex screw. Find the screw on the side of the outlet tube.

4. Remove the screw and save it for step 9. 5. Take off the screen-type spark arrester assembly. 6. Shake loose particles out of the screen assembly.

7.1.3 ELECTRICAL SYSTEM FUSES 7. Clean the screen with a wire brush. (Soak it in oil solvent if necessary.)

8. If any breaks in the screen or weldments are discovered, replace the assembly with Part No. 807-67. 9. Return the screen assembly to the outlet tube and refasten it with the screw from Step 4.

NOTE: On the Vanguard, Vanguard2, Bigfoot and Response one of the center fuses in the fuse block is a spare and can be used for accessory equipment.

7.2 DRIVE SYSTEM & TIRES

7.1.4 SPARK PLUGS Remove and inspect the spark plugs after every 100 hours of operation. Clean the plugs and reset the gap as detailed in the engine owner’s manual.

Replace the spark plugs if the electrodes are corroded or damaged or if the insulator is cracked. Use the correct plug for the engine as detailed in the engine owner’s manual.

Re-install the spark plugs carefully, taking care to start the threads properly. Torque the plugs to 10 - 15 ft. lbs (14 to 20 N·m). Do not over tighten.

7.1.5 SPARK ARRESTER 7.2.1 DRIVE BELT Cleaning the Spark Arrester (only for equipped models) The drive belt transmits power from the driver clutch (on the engine) to the driven clutch (on the transmission). These components are located on the left side of the engine compartment. (Figure 7-2)

SECTION 7 MAINTENANCE INFORMATION

Figure 7-2. Location of drive clutches and drive belt Figure 7-3. Removing the drive belt

Check the drive belt after every 25 hours of operation, or whenever there is a noticeable reduction in clutch performance. Replace the belt when:

To install the Drive Belt:

• the top width of the belt has worn to 1-5/16" (33mm) • cracks, fraying or shredding is apparent • it becomes contaminated with oil or some other fluid

If this procedure is not carried out as described, the edge of the fixed face may cut or damage the drive belt. 1. Position the belt around the driver clutch first.

Refer to the ARGO Parts Manual for correct drive belt part number.

2. Ease the belt over the edge of the fixed face on the driven clutch and at the same time, turn the inside, movable face clockwise.

To Remove the Drive Belt 1. Make sure ignition is turned off.

3. Remove the firewall.

4. Place the transmission in N (neutral).

7.2.2 CLUTCH MAINTENANCE

5. Ease the belt over the fixed half pulley of the driven clutch starting from the bottom of the clutch, while turning the clutch counterclockwise until the belt is off. (Figure 7-3).

2. Remove the engine access hood.

6. Remove the belt from the driver clutch.

• • • • • • • 24

Figure 7-4. Location of the sliders

Clutch Inspection Inspect the nylon sliders every 50 hours. The nylon sliders are mounted in the driven clutch moveable pulley. (Figure 7-4). When the clutch shifts, the cam moves on the nylon sliders. Replace the nylon sliders before there is aluminum to aluminum contact between the cam and the movable pulley. Driven clutch disassembly is required to replace the nylon sliders properly. Return the vehicle to an ARGO dealer for service.

Figure 7-6. Securing tensioner cam

7.2.3 DRIVE CHAINS

To install the Drive Chains:

Roller chain “stretch” results from wear to the chain pins and bushings because of the loss of lubricant.

1. Position the drive chain over the slider block and around the drive sprockets.

To prevent sprocket damage and unnecessary breakdowns, replace the chains when:

• • • •

Use a pair of modified 7R Vice Grips to hold the ends of the chain together while inserting the connecting link. Some drive chains have no slack, and replacement of the connecting link is difficult without this tool. Modified Vice Grips can be ordered from your ARGO dealer (ARGO Part No. 658-08) or refer to Appendix 1 for modification information.

To remove the Drive Chains: 1. Place the gearshift in the N (neutral) position. 2. Remove the floor pans.

3. Replace the outside plate and spring clip. The open end of the clip must face rearward when it is on top of the chain.

4. Remove the vice-grips, securing the cam assembly in its lowest position. 5. Repeat steps 1 to 4 until all chains are replaced.

SECTION 7 MAINTENANCE INFORMATION

Figure 7-7. Removal of the spring clip

Figure 7-10. Wear groove on the slider block

The chain tensioning system consists of a torsion spring loaded cam assembly with a slider block which takes up the slack on the bottom side of all but the front final drive chains. As the chain wears, the chain tensioning mechanism adjusts semiautomatically. Under most conditions, the tensioner cam assembly will move to the next step of adjustment simply due to normal drive system dynamics. Sometimes, however, the cam assembly can bind due to debris caught in the area. IT IS VERY IMPORTANT TO CHECK THAT THE CAM ASSEMBLY IS PROGRESSING PROPERLY. CHECK FOR PROPER CHAIN TENSIONER OPERATION AFTER THE FIRST TWO HOURS OF USE AND THEN EVERY 10 HOURS OF VEHICLE OPERATION, WHEN THE DRIVE CHAINS ARE BEING LUBRICATED. Each step of the cam takes up about 2.5 inches of chain slack (see Fig. 7-11).

Figure 7-8. Chain connection link components

7.2.4 DRIVE CHAIN TAKE-UP SYSTEM Figure 7-11. Chain slack required before the tensioner will progress to the next step.

Check for proper chain tensioner operation every 10 hours of vehicle operation. Figure 7-9. Installing the connecting link

3. With pliers, pry the slider block off the cam assembly as illustrated in Figure 7-13.

6. Remove the locking pliers securing the cam assembly in its lowest position. 7. Pull up on the cam assembly to allow it to take up as much chain slack as possible. 8. Replace the floor pans.

Figure 7-13 Prying the Slider Block off the Cam Assembly

Figure 7-15. Measuring idler chain deflection

SECTION 7 MAINTENANCE INFORMATION To check the idler chain adjustment, push the slack side of the chain and measure the amount of chain deflection (Figure 715). Adjust the idler chain tension if deflection is more than 3mm (1/8").

Idler Chain Adjustment 1. Remove the firewall from the vehicle as detailed in Section 7.3.1 for the Vanguard and Section 7.4.4 for the Vanguard2, Bigfoot, Response and Conquest.

3. Remove the idler chain from the vehicle.

2. Loosen the 2 left side clamping nuts and 1 front pivot shaft nut with a 15/16" socket wrench (figure 7-16). Loosen the 3/8" hex nut (117-15) securing the adjustment support (60227), just above the transmission, to the hood frame assembly. (Refer to Section 6.0 of the Parts Manual.)

4. Repeat steps 1 to 3 to remove the other idler chain.

3. Turn the vertical adjustment bolts counter-clockwise to raise the power pack and tighten the idler chains. The idler chains are properly adjusted when the deflection measures 3 mm (1/8"), (Figure 7-15). 4. Tighten the 2 left side clamping nuts and 1 pivot shaft nut securely. Tighten the adjustable support fasteners with the rubber bumper (126-88) pressed down firmly onto the top of the transmission. Figure 7-17. Position of idler chain link for removal

NOTE: Use a pair of modified 7R Vice Grips to hold the ends of the chain together while inserting the connecting link. There may be no slack in the idler chain, making installation of the connecting link difficult without this tool. Modified Vice Grips can be ordered from your ARGO dealer (ARGO Part No. 65808) or refer to Appendix 1 for modification information.

Idler Chain Replacement Replacement of the idler chains is required if the adjustment bolt is fully extended and idler chain deflection still exceeds 3 mm (1/8").

3. Replace the outside plate and spring clip as shown in Figure 7-7.

To Remove the Idler Chains:

4. Repeat steps 1 to 3 to replace the other idler chain.

Loosen the power pack clamping nuts and adjusting bolts as shown in Figure 7-16 and proceed as follows:

SECTION 7 MAINTENANCE INFORMATION 7.2.6 TIRE INFLATION Improperly inflated tires can cause the vehicle to pull to one side, requiring constant steering correction. Suggested inflation for the Runamuk 22x10.00-8, Rawhide III 22x11.00-8 and Rawhide III 25x12.00-9 is between 2.5 to 3.5 psi (17 to 24 kPa). Maximum operating pressure is 5 psi (34 kPa). A special low pressure tire gauge (ARGO Part No. 619-10) is available from your ARGO dealer. 7.2.7 TIRE REPAIR AND REPLACEMENT Repair a flat tire by removing the tire completely from the rim. Proper tire changing equipment is necessary to remove and remount the tire. Figure 7-18. Bearing Flange and Cork Gasket

Apply a radial tire patch on the inside of the tire over the puncture or hole. Remount the tire on the rim using ONLY WATER as a bead lubricant. Spoon the tire onto the rim to prevent tire bead area damage. THE TIRE MAY EXPLODE IF OVER-INFLATED. Place the tire and rim assembly in a protective cage to inflate and to seat the beads. Never inflate over 32 psi (220 kPa) to seat the bead. Once both beads are seated, deflate to 2.5 to 3.5 psi (17 to 24 kPa), 5 psi (34 kPa) maximum operating pressure. A special, low pressure tire gauge (ARGO Part No. 619-10) is available from your ARGO dealer. Replace badly worn or damaged tires with original equipment Goodyear tires. Consult your ARGO dealer if in doubt. Any other tires (size, type or tread pattern), will affect the skid steering characteristics of the vehicle.

Figure 7-19. Re-tightening bolts.

7.3 MECHANICAL BRAKES - 6x6 VANGUARD 7.3.1 GENERAL

ARGO track systems are designed for use ONLY with original equipment Goodyear Runamuk tires.

7.2.8 AXLE BEARING MOUNTING The axles are mounted to the Argo using special cork gaskets between the flanged bearings and the outside surface of the lower body (see Figure 7-18). During the initial run-in period, the gasket material may relax causing the nuts to loosen slightly. These should be checked and re-tightened after initial 8 hours of use and then after every 100 hours. See Figure 7-19.

To remove the firewall: 1. 2. 3. 4.

Remove the front floor pan. Turn the firewall release catches (located at the top right and left side of the firewall) counter-clockwise 1/4 turn. Pull both steering levers back, away from the dash as far as possible. Pull the top of the firewall back and lift it out of the vehicle.

SECTION 7 MAINTENANCE INFORMATION Mechanical brake inspection procedure

4. Adjust the other brake caliper assembly by repeating steps 1 to 3.

With the firewall removed, inspect both brake caliper assemblies.

Figure 7-21. Tightening the lock nut

7.3.3 BRAKE PAD REPLACEMENT During the inspection of all 4 brake pads, if they are: • worn to 3 mm (1/8") thickness as shown in Figure 7-22; • glazed and brake efficiency is affected; or • contaminated with lubricant and brake performance is affected; they are no longer serviceable and must be replaced.

Figure 7-20. Mechanical brake assemblies

7.3.2 BRAKE CALIPER ADJUSTMENT Adjust the calipers when:

• the brake adjustment nuts are tightened all the way but the steering lever travel still exceeds 7" or

• the total clearance between the brake pads and the brake disc exceeds .010". To adjust the brake calipers: 1. Tighten the lock nut with a 1/2" open end wrench, no wider than the thickness of the lock nut (Figure 7-21). As the lock nut is tightened, measure the clearance between the brake disc and pad as shown in Figure 7-22, using a .010" feeler gauge. .010" is the correct clearance between the left brake pad and the brake disc when the right pad is pressed against the disc.

Figure 7-22. Measuring the distance between the brake disc and brake pad.

SECTION 7 MAINTENANCE INFORMATION 5. If the distance from the dash is greater, refer to Section 7.3.4 STEERING LEVER ADJUSTMENT to properly set the left lever. To reinstall the firewall: 1. Pull both steering levers back, away from the dash as far as possible. 2. Position the firewall in the driving compartment. 3. Insert the bottom edge of the firewall in front of the retaining bracket. 4. Move the top of the firewall forward into position, aligning the two release catches.

Figure 7-23. Brake pad wear, mechanical brakes

7.3.4 STEERING LEVER ADJUSTMENT

5. Turn the two release catches clockwise 1/4 turn to lock.

Adjust the steering levers when: • steering levers travel more than 18 cm (7") from the dash to apply the brakes; • the levers are not parallel when the brakes are applied; or • the brake adjustment nuts have been removed during the removal of the firewall.

7.4 HYDRAULIC BRAKES - VANGUARD2, BIGFOOT, RESPONSE and CONQUEST 7.4.1 GENERAL Although the hydraulic brake system is self adjusting, the following require periodic attention:

7.4.2 BRAKE FLUID LEVEL

7.3.5 HOLDING BRAKE ADJUSTMENT

After every 50 hours of operation, check the brake fluid level through the side mounted view window in each master cylinder (Figure 7-24). The fluid level must be above the top of the view window.

Although the holding brake system has been factory adjusted, it should be checked after every 25 operating hours to ensure the correct adjustment.

If the brake fluid is below this level: 1. Thoroughly clean the master cylinder cover and surrounding area. 2. Remove the two cover screws, lift off the cover and the gasket.

The use of an improperly adjusted holding brake is a serious safety hazard, and could lead to vehicle damage or personal injury.

3. Add only fresh clean SILICONE - DOT 5 BRAKE FLUID (ARGO Part No. 126-19) to the correct level.

1. Pull the left steering lever back. 2. While holding the lever, lift the spring loaded brake lever until it contacts the pin in the steering lever.

4. Replace the cover on each master cylinder, making sure the rubber gaskets are properly seated before tightening the cover screws.

3. Release the steering lever, allowing the holding brake lever to lock the left brake on. 4. If the steering lever grip is approximately 18 cm (7") from the dash, the holding brake system is correctly adjusted.

• the brake lining material molded to each metal backing • •

Figure 7-24. Hydraulic brake cylinder and fluid level

plate is worn to 0.10" thickness. (Figure 7-26) the pads are glazed and brake performance is affected. the pads are contaminated with lubricant, and brake performance is affected.

To replace the brake pads:

Remove both cotter pins from each brake caliper. Remove each brake caliper from the transmission using a 5/16" hex driver to remove the two 103-41 SHCS mounting bolts accessible through the brake disc holes as shown in Figure 7-25. Without disturbing the connection of the hydraulic hose assembly, swing the caliper away from the brake disc to allow the removal of the brake pads as shown in Figure 7-27. Install the brake pads into the caliper assembly. Remount the caliper to the transmission, using #242 Loctite or equivalent removable compound on the threads of the 103-41 SHCS mounting bolts and tighten securely. Insert two new cotter pins and bend the ends over to secure the pads in position.

7.4.3 CHANGING BRAKE FLUID The inherent stability of Silicone DOT 5 Brake Fluid reduces the need for frequent brake fluid replacement. Inspect the fluid for degradation (discolouration or particles) during normal fluid level inspections. If discolouration has occurred, the brake fluid system should be drained, flushed and re-filled with fresh brake fluid. If particles are evident in the fluid, drain the system, overhaul the master cylinder and the brake caliper before flushing and refilling. An ARGO dealer will preform these operations for you.

Pump the steering levers a few times to build up proper pressure and to locate the pads in the caliper assembly. Check the steering lever travel and adjust if required.

Do NOT operate the ARGO with the firewall removed. 7.4.5 HOLDING BRAKE ADJUSTMENT

Figure 7-25. Hydraulic brake assemblies

The holding brake system has been factory adjusted to ensure proper braking effectiveness. However, before the vehicle is used for the first time, and after every 25 hours of operation, the adjustment of the holding brake must be inspected.

The use of an improperly adjusted holding brake is a serious hazard, and could lead to vehicle damage or personal injury. 1. Pull each steering lever back until you feel resistance. Figure 7-26. Brake pad wear, hydraulic brakes

2. While holding the levers back, push each holding brake handle down until it rests against the brake lever stop. 3. Check the distance between the holding brake stop on each steering lever and the holding brake adjusting screw. 4. If the distance is approximately 1/16" (1.6mm) the holding brake system is correctly adjusted. 5. If not, turn the holding brake adjuster screw in the direction required for correct distance.

If the holding brake system is too tight, excessive pressure in the brake system will damage the seals. Figure 7-27. Removing the brake pads from the brake caliper

If the vehicle is equipped with an enclosed cab of any sort, make sure there is plenty of ventilation to avoid exposure to exhaust and engine fumes. Engine exhaust contains carbon monoxide; an odourless, colourless toxic gas that will cause serious personal injury or death. Inspect the exhaust system periodically for worn or damaged components. Listen for a change in exhaust or engine noise that may indicate a dangerous exhaust leak. If a leak is detected, have the exhaust system repaired immediately before further use. Check the area around the exhaust system periodically for accumulated debris, particularly when traveling through dry vegetation. Failure to inspect and clean the exhaust system on a regular basis may create a fire hazard. The tail pipe exiting through the left side of the upper body becomes very hot when the vehicle is operated. DO NOT ALLOW ANYONE TO TOUCH THE EXHAUST COMPONENTS. A SEVERE BURN CAN RESULT.

An annual complete check over of your ARGO vehicle is recommended. This will reduce maintenance costs over the life of your vehicle and ensure it will function properly during use periods.

SECTION 7 MAINTENANCE INFORMATION BEFORE EACH USE

AFTER INITIAL 2hrs.

8hrs.

EVERY

20hrs. 10hrs. 25hrs. 50hrs. 100hrs. 250hrs.

SECTION REF.

CHECK COOLANT LEVEL (CONQUEST) X CHECK FAN BELT TENSION (CONQUEST) X CHECK FUEL LEVEL X 2.2 CHECK TIRE INFLATION X 7.2.6 CHECK TWIST GRIP THROTTLE OPER. X 2.2 CHECK STEERING LEVER TRAVEL X 2.2 CHECK ENGINE INTAKE/EXH. FOR OBSTR. X 2.2 CHECK THAT DRAIN PLUGS ARE IN PLACE X 5.6 CHECK ENGINE OIL LEVEL X 6.1.1 CHANGE ENGINE OIL & OIL FILTER - KAWASAKI X X 6.1.3 - BRIGGS & STRATTON X X 6.1.3 CHECK TRANSMISSION OIL LEVEL X X 6.2.1 CHANGE TRANSMISSION OIL X X 6.2.2 CLEAN AIR PRE-CLEANER X 6.3.1 CHECK CLEAN/REPLACE AIR FILTER X 6.3.1 REPLACE FUEL FILTER X 6.3.2 LUBRICATE DRIVEN CLUTCH X 6.4.2 SERVICE DRIVER & DRIVEN CLUTCH X 6.4.2 LUBRICATE DRIVE CHAINS X 6.4.3 REMOVE, CLEAN & LUBE. DRIVE CHAINS X 6.4.3 LUBRICATE IDLER CHAINS X 6.4.4 REMOVE, CLEAN & LUBE. IDLER CHAINS X 6.4.4 LUBRICATE AXLE FLANGE - OUTER CAVITY X 6.4.5 LUBRICATE AXLE FLANGE - INNER CAVITY X 6.4.5 LUBRICATE INNER AXLE BEARINGS X 6.4.7 LUBRICATE IDLER BEARINGS X 6.4.6 LUBRICATE STEERING LEVERS X CHECK BATTERY FLUID LEVEL & CAPS X 7.1.2 CLEAN BATTERY TERMINALS & CONNEC. X 7.1.2 CLEAN BATTERY X 7.1.2 CLEAN, ADJUST/REPLACE SPARK PLUGS X 7.1.4 CHECK THE DRIVE BELT X 7.2.1 CHECK NYLON SLIDERS - DRIVEN CLUTCH X 7.2.2 CHECK SLIDERS - CHAIN TAKE-UP SYSTEM X X X 7.2.4 CHECK & ADJUST IDLER CHAINS X X 7.2.5 SERVICE THE CLUTCH UNITS X 6.4.2 INSPECT BRAKE PADS X 7.3.1 ADJUST HOLDING BRAKE X 7.3.5 CHECK HYD. BRAKE FLUID LEVEL/COND. X 7.4.2 CHECK FUEL TANK CONNECTIONS/LINES X INSPECT WIRING HARNESS X TIGHTEN BEARING EXT. BOLTS X X 7.2.8 CLEAN OUT SPARK ARRESTER X 7.1.5 The intervals shown on the schedule are based on average operating conditions. Vehicles which are subjected to severe use and wet or dusty conditions will require more frequent servicing. Use only Argo replacement parts to ensure safe operation of the vehicle and to comply with the warranty coverage. We strongly recommend that an Argo Dealer perform a complete check-over of your vehicle after the initial 20 hours of operation, then once each year. This will reduce maintenance costs over the life of your vehicle.

SECTION 8 TROUBLE SHOOTING MALFUNCTION (SYMPTOM)

PROBABLE CAUSE

CORRECTIVE ACTION

Electric starter inoperative

1. Loose electrical connections

1. Clean and re-tighten electrical connections 2. Recharge battery or replace as necessary 3. Return the vehicle to an Argo dealer for servicing

2. Battery charge low or dead 3. Faulty starter motor

Engine turns over but will not start

Engine will not run Vehicle will not move or turn

Vehicle pulls to right

1. Right tire pressure too low 2. Left tire pressure too high 3. Right brake engaged

4. Right side drive chain broken Vehicle pulls to left

1. Pull out the choke and try to start again 2. Refill tank 3. Remove obstruction or replace filter as necessary 4. Adjust as detailed in the engine manufacturer’s manual 5. Clean and re-gap or replace 6. Have unit serviced by a properly trained and equipped mechanic 7. Take the vehicle to a factory authorized engine repair outlet 8. Check that electric fuel pump is operating. Make sure fuel shut off solenoid is activated to allow fuel into carburetor.

1. See “Vehicle pulls to right” substitute right with left

SECTION 8 TROUBLE SHOOTING MALFUNCTION (SYMPTOM)

PROBABLE CAUSE

CORRECTIVE ACTION

Severe vibration when vehicle is operated

1. Engine loose on mounts

1. Take vehicle to an Argo dealer for service. 2. Same as above.

2. Driver or driven clutch or engine defective 3. Axle bent 4. Wheel rim bent 5. Worn or damaged drive belt

Water leaks into lower body

Tire leaks air

2. Tire is not properly seated on bead

3. Position of air leak is not obvious

4. Defective valve Hydraulic brakes are spongy, or there is excessive steering lever travel

1. Air in hydraulic system 2. Leak in system

3. Loose brakes Brakes ineffective

1. Pads have overheated and glazed 2. Pads worn beyond 0.10" 3. Pads are contaminated with lubricant

There is a loud bang when the vehicle is turned right or left

1. Idler chains worn/loose 2. Drive chains worn/loose

3. Remove and straighten or replace. 4. Replace. 5. Replace. Clutch service may be required. 1. Replace the bearing flange gaskets. 2. Replace the bearing flange seal. 3. Caulk under 103-81 bolt heads with silicone sealer. 4. Repair or replace vehicle lower body 5. Secure drain plugs. 1. Remove tire from rim and repair the hole with a radial tire patch or install a tube in the tire. 2. Deflate tire and carefully push tire bead off the rim. Clean the rim bead area to remove dirt and foreign matter. Re-inflate tire. 3. Submerge tire and rim in a water tank. Air may be escaping through the rim halves or the valve stem. Repair as required. 4. Replace defective valve. 1. Have an Argo dealer bleed the brake system and add fluid. 2. Have an Argo dealer check all fittings, hoses, calipers and seals for loose connections or leakage. Refill as needed. 3. Adjust or tighten. 1. Have the pads cleaned by an Argo dealer or replace pads. 2. Replace. 3. Have the pads cleaned by an Argo dealer or replace pads. 1. Adjust/replace idler chains as required 2. Adjust/replace drive chains as required

SECTION 9 CLEANING AND STORAGE 9.1 CLEANING THE VEHICLE

Prepare the Battery for Storage

Remove the battery from the vehicle. Clean it and charge it with a battery charger. Coat the battery terminals with a multipurpose grease to prevent corrosion. Store the battery in a cool dry place.

9.2 STORING THE VEHICLE

Do not store the battery near flames, sparks or any source of fire. Batteries can explode if exposed to flames or sparks, causing serious personal injury.

When the vehicle is stored for an extended period, the following preparation is required:

Recharge the battery monthly. Clean the Vehicle Protect the Electrical System Remove all dirt and water from the vehicle body as directed above.

Spray the wiring harnesses and all the electrical connections with a silicone based lubricant (WD40 or equivalent) to prevent corrosion.

Remove the drain plugs if the vehicle is not fully sheltered from the elements.

Carefully inspect the wiring for loose connections, bare wires or corrosion. Repair as necessary. Raise the Vehicle

Any water accumulation in the vehicle will, over time, destroy chains, sprockets and bearings. Grease all bearings and flanges (refer to Section 6.4.5).

Place blocks under the front and rear of the vehicle to raise the tires off the ground. The blocks must be placed under the frame members to prevent body damage (Figure 9-1).

Bearing corrosion due to inadequate preparation for storage is the leading cause of premature bearing failure. Drain the Fuel System Insert a siphon hose into the gas tank through the filler neck and drain the gasoline. Start the engine and run it until all fuel in the system is consumed.

Figure 9-1 Correct placement of blocks

Preparing the Engine for Storage

Read the engine operatorâ&#x20AC;&#x2122;s manual and carry out all recommended storage procedures.

Add fuel stabilizer (ARGO Part No. 125-85) to the fuel tank and fill with fresh gasoline. Run the engine for a few minutes to allow the treated fuel to reach the carburetor.

SECTION 10 POTENTIAL HAZARDS POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operating the Argo without reading and understanding the Operator’s Manual

The risk of accident is greatly increased if the operator does not know how to operate the Argo properly in different situations and on different types of terrain.

New or inexperienced operators should read and understand the Operator’s Manual. They should then regularly practice the operating techniques described in this Operator’s Manual.

Allowing anyone under age 16 to operate this vehicle.

Children under the age of 16 may not have the skills, abilities, or judgement needed to operate the Argo safely and may be involved in an accident causing severe injury or death.

No one under the age of 16 should be allowed to operate the Argo.

Operating or riding as a passenger in the Argo without wearing an approved motorcycle helmet, eye protection, and protective clothing.

Operating or driving without an approved motorcycle helmet increases the chance of severe head injury or death in the event of an accident. Operating or driving without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.

Wear an approved safety helmet and eye protection when driving or riding in the vehicle.

Operating the Argo after or while consuming alcohol or drugs.

Could seriously affect your judgement, cause you to react more slowly, and affect your balance and perception. This could result in an accident.

Never allow anyone under the influence of alcohol or any other intoxicating substance to drive or ride in the vehicle. Never use with drugs or alcohol.

Carrying passengers in Riders can fall off and be killed. the dump box.

No riders in the dump box.

Carrying cargo when using the Argo in water.

Argo vehicles may sink if they fill with water, resulting in injury or drowning to driver and passengers. If the vehicle upsets or swamps, exposure in cold water significantly reduces the chance of survival.

Be especially cautious when operating a loaded vehicle (cargo and/or passengers) in water. Observe the capacity limits. Do not enter water if the vehicle is overloaded. Use extra caution when operating the Argo in cold water.

Carrying cargo in the dump box when used in water.

Greatly reduces your ability to balance and control the Argo in the water. Could cause an accident, including capsizing and sinking, resulting in injury or drowning to driver and passengers.

Do not exceed the rated capacity of the dump box equipped Argo when used in water.

Operating the Argo in water without drain plugs properly installed.

Always make sure the drain plugs are properly Will cause the vehicle to fill with water and cause it to capsize or sink, which could result in installed in the Argo as described in the Operator’s Manual. injury or drowning to driver and passengers.

Using the Argo to tow anything in the water other than an Argo amphibious trailer.

Greatly reduces your ability to balance and control the Argo in the water. Could cause an accident, including capsizing and sinking, which could result in injury or drowning to driver and passengers.

Never tow anything other than an Argo amphibious trailer when the Argo is used in water. Keep cargo low and centered in the trailer, especially if used in water.

Operating the Argo in rough water.

Greatly reduces your ability to balance and control the Argo in the water. Could cause an accident, including capsizing and sinking, which could result in injury or drowning to driver and passengers.

Do not attempt to navigate any body of water with a strong current. Avoid water operation under windy conditions. Do not attempt to cross large bodies of water. Stay close to shore in case of emergency and you have to leave the water.

SECTION 10 POTENTIAL HAZARDS POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operating or driving the Argo in water without the occupants wearing an approved personal flotation device (PFD).

If you lose control of the Argo in water and it capsizes and sinks, the driver and passengers may be injured or drown.

Operating the Argo in water without taking along a paddle.

Equip the vehicle with a paddle and bailing can. If you run out of gas or have an engine failure the Argo will not be able to move under itâ&#x20AC;&#x2122;s own power and you may be stranded.

Failure of driver and Water may enter the vehicle and cause it to capsize or sink, which could result in injury or passengers to adjust drowning to driver and passengers. positions so that the vehicle is floating level when operating the Argo in water.

All occupants must wear an approved personal flotation device (PFD) or life jacket while travelling in water.

When using the Argo in water, adjust the position of cargo and passengers so the vehicle floats level.

Failure to enter the water correctly.

You may cause waves, which will enter the Argo and cause it to capsize or sink, which could result in injury or drowning to driver and passengers.

The point of entry should be free of rocks, stumps and other obstacles. Enter the water from a firm, gradual slope whenever possible. Be careful not to submerge the bumper as you enter the water.

Carrying more than specified number of people in an Argo, either on land or in water.

Greatly reduces ability to balance and control the Argo on both land and in the water and could cause an accident, resulting in injury or death to driver and passengers.

Never exceed the load capacity of the Argo: 6x6 - Land-4 people/317 kg (700 lbs.) - Water-2 people/158 kg (350 lbs.) 8x8 - Land-6 people/454 kg (1000 lbs.) - Water-4 people/317 kg (700 lbs.)

Overloading the vehicle.

Heavy loads and high loads decrease the stability of the vehicle and may cause it to roll.

Follow the recommended load capacity for your vehicle listed in Section 1.

Exceeding the weight limitation will decrease the stability of the vehicle on inclines and increase the possibility of rolling over backwards when climbing a grade.

The rear compartment capacity of all 6 wheel Argo vehicles is 65 kg (140 lbs). Do not exceed this weight in the rear compartment.

Failure to fasten seat If the Argo overturns, the driver and passengers Seat belts must be properly adjusted and worn belts if the Argo is may be thrown from the vehicle and the roll bar by all occupants at all times EXCEPT when equipped with rollover or roll cage could strike them. operating in water. protection. Do not use seat belts or any passenger restrainFailure to unfasten seat If the Argo capsizes or sinks the driver and belts (if the Argo is so passengers may be unable to unfasten their seat ing device while operating an Argo in water. belts and may drown. equipped) when the vehicle is in water. Always inspect your Argo each time you use it Failure to inspect the Increases the possibility of an accident or to make sure it is in safe operating condition. Argo before operating. equipment damage. Always follow the inspection and maintenance Failure to properly procedures and schedules described in this maintain the Argo. Operatorâ&#x20AC;&#x2122;s Manual.

SECTION 10 POTENTIAL HAZARDS POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operating the Argo with improper tires or with improper or uneven tire pressure.

Use of improper tires on the Argo, or operation of the Argo with improper or uneven tire pressure may cause loss of control increasing your risk of an accident.

Always use the size and type tires specified in this Operatorâ&#x20AC;&#x2122;s Manual for this Argo. Always maintain proper tire pressure as described in this Operatorâ&#x20AC;&#x2122;s Manual.

Operating the Argo with improper modifications.

Improper installation of accessories or modification of the Argo may cause changes in handling which in some situations could lead to an accident.

Applying brakes suddenly when going downhill.

Sudden braking can cause the vehicle to roll over forward.

Never modify the Argo through improper installation or improper use of accessories. All parts and accessories added to this Argo should be genuine Argo components designed for use on the Argo and should be installed and used according to instructions. If you have questions, consult an authorized Argo dealer or contact Ontario Drive & Gear Limited at 1-519-6624000 Gently apply the brakes to control downward vehicle speed. Do not jam on the brakes while travelling downhill.

Operating the Argo on Pavement may seriously affect handling and control. paved surfaces.

Do not drive your vehicle on asphalt or concrete roadways.

A collision can occur with another vehicle. Operating Argo on public streets, roads or highways.

Never drive on public roads.

Operating at excessive Personal injury or vehicle damage may result. speeds.

Do not drive the vehicle at high speeds over unfamiliar or rough terrain. Never operate at speeds too fast for your skills or the conditions.

Failure to use extra Personal injury or vehicle damage may result. care when operating the Argo on unfamiliar terrain. Could cause loss of traction or vehicle control, Failure to use extra care when operating on which could result in an accident, including an overturn. rough, slippery or loose terrain. Turning improperly. When turning, the back of the vehicle swings to the opposite direction of the turn, creating a risk of hitting persons or objects. Sharp turns, especially at high speeds or when heavily loaded, may cause the vehicle to roll over.

Do not drive the vehicle at high speeds over unfamiliar or rough terrain.

Driving on inclines with a loaded vehicle.

Heavy loads and high loads decrease the stability of the vehicle and may cause it to roll.

Going downhill improperly.

Sudden braking can cause the vehicle to roll over forwards.

Use extreme CAUTION when negotiating inclines with a loaded vehicle. Be prepared to shift occupant weight and load forward or have passengers get out of the vehicle to walk up an incline. Avoid steep declines when possible. When a steep decline cannot be avoided, shift occupant weight to the rear of the vehicle to prevent the vehicle from rolling over.

Do not operate on rough, slippery or loose terrain until you have learned and practised the skills necessary to control the Argo on such terrain. Always take precautions when making turns to avoid rolling the vehicle or hitting persons or objects. Slow the vehicle down before making a turn. Do not apply the brakes too suddenly.

SECTION 10 POTENTIAL HAZARDS POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Improperly crossing Side slope operation greatly increases the risk of Do not drive your vehicle across the side of a hills or turning on hills. rolling the vehicle over sideways. hill. Prolonged side slope operation may cause Observe the engine angle of operation limitaengine damage. tions in Section 5.2. Stalling or rolling backwards while climbing a hill.

Could cause loss of control which could lead to an accident including an overturn.

Improperly operating over obstacles.

Personal injury or vehicle damage may result.

Skidding or sliding.

Improperly operating in reverse.

Try to avoid steep hills. Maintain steady speed when climbing a hill. If you lose all forward speed: - keep weight uphill - lean toward the hill - pull back on both control levers to apply brakes. - slowly coast backwards down the hill using the control levers

Before operating in a new area, check for obstacles. Never attempt to drive over large obstacles such as large rocks or fallen trees. When you go over obstacles always follow proper procedures as described in this Operatorâ&#x20AC;&#x2122;s Manual. You may lose control of the Argo. You may also Learn to safely control skidding or sliding by regain traction unexpectedly which may cause practising at slow speeds and on level, smooth the Argo to overturn. terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. You could hit an obstacle or person behind you Carefully practice backing up and turning in an resulting in serious injury. open area until you become accustomed to this procedure. Take precautions to avoid hitting persons or objects.

Use of the holding brake as a parking brake.

The holding brake system is not a parking brake, and therefore is not designed to hold the vehicle in place for long periods of time. The holding brake is for short term use only. The hydraulic brake pressure could drop over time, releasing the brakes, allowing the vehicle to roll into persons or objects, causing serious injury.

Using the firewall to brace your knees.

Damage to the firewall and serious personal Do not push against the firewall with your injury can result from the driven clutch wearing knees. through the firewall.

Running the engine in a closed building or confined area.

Engine exhaust gases contain poisonous carbon Never start or run the engine in a closed monoxide. Carbon monoxide is odourless, building or confined area. colourless and can cause serious injury or death.

Adding fuel while the engine is running or hot.

Gasoline is extremely flammable and can explode under certain conditions, causing serious injury or death.

Filling outboard motor Gasoline is extremely flammable and can fuel tanks while they explode if ignited, causing serious injury or are in the Argo. death.

When parking on an incline, engage the holding brake levers, leave the vehicle in gear, turn the engine off and block the vehicleâ&#x20AC;&#x2122;s wheels.

Do not add fuel while the engine is running or hot. Fill outboard motor fuel tanks outside of the vehicle. Wipe up any spilled fuel immediately. Do not carry or store fuel tanks in a vehicle equipped with a cab or convertible top unless adequate ventilation is provided.

SECTION 11 ACCESSORY INFORMATION 11.1 GENERAL This section deals with accessories that have been specifically designed for the ARGO and can be purchased separately from your dealer. Special operating procedures and safety precautions must be observed before operating or using certain accessories.

11.2 CARGO TIE DOWNS (Part No. 614-06) Temperature changes will cause the segments to expand or contract and will also change the tire pressure. In order to maintain suitable tension on the track system, observe the following precautions:

• If the track-equipped vehicle is stored in a warm area, al•

Never attempt to raise the vehicle by using the tie down rings as lifting points.

•

Never exceed gross vehicle weight. Never exceed the maximum rear compartment weight for 6-wheelers (65 kg/140 lbs.).

ways allow the tires and tracks to reach the outdoor temperature and re-check tire inflation before use. Do not over-inflate tires (3 p.s.i. max.). Damage to the lower body could result from the track segments rubbing against the lower body. Pay special attention to the tracks during the first few hours of use. During this time the tracks may become loose/slack, start touching the lower body or the tires may slip inside the tracks. If this occurs check tire pressure. DO NOT INFLATE OVER 3 psi. REMOVE THE HALF SEGMENT OF EACH TRACK IF REQUIRED TO REDUCE SLACK.

11.3 ARGO TRACK SYSTEMS (Standard Track - Part Nos. 615-25 & 815-25, Super Track - Part Nos. 625-00, 625-35 & 825-00) Over-inflating the tires will cause excessive and premature wear of the tires and the Argo track system. Overinflation may also cause axle and/or bearing damage. Under-inflation of the tires may allow them to slip in the tracks or may lead to the unseating of the tire bead from the wheel rim. The tires may climb out of the track system during a turn or on side slope operation. Check that all tires are correctly inflated. Avoid sharp, high speed turns when the Argo is heavily loaded.

There are two different types of track systems available for use with the Argo, the standard track system and Super Track. Standard tracks and Super Tracks are similar in basic design and use the same pins and lock collars to join the segments together. However, Super Tracks are wider than standard tracks. The track systems spread the weight of the vehicle over a larger area than the tires, thereby reducing the ground pressure and allowing the vehicle to stay on top of, rather than sinking into, soft terrain.

11.3.1 Operating Precautions An Argo equipped with tracks has a reduced carrying capacity in water. Tracked 6 wheel models have a 120 kg/264 lbs. capacity. Tracked 8 wheel models have a 270 kg/589 lbs. capacity. Refer to Section 5.6 of this manual for additional information on safe operation in water.

The segmented track design allows the replacement of only those segments that may have become damaged or worn with use.

SECTION 11 ACCESSORY INFORMATION 11.4 ICE CLEAT KIT (Part Nos. 625-20 & 825-20) CAUTION should be observed when operating in winter conditions and a drop in temperature occurs. Snow and slush accumulation in the track could freeze, resulting in damage to the track system. Slush, snow and ice accumulation should be cleared from the axles and track periodically to prevent build-up.

ARGO ice cleats are stamped steel cleats that bolt to the outer edges of the Super Track segments to grip on hard pack snow and ice to improve traction and stopping.

EXTREME CAUTION must be observed when using the track systems on icy surfaces. Steering and braking effectiveness will be reduced. Reduce speed.

11.5 OUTBOARD MOTOR BRACKET (Part No. 617-00) The outboard motor bracket accepts gasoline or electric outboard motors of up to 9.9 horsepower. Long shaft models are recommended to avoid cavitation during operation. When selecting an outboard specifically for the Argo, consider a lightweight 4 to 5 h.p. model for ease of handling, installation and adequate propulsion. When traveling on land it is recommended that the outboard motor be transported safely in the rear compartment of the Argo.

11.3.2 Standard Tracks Standard Tracks are intended to extend the use of the Argo so that it can be driven over softer terrain conditions such as mud, swamp, muskeg and snow. The standard track system is well suited for a wide variety of terrain conditions. However, for deep snow conditions, the Super Track system will outperform the standard track system.

Deformation of the body components adjacent to the outboard motor bracket may occur when outboard motors are left installed in hot temperatures. Caution should be observed when turning an outboard motor equipped Argo on land. Since the rear of an Argo swings sideways during a turn, the motor could strike a person or object causing injury or damage.

11.3.3 Super Tracks Super Tracks provide the maximum â&#x20AC;&#x153;flotationâ&#x20AC;? available for the Argo. They are very effective in deep snow, swamp and muskeg. Care must be used while traveling over uneven ground conditions. The extra width of the segments can lead to the segments tipping to one side on the tire to such an extent that the tire guide forces the tire bead off the rim. SUPER TRACKS ARE NOT RECOMMENDED FOR TRAVEL OVER LOGS, STUMPS OR ROCKS.

SECTION 11 ACCESSORY INFORMATION 11.6 OUTBOARD MOTOR SUPPORT (Part No. 618-00) Damage may result to the cover if the vehicle is transported at highway speeds with the cover in place. If the cover must be used while transporting the vehicle, damage may be minimized by placing padding over sharp corners such as the tail pipe or the winch and tying the cover securely in place against the Argo body.

11.9 POWER WINCH (Part No. 622-40 & 622-70 ) The power winch mounts to the front of the Argo and can be used for self-recovery and to raise and lower the snowplow blade (Part No. 657-00). The winch has a free-wheeling feature that allows the cable to be pulled off the winch drum without using the 12 volt electric motor.

11.7 OUTBOARD MOTOR BRACKET - SIDE MOUNT (Part No. 618-10 ) The side mount outboard motor bracket attaches to the right rear of any Argo model. It allows the attachment of a gasoline or electric outboard motor of 9.9 horsepower maximum. When traveling on land it is recommended that the outboard motor be transported in the rear compartment of the Argo.

The electrical components and the wiring design of the winch kits prevent the use of the winch motor unless the ignition key is turned to the â&#x20AC;&#x2DC;onâ&#x20AC;&#x2122; position. This is a safety feature that prevents the unauthorized use of the winch when the vehicle is parked. After the installation of the winch kit is completed, test the electrical connections by moving the toggle switch control from side to side with the ignition switch removed. If the winch DOES NOT operate the connections are correct. If the winch starts during this test have the installer correct the wiring connections immediately.

Use caution when turning in confined spaces or close to bystanders. Personal injury or damage may result.

11.9.1 Rules For Safe Operation 1. The X2 winch is rated at 3,000 pounds (single-line) capacity. DO NOT OVERLOAD. DO NOT ATTEMPT PROLONGED PULLS AT HEAVY LOADS. DO NOT MAINTAIN POWER TO THE WINCH IF THE MOTOR STALLS. Overloads can damage the winch and/or the wire rope and create unsafe operating conditions. For heavy loads, we recommend the use of the optional pulley block and hook assembly (Superwinch Part No. 1503) to double line the wire rope. (Figure 11-2) This reduces the load on the winch and the strain on the wire rope by approximately 50%.

Figure 11.1 Warning Label 618-21

11.8 ARGO STORAGE COVERS (Part Nos. 621-10; 621-20; 821-10 & 821-20 ) The Argo storage covers prevent debris, rain water or snow from accumulating in the Argo. Secure the cover by pulling it down over the bumper and tying the cord tightly in place. A cord or tie strap through the side grommets and under the vehicle lower body securely holds the cover in place in windy conditions.

SECTION 11 ACCESSORY INFORMATION

Figure 11-2 Double Line

2. Periodically check the winch installation to assure that all bolts are tight.

Figure 11.4 Incorrect and correct hook-up

3. DO NOT “move” your vehicle to assist the winch in pulling a load. The combination of the winch and vehicle pulling together could overload the wire rope and the winch itself.

It is a good idea to lay a heavy blanket or jacket over the wire rope near the hook end when pulling heavy loads (Figure 11.5). If a wire rope failure should occur, the cloth will act as a damper and help prevent the rope from whipping.

Figure 11-5 Using a cloth damper

10. Your winch is not designed or intended for overhead hoisting operations. Never use your winch for lifting or moving people.

6. USE HEAVY LEATHER GLOVES when handling wire rope. Do not let wire rope slide through your hands. A broken strand could seriously injure your hands.

11. Avoid continuous pulls from extreme angles as this will cause the wire rope to pile up at one end of the drum (Figure 11-6). This can jam the wire rope in the winch causing damage to the wire rope or the winch itself.

7. Keep clear of winch wire rope and hook when operating winch. Never put your fingers through the hook when reeling in the last few feet of line. If your finger should become trapped in the hook, you could lose your finger. Use the HANDSAVER BAR (Figure 11.3) to guide the hook within the last few feet. Never guide a wire rope onto the drum with your hand.

Figure 11-6 Correct and incorrect positioning for continuous pulls.

12. Always operate the winch with an unobstructed view of the winching operation.

Figure 11.3 Using the Handsaver Bar

8. NEVER HOOK THE WIRE ROPE BACK ONTO ITSELF. Use a nylon sling. Hooking the wire rope onto itself can damage the rope (Figure 11.4).

13. Do not operate the winch when under the influence of drugs, alcohol or medication. 14. Never work on or around the fairlead or winch drum when the winch is under load.

SECTION 11 ACCESSORY INFORMATION 15. When using your winch to move a load, place the vehicle transmission in neutral, set vehicle parking brake, chock all wheels, and keep the engine running.

(1)

This is the start of a kink. At this time, the wire rope should be straightened.

(2)

The wire rope was pulled and the loop has tightened to a kink. The wire rope is now permanently damaged and must be replaced.

(3)

The result of kinking is that each strand pulls a different amount, causing the strands under greatest tension to break and reduce load capacity of the wire rope. The wire rope must be replaced.

Keep a tightly and evenly wound wire rope drum. Do not allow the wire rope to become loosely wound. A looselywound spool allows a wire rope under load to work its way down into the layers of wire rope on the drum. When this happens, the wire rope may become wedged within the body of the windings damaging the wire rope. To prevent this problem, keep the wire rope tightly and evenly wound on the drum at all times. During winching, periodically check to see that the wire rope is winding on evenly. A good practice is to rewind the wire rope under tension after each use. One way to do this is to attach the hook to a stationary object at the top of a small hill or incline and winch your vehicle up the incline.

11.10 REAR MUD FLAP KIT

11.11 TRAILER HITCH KIT (Part No. 626-10) The trailer hitch kit is optional for the Vanguard models and is standard on all other models. It mounts at the rear of the Argo. Maximum tongue weight is 100 lbs./45 kgs. Maximum pull weight is 800 lbs./364 kgs. 11.12 BILGE PUMP KIT (Part No. 638-25)

Use a pulley block for heavy loads. To maximize winch and wire rope life, use a pulley block (Superwinch Part No. 1503) to double line heavier loads.

The pull required to start a load moving is often much greater than the pull required to keep it moving. Avoid frequent stopping and starting during a pull.

Prevent kinks before they occur.

(Part No. 625-10)

The bilge pump kit features a 12 volt, 500 gallon per hour pump to empty water from the lower body. Operated by a dash mounted push/pull switch, the bilge pump is recommended for any amphibious use of an Argo.

The pump is not designed to run dry. Use only when water has collected in the lower body.

SECTION 11 ACCESSORY INFORMATION 11.13 HANDRAIL KITS (Part Nos. 639-20 & 839-20) Handrails mount to the top of the upper body around the rear compartment, providing a convenient passenger hand hold or cargo tie down point.

Do not attempt to lift the vehicle by using the handrails.

The following decal should be attached to the inside of the windshield:

11.14 TOW HOOK KIT (Part No. 642-00) The tow hook kit is a steel fabrication that bolts securely through the bumper and both body halves at the front or rear of the vehicle.

The tow hook is not intended to secure an Argo to a trailer or truck bed. Body deformation could result from a downward pull. 11.15 WINDSHIELD (Part No. 648-75) The windshield features an anodized aluminum frame with rubber mounted 24" high x 48" wide laminated safety glass. It mounts to the top of the dash area of any Argo model, folds down and secures in place over the hood and is required for the convertible top.

If this decal is not attached to the windshield, contact your Argo retailer for a free-of-charge replacement. The part number is 126-84. 11.16 CONVERTIBLE TOP (Part No. 649-33, 649-50 & 849-50)

DO NOT transport the Argo at highway speeds with the windshield upright. For transportation at highway speeds, it is recommended that the vehicle be reversed on the truck or trailer so that the front of the Argo faces to the rear. The windshield should be folded down and secured in place using a rope or a tie down strap.

Never fold the clear plastic windows; always roll them up to store them in place on the top assembly or remove them. To fold the convertible top for storage, unzip the side and rear doors and the side panels, lay them aside and unsnap the domes along the front of the roof panel from the windshield frame. Fold the aluminum top frames together and roll the overhead panel around the frames loosely. Then, roll the window panels around the top material so the boot will cover the complete assembly for protection.

SECTION 11 ACCESSORY INFORMATION 11.17.1 Alternator Kit for Conquest (Part No. 850-40) Check the V-belt tension frequently to be sure belt deflection is no more than 1/8" or 3 mm with approximately 6 lbs. or 3 kgs of force applied to the belt, halfway between the pulleys. Adjust the belt tension as necessary. Failure to do so will reduce the charge rate and lead to battery failure.

11.18 SNOW PLOW KIT (Part No. 657-13) The snow plow assembly attaches to the front of the Argo at two mounting brackets that bolt to the front axle bearing extension housings. The plow blade is raised and lowered by operating the power winch in and out.

Hearing protection is strongly advised when operating the vehicle equipped with any convertible top assembly. The following decal should be attached to the inside of the windshield:

If this decal is not attached to the windshield, contact your Argo retailer for a free-of-charge replacement. The part number is 126-84.

The Argo four wheel amphibious trailer is designed as an additional cargo carrier for any Argo model. It is not intended for the transportation of people. Trailer load capacity is 600 lbs or 270 kgs at a recommended tire pressure of 4 psi.

11.17 ALTERNATOR KITS (Part No. 650-60 & 850-60 for the Vanguard, Vanguard2, Bigfoot & Response/Part No. 850-40 for the Conquest)

11.19.1 Operating Precautions

The externally mounted, belt driven, 40 amp alternator is recommended when electrical accessories such as a winch are added to the vehicle.

Keep cargo low and centered in the trailer, especially if used in the water. Secure the load in place to keep it from shifting when traveling in uneven terrain. Avoid sudden stops when towing the trailer downhill to prevent the trailer from colliding with or passing the Argo.

Do not step on or place loads on the edge of the body over the trailer wheels. This area of the trailer body is intended only as a mud guard. Follow the instructions listed in Section 6.4.5 of this manual to service the axle bearings. Do not allow water and debris to accumulate in the bottom of trailer body to avoid premature bearing failure.

SECTION 11 ACCESSORY INFORMATION

Keep fingers clear of tongue swiveling components.

11.20 HEATER KIT - Conquest (Part No. 848-10) The heater kit includes a conventional automotive style hot coolant heater core with 2 speed fan to circulate the warm air through the ducts to the right side of the driver’s compartment and the windshield. In some operating conditions, ie. high humidity or full passenger load, defrosting the windshield and side panel windows may not be effective. When the heater is not required, the heater valve should be closed, diverting all of the coolant through the engine radiator. In extremely cold weather and operating at low load, the heater may perform like a second radiator and keep the engine from reaching proper operating temperature. Under these conditions, a piece of cardboard or similar material should be used to partially cover the engine radiator.

DO NOT use the ROPS as an attachment point for towing or winching the Argo. Check fastener tightness annually. Inspect for and replace any damaged or worn parts of the ROPS and the seat belts.

The 850-40 Alternator is essential to provide the electrical power to operate the heater fan and maintain the battery charge rate.

11.22 REAR BENCH SEAT (Part No. 849-60) This bench seat assembly is similar to the front bench seat design, providing a back rest and more comfort for two persons riding in the rear compartment of any current Argo 8 x 8 model. The seat cushion and back rest are easily removed to use the rear compartment for cargo.

11.21 ROLL OVER PROTECTIVE STRUCTURES (Part Nos. 848-40-2, 848-40-4 & 648-40) Roll Over Protective Structures (ROPS) are designed for use on all Argo models. Part No. 848-40-2 provides roll over protection and lap belts for the driver and front seat passenger of all Argo 8 x 8 models. Part No. 848-40-4 provides roll over protection and lap belts for driver, front seat passenger and two passengers in the optional rear bench seat (Part No. 84960). Part No. 648-40 provides roll over protection and lap belts for driver and front seat passenger of all Argo 6 x 6 models.

Always ensure that the spring loaded pull pin (Part No. 849-72) on each side is fully engaged after installing the seat. Pull the seat hard to ensure that it is secured properly. Never attach a tow line to the handrail of the seat back rest. When a roll over protection structure (ROPS) is installed, seat belts must be installed for rear bench seat passengers and used properly.

The ROPS design provides reasonable protection from injury in the event of a rollover. DO NOT rely on it to protect the occupants from irresponsible driving. The ROPS has been designed to meet the requirements of the Occupational Health and Safety Act - Regulation 856 ‘RollOver Protection Structures’ for the Province of Ontario, Canada.

SECTION 11 ACCESSORY INFORMATION Never attach anything to the Roll Bar other than Ontario Drive & Gear 648-15 Roll Bar specific accessories. The Roll Bar reduces vehicle stability. Always use common sense when traveling over rough terrain. The Roll Bar is designed to reduce the chance of injury. DO NOT rely on it to protect the vehicle occupants from irresponsible driving. The Roll Bar could come in contact with tree branches. Falling branches or vehicle upset could occur. Use extreme caution when traveling on narrow tree lined trails. DO NOT use the Roll Bar as an attachment point for towing or winching. Check the torque of the Roll Bar nuts and bolts annually and replace any parts that are damaged. When the Roll Bar is installed, never carry more than two people in the Argo. Replace worn or damaged seat belt straps and buckles.

11.23 DUMP BOX KIT (Part Nos. 835-00 & 835-01) The dump box kit can be installed on any Argo 8 x 8. It improves the load carrying versatility of the Argo.

Keep hands and arms clear when lowering box. No riders in box; riders can fall off and be killed Installation of dump box reduces vehicle capacity; On land: 408kg (900lbs) On water: 227kg (500lbs) (Capacity includes: occupants, cargo and fuel) Tie loads down. Spread loads evenly. Operators should use caution when turning in confined spaces and close to bystanders. The dump box decreases the rear clearance of the Argo. Never operate dump while moving. Operate dump on level ground only. The dump box decreases the vehicle stability. Operate the vehicle with extra precautions when on uneven terrain and in water.

Failure to comply with the above could result in personal injury or death. 11.25 12V Accessory Outlet Kit (Part No. 633-25) The 12V Accessory Outlet Kit contains a 12V outlet, wire harness complete with in-line fuse holder & fuse, and the necessary hardware to mount the outlet in the upper body of any Argo model. When mounting the outlet, be sure to select an area within reach for the wire harness. The wire harness gets connected directly to the battery terminals so any mounting location chosen, must allow the harness to reach both the outlet and the battery. When mounting, be sure that the wire harness is securely clipped into place and not left dangling near moving parts within the engine compartment.

Note: Frequent use of the powered dump box will result in battery drain. The installation of an alternator kit is strongly suggested. 11.23.1 Dump Box Operating Guidelines 1. 2. 3.

Because the outlet is wired directly to the battery, it is constantly "live," even without the key turned on. Excessive use will run down the battery.

11.24 ROLL BAR KIT (Part No. 648-15) The roll bar is designed for use on all Argo 6 x 6 models. The roll bar provides some roll over protection and lap belts for the driver and front seat passenger.

This outlet is NOT designed to support nor should it be used as a cigarette lighter socket.

ARGO New Vehicle Limited Warranty The warranty period is limited to 12 months from the date of retail sale, with the following exceptions: Engine - 24 months from the date of retail sale separately by the engine manufacturerâ&#x20AC;&#x2122;s service network Exide Battery - 12 months free replacement from the date of retail sale by the battery manufacturerâ&#x20AC;&#x2122;s service network, 25 months total warranty, pro-rated Tires - 3 months from the date of retail sale Ontario Drive & Gear Limited hereby warrants to the original retail purchaser that each new and unused ARGO is free from any defect in material or workmanship for the warranty period specified, under normal use and service by the original purchaser. This warranty is void unless a Warranty Registration Form 670-11 and Pre-Service Checklist Form 670-11 have both been properly completed and returned to Ontario Drive & Gear Limited within 10 days of the date of retail sale. This warranty is not transferable unless an application of transfer has been approved by Ontario Drive & Gear Limited and a new warranty card has been issued. This warranty shall not apply to used or demonstrator ARGOs or to such units delivered to a distributor or dealer more than 12 months before its retail sale, unless a warranty validation is obtained from Ontario Drive & Gear Limited by written notice specifying the vehicle in question. This warranty is void immediately upon the ARGO being used in any speed contest (racing, dragging, etc.). This warranty does not cover the following items: 1. Machines or parts lost or damaged during shipment. 2. Normal maintenance or adjustments after initial pre-servicing is completed. 3. Normal replacement of service items. 4. Accessory items not supplied by Ontario Drive & Gear Limited. 5. Damages resulting from: - misuse, accident, theft or fire - use of improper or insufficient fuel, fluids or lubricants - use of parts other than genuine ARGO replacement parts - modifications, alteration, tampering or improper repair performed by parties other than an authorised ARGO dealer or distributor - any device or accessories installed by parties other than an authorised ARGO dealer or distributor 6. Batteries that fail due to improper charging or installation; broken container, cover or terminal sulphation or dehydration; damage caused by fire, excessive heat, wreckage, explosion, freezing, the addition of any chemical or solution other than the battery grade sulphuric acid. This shall constitute the complete and only warranty given by Ontario Drive & Gear Limited, and, except as specifically set forth in the foregoing, Ontario Drive & Gear Limited shall not, in any event, be liable for any losses, damages or costs, whether special, incidental, consequential or otherwise, in any way related to any vehicle or its sale. No warranty, expressed, implied or statutory, as to merchantability, fitness for a particular purpose, description, quality or any other matter is given in connection with any ARGO vehicle or its sale and no agent, employee or other person has any authority to vary any of the foregoing provisions. Provided, however, that this clause shall be severable where voided by application of the Consumer Protection Act.

ARGO RETAILER... Please complete this page at the time of sale to the new owner so your customer has all pertinent information that may be required.

SOLD TO: ______________________________________________________ STREET ADDRESS:______________________________________________ CITY OR TOWN:_______________________PROV/STATE: ______________ POSTAL/ZIP:____________________________________________________

DATE OF SALE: _________________________________________________ WARRANTY PERIOD EXPIRES: ____________________________________

ARGO PRODUCTS MANUFACTURED BY: Ontario Drive & Gear Limited P.O. Box 280, 220 Bergey Court New Hamburg, Ontario N0B 2G0 Canada Phone: (519) 662-2840 Fax: (519) 662-2421 www.argoatv.com

OPERATORâ&#x20AC;&#x2122;S MANUAL this cle. e v o ehi m v e ot r m this n Do l fro nua ma MANUAL NO. 671-04 Rev. 10

Printed in Canada

05/2003

A MESSAGE FROM THE PEOPLE WHO BUILT YOUR ARGO Thank you for selecting an ARGO amphibious, off-road utility vehicle! Ontario Drive & Gear Limited has been building ARGO vehicles since 1967. By listening carefully to our customers and responding to their needs, we have been constantly improving the ARGO and will continue to do so. Over thirty thousand ARGO vehicles have provided reliable service all over the world. From Britain to the Far East, Alaska to the Antarctic, and from the tropical forests of South America to the deserts of Saudi Arabia. We are proud to provide you with a vehicle that represents the ultimate in amphibious, all-terrain transportation. Your safety and the safety of all ARGO users is of the greatest concern to us. You will find numerous safety statements in this manual. Please read and follow them carefully. Always be safety conscious when you operate your ARGO and remember it is a motorized vehicle. The ARGO is easy to drive and you will soon be tempted to take on new challenges. Please take the time to develop your driving skills before doing so. Observe the recommendations outlined in this Operatorâ&#x20AC;&#x2122;s Manual and remember; some things are just impossible, even with an ARGO. WELCOME TO THE WORLD WIDE ARGO FAMILY!

673-04 Argo Service Manual 673-04CD Argo Service Manual on CD-ROM 673-25 Argo Service Video Ontario Drive & Gear has produced resources which provide the Argo owner with step-by-step instructions on how to perform general service procedures on vehicles produced since 1992. Everything from removal and replacement of brake pads to rebuilding the transmission. Itâ&#x20AC;&#x2122;s all there. Removal and replacement of engines is included, however, engine overhaul is not. A separate overhaul manual is available for each engine from your Argo dealer. Order these materials from your selling dealer or from Ontario Drive & Gear directly (have your VISA card information ready). Costs are $15.00 for the paper manual 673-04, $5.00 for the CD-ROM, or $33.00 for the 4 hour video.

Read this manual before you operate your ARGO. It contains safe operating instructions and warns the user about potential hazards that can result in personal injury.

Warnings are identified in the text by the following symbol:

Warning text warns the user about potential hazards that can result in personal injury or death.

Cautions are identified in the text by the following symbol:

Caution text contains cautions that can prevent damage to the vehicle.

This manual is based on the latest product information available at the time of printing. Ontario Drive & Gear Limited reserves the right to make changes at any time and without obligation. Reproduction of any part of this publication is prohibited without prior written permission. Une version francaise du manuel d’operation est disponsible sous le numero suivant 671-04FR. Les plaquettes d’avertissement et d’instructions qui apparaissent sur l’Argo sont aussi disponsibles en francais sous le numero suivant 126-73. © Ontario Drive & Gear Limited, 2000

PREFACE This manual describes the controls, operation and basic maintenance procedures for all VANGUARD, VANGUARD2, BIGFOOT, RESPONSE and CONQUEST models of the ARGO from date of printing. Please take the time to read this manual carefully, for your safety and that of others. By following these instructions, you will ensure extended, trouble free operation of your vehicle. For maintenance and adjustment of the engine, refer to the engine manufacturer’s operation and maintenance manual included in your vehicle’s information package. Before you drive your ARGO, make sure you understand how to use all controls, particularly the brakes and steering levers. Learn how to drive your vehicle in an open level area, away from buildings, trees and other obstacles, until you are completely familiar with its operating characteristics. Drive very slowly until your driving skills improve, and drive with caution and consideration at all times. The risk of accident or injury is greatest during the first weeks of use. Take special care during this period. ALWAYS RESPECT OUR ENVIRONMENT. CAUTION TO THE ARGO OWNER/OPERATOR • Make sure everyone who drives this vehicle receives proper operating instructions and reads this Operator’s Manual. • No one under the age of 16 should be allowed to operate the ARGO. Children under the age of 16 may not have the skills, abilities or judgement needed to operate the Argo safely and may be involved in an accident causing severe injury or death. • Never allow anyone under the influence of alcohol or any other intoxicating substance to drive or ride in the vehicle. • Wear an approved safety helmet and eye protection when driving or riding in the vehicle. • Special operating and safety procedures described in this manual must be observed before and during water operation as outlined in Section 5. • When operating your vehicle for extended periods of time, we recommend the use of approved hearing protection. • Equip your vehicle with a fire extinguisher and a first aid kit. • Equip your vehicle with basic tools for emergency repairs. • Before starting your engine, check for spilled gasoline and wipe any up immediately. Gasoline is a potentially explosive substance that can cause serious personal injury when ignited. • Keep the floor pans secured in place at all times. Fingers, feet, animal tails or paws can be injured in the drive components beneath the floor pans. The floor pans also help keep damaging debris out of the drive components. • Make sure all passengers remain seated while the vehicle is in motion. Advise your passengers to hold onto the vehicle at all times. • Never overload your vehicle. Trying to steer an overloaded vehicle can overheat the brakes. This will lead to brake fade which means loss of steering control and the ability to stop the vehicle. Overloading your vehicle can lead to premature brake system failures and costly damage to drive chains, axles or bearings. Follow the recommended load capacity for your vehicle listed in Section 1. • Do not drive the vehicle at high speeds over unfamiliar or rough terrain. Personal injury or vehicle damage may result. • Certain terrain and steep hills cannot be traversed safely with the Argo or any other vehicle. Do not attempt to drive over terrain that is questionable. • Do not drive your vehicle on asphalt or concrete roadways. When the vehicle turns, its tires skid on the driving surface. Asphalt or concrete causes extensive tire wear. • Use common sense at all times when driving your vehicle. • The Argo engine hood is designed to stay fastened in place while the vehicle is being driven. If the Argo is transported by truck or trailer, the hood should be removed and carried in the transport vehicle or secured in place on the Argo with rope or tie down straps. Wind or turbulence at road speeds could result in the loss of the hood. IMPORTANT Operate this vehicle with safety constantly in mind. Off-road vehicles face unpredictable and often hazardous terrain conditions. It is ultimately the operator’s responsibility to handle the vehicle safely within its limitations and to decide when and where to travel.

TABLE OF CONTENTS SECTION 1.0

2.0

3.0

4.0

5.0

PAGE

1 1 1 1 3 3 4 5

6 6 6 7 7

8 8 9 9 9 10 10 10 11 11

12 12 12 12 12 12 12

13 13 13 13 14 14 15 15 15 15 16 16

III

TABLE OF CONTENTS SECTION 6.0

7.0

PAGE

6.3

6.4

TABLE OF CONTENTS SECTION

PAGE 7.2.5

27 28 28 28 28 29 29 29

7.3

29 29 29 30 30 30 31 31 31

7.4

31 31 31 32 32 32 32 32 33 33 34 34

7.5

MAINTENANCE SCHEDULE ....................................................................................... 35

7.2.6 7.2.7 7.2.8

8.0

TROUBLESHOOTING ............................................................................................................. 36

9.0

10.0

POTENTIAL HAZARDS ............................................................................................................ 39

11.0

ACCESSORY INFORMATION 11.1 GENERAL ............................................................................................................. 43 11.2 CARGO TIE-DOWNS (Part No. 614-06) ............................................................................ 43

38 38 38 38 38 38 38 38 38

TABLE OF CONTENTS SECTION 11.3

11.4 11.5 11.6 11.7 11.8 11.9

11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20 11.21 11.22 11.23 11.24 11.25

PAGE ARGO TRACK SYSTEMS (Standard Track and Super Track) ................................................... 43 11.3.1 Installation Instructions ............................................................................................... 43 11.3.2 Removal of Argo Tracks ............................................................................................... 45 11.3.3 Operating Precautions .................................................................................................. 45 11.3.4 Standard Tracks ............................................................................................................ 45 11.3.5 Super Tracks ................................................................................................................. 45 ICE CLEAT KIT (Part Nos. 625-20 & 825-20) .............................................................................. 45 OUTBOARD MOTOR BRACKET (Part No. 617-00) ................................................................... 45 OUTBOARD MOTOR SUPPORT (Part No. 618-00) .................................................................... 46 OUTBOARD MOTOR BRACKET - SIDE MOUNT (Part No. 618-10) ......................................... 46 ARGO STORAGE COVERS (Part Nos. 621-10; 621-20; 821-10; 821-20 ........................................ 46 POWER WINCH (Part Nos. 622-40 & 622-70) ............................................................................. 46 11.9.1 Rules for Safe Operation ............................................................................................... 46 11.9.2 Tips for Extending the Life of Your Winch .................................................................... 48 REAR MUD FLAP KIT (Part No. 625-10) .................................................................................... 48 TRAILER HITCH KIT (Part No. 626-10) ...................................................................................... 48 BILGE PUMP KIT (Part No. 638-25) ............................................................................................ 48 HANDRAIL KITS (Part No. 639-20 & 839-20) ............................................................................. 49 TOW HOOK KIT (Part No. 642-00) ............................................................................................. 49 WINDSHIELD (Part No. 648-75) ................................................................................................. 49 CONVERTIBLE TOP (Part Nos. 649-33, 649-50 & 849-50) ........................................................... 49 ALTERNATOR KITS (Part Nos. 650-60, 850-60 & 850-40) .......................................................... 50 11.17.1 Alternator Kit for Conquest ............................................................................................. 50 SNOW PLOW KIT (Part No. 657-13) .......................................................................................... 50 AMPHIBIOUS TRAILER (Part No. 695-75) ................................................................................. 50 11.19.1 Operating Precautions ..................................................................................................... 50 HEATER KIT - CONQUEST (Part No. 848-10) ............................................................................ 50 ROLL OVER PROTECTIVE STRUCTURES (Part Nos. 848-40-2 & 848-40-4) .............................. 51 REAR BENCH SEAT (Part No. 849-60) ....................................................................................... 51 DUMP BOX KIT (Part Nos. 835-00 & 835-01) ............................................................................. 51 11.23.1 Dump Box Operating Guidelines ................................................................................... 52 ROLL BAR KIT (Part No. 648-15) ................................................................................................ 52 12V ACCESSORY OUTLET KIT (Part No. 633-25) ...................................................................... 52

APPENDIX 1

SPECIAL TOOLS VICE GRIP MODIFICATIONS .................................................................................................... 53

SECTION 1 GENERAL INFORMATION 1.1 AMPHIBIOUS OPERATION

1.3 WIND CHILL FACTOR

Maintenance procedures described in this manual can be carried out by the operator. These procedures include: 1. 2. 3. 4. 5.

checking fluid levels changing the engine and transmission oil cleaning and replacing filters preventative maintenance inspections, adjustments, repairs and trouble-shooting

673-00 1977-1986 ARGO Service Manual 673-01 1987 ARGO Service Manual 673-02 1988 Supplement 673-04 Service Manual 673-04CD Service Manual on CD-ROM 673-25 Argo Service Video

Your Argo dealer will perform regular maintenance and lubrication for a reasonable service charge.

1.4 MODELIDENTIFICATION

Carefully observe the maximum load capacity for your vehicle on land and in water as listed in the following:

SECTION 1 GENERAL INFORMATION ARGO 6 x 6 VANGUARD (S)

ARGO 6 x 6 VANGUARD2 (SN)

Serial Number: Engine:

S-6999 Briggs & Stratton Vanguard, 480 cc (16 h.p.) VTwin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Mechanical, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 16 Amp magneto type charging system, electronic ignition Speed: Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) SEE SECT.1.4.1 Water - 2 adults or 158 kg (350 lbs.) Maximum Rear Capacity: Land and Water - 63 kg (140 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 348 kg (765 lbs.)

Serial Number: Engine: Twin, Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains: Electrical:

ARGO 6 x 6 BIGFOOT (BF)

ARGO 8 x 8 RESPONSE (RB)

Serial Number: Engine:

BF-9212 Briggs & Stratton Vanguard, 570 cc (18 h.p.) VTwin, 4 cycle, air cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Hydraulic, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain and single RC-60 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp magneto type charging system, electronic ignition Speed: Land - 39 km/h (24 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) SEE SECT.1.4.1 Water - 2 adults or 158 kg (350 lbs.) Tires: 25x12.00-9NHS, 2 ply Dry Weight: 414 kg (910 lbs.)

Serial Number: Engine: Twin, Transmission: Clutch: Fuel Capacity: Steering/Brakes: Drive Chains: Electrical:

ARGO 6 x 6 CONQUEST (C)

ARGO CONQUEST (CB)

Serial Number: Engine:

SN-7888 Briggs & Stratton Vanguard, 480 cc (16 h.p.) V4 cycle, air cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic, 9" disc with holding brake system Double RC-50 roller chain 12 volt D.C. battery, 435 cranking amps at 0 F; 16 Amp magneto type charging system, electronic ignition Speed: Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 4 persons or 317 kg (700 lbs.) SEE SECT.1.4.1 Water - 2 adults or 158 kg (350 lbs.) Maximum Rear Capacity: Land and Water - 63 kg (140 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 348 kg (765 lbs.)

RB-12075 Briggs & Stratton Vanguard, 570 cc (18 h.p.) V4 cycle, air cooled 2 forward speeds, neutral and reverse Variable speed torque converters 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Hydraulic, 9" disc with holding brake system Double RC-50 roller chain 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp magneto type charging system, electronic

ignition Land - 30 km/h (20 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 6 persons or 454 kg (1000 lbs.) SEE SECT.1.4.1 Water - 4 adults or 317 kg (700 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 436 kg (960 lbs.) Speed:

CB-10847 Kawasaki 620 cc (20 h.p.) V-twin 4 cycle, liquid cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Hydraulic Caliper, 9" disc with holding brake system Drive Chains: Double RC-50 roller chains Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp charging system, battery ignition Speed: Land - 30 km/h (20 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 6 persons or 454 kg (1000 lbs.) SEE SECT.1.4.1 Water - 4 adults or 317 kg (700 lbs.) Tires: 22x10.00-8NHS, 2 ply Dry Weight: 465 kg (1025 lbs.)

C-12747 Kawasaki 620 cc (20 h.p.) V-twin 4 cycle, liquid cooled Transmission: 2 forward speeds, neutral and reverse Clutch: Variable speed torque converters Fuel Capacity: 32 litres (7.0 Imp. Gal., 8.4 U.S. Gal.) Steering/Brakes: Hydraulic, 9" disc with holding brake system Drive Chains: Double RC-50 roller chain and single RC-60 roller chain Electrical: 12 volt D.C. battery, 435 cranking amps at 0 F; 20 Amp charging system, battery ignition Speed: Land - 35 km/h (22 mph) Water - 3 km/h (2 mph) Load Capacity: Land - 2 persons or 317 kg (700 lbs.) SEE SECT.1.4.1 Water - 2 adults or 158 kg (350 lbs.) Tires: 25x12.00-9NHS, 2 ply Dry Weight: 450 kg (990 lbs.)