JOHN DEERE
WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION
2160 May 2004
Trail Buck Utility ATV 500, 650, 650EX and 650EXT TM2160 MAY 2004
TECHNICAL MANUAL
North American Version Litho in U.S.A.
INTRODUCTION Manual Description Introduction
This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: •
Table of Contents
•
Specifications and Information
•
Identification Numbers
•
Tools and Materials
•
Component Location
•
Schematics and Harnesses
•
Theory of Operation
•
Operation and Diagnostics
•
Diagnostics
•
Tests and Adjustments
•
Repair
•
Other
Safety Technical Data Engine Electrical Drive Train Steering Suspension
NOTE: Depending on the particular section or system being covered, not all of the above groups may be used. The bleed tabs for the pages of each section will align with the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section through the last section. We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us.
All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT© 2004 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT© 2004
Introduction
Brakes Body / Frame
INTRODUCTION
Introduction
-4
SAFETY Handle Fluids Safely - Avoid Fires
Safety
Recognize Safety Information
Be Prepared For Emergencies
MIF
This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe servicing practices.
Understand Signal Words
MIF
A signal word - DANGER, WARNING, or CAUTION - is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
• When you work around fuel, do not smoke or work near heaters or other fire hazards. • Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. • Make sure machine is clean of trash, grease, and debris. • Do not store oily rags; they can ignite and burn spontaneously.
Replace Safety Signs
•
Be prepared if a fire starts.
•
Keep a first aid kit and fire extinguisher handy.
• Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Use Care In Handling and Servicing Batteries
MIF
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
MIF
Safety
-1
SAFETY Prevent Battery Explosions • Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. • Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. • Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.
Service Machines Safely
Prevent Acid Burns • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid acid burns by: 1. Filling batteries in a well-ventilated area.
MIF
2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure.
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
If you spill acid on yourself: 1. Flush your skin with water.
Use Proper Tools
2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10 - 15 minutes. 4. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil.
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.
Park Machine Safely
3. Get medical attention immediately.
Wear Protective Clothing
MIF
Before working on the machine: MIF
Wear close fitting clothing and safety equipment appropriate to the job.
1. Lower all equipment to the ground. 2. Stop the engine and remove the key.
Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device
Safety
3. Disconnect the battery ground strap. 4. Hang a “DO NOT OPERATE” tag in operator station.
-2
SAFETY Support Machine Properly and Use Proper Lifting Equipment
Work In Ventilated Area
MIF MIF
If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
Warning: California Proposition 65 Warning
Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual.
Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Work In Clean Area
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Before starting a job: 1. Clean work area and machine.
Remove Paint Before Welding or Heating
2. Make sure you have all necessary tools to do your job.
Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts.
Using High Pressure Washers Directing pressurized water at electronic/electrical components or connectors, bearings, hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle.
Service Tires Safely
Illuminate Work Area Safely
MIF
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
Safety
Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can -3
SAFETY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.
structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Service Cooling System Safely
Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.
Live With Safety
MIF
Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off machine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
Handle Chemical Products Safely MIF
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
MIF
Safety
-4
SPECIFICATIONS TABLE OF CONTENTS Specifications
Table of Contents
Fastener Torques..............................................7 Metric Fastener Torque Values ......................7 Inch Fastener Torque Values .........................8 General Information..........................................9 Gasoline .........................................................9 Gasoline Storage............................................9 4 - Cycle Gasoline Engine Oil ......................10 Break-In Engine Oil - 4-Cycle Gasoline........10 Hydrostatic Transmission and Hydraulic Oil.11 Gear Case Oil...............................................12 Gear Transmission Grease ..........................12 Alternative Lubricants...................................12 Synthetic Lubricants .....................................13 Lubricant Storage .........................................13 Mixing of Lubricants .....................................13 Oil Filters ......................................................13 Coolant Specifications ...................................13 Gasoline Engine Coolant..............................13 Gasoline Engine Coolant Drain Interval .......14 Specifications - Trail Buck.............................15 Engine Specifications - 500..........................15 Engine Specifications - 650..........................15 Engine Specifications - 500 and 650............15 Electrical Specifications................................18 Carburation Specifications ...........................19 Cooling Specifications ..................................19 Drive Train Specifications.............................20 Steering Control Specifications ....................20 Suspension Specifications ...........................20 Brakes Specifications ...................................20 Tires and Wheels Specifications ..................21 Dimension Specifications .............................21 Capacities Specifications .............................21 Torque Specifications...................................22
Specifications Table of Contents - 5
SPECIFICATIONS TABLE OF CONTENTS
Specifications Table of Contents - 6
SPECIFICATIONS FASTENER TORQUES Fastener Torques Metric Fastener Torque Values 4.8
9.8
10.9
4.8
8.8
9.8
10.9
12.9
4.8
8.8
9.8
10.9
12.9
10
5
12.9 12
10
10
10
5 5
Property Class and Nut Markings
12.9
8.8
12
Property Class and Head Markings
10
10
12
MIF
Class 4.8
Class 8.8 or 9.8
Class 10.9
Class 12.9
Lubricated a Dry a
Lubricated a Dry a
Lubricated a Dry a
Lubricated a Dry a
SIZE N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
M6
4.8
3.5
6
4.5
9
6.5
11
8.5
13
9.5
17
12
15
11.5
19
14.5
M8
12
8.5
15
11
22
16
28
20
32
24
40
30
37
28
47
35
M10
23
17
29
21
43
32
55
40
63
47
80
60
75
55
95
70
M12
40
29
50
37
75
55
95
70
110
80
140
105
130
95
165
120
M14
63
47
80
60
120
88
150
110
175
130
225
165
205
150
260
109
M16
100
73
125
92
190
140
240
175
275
200
350
225
320
240
400
300
M18
135
100
175
125
260
195
330
250
375
275
475
350
440
325
560
410
M20
190
140
240
180
375
275
475
350
530
400
675
500
625
460
800
580
M22
260
190
330
250
510
375
650
475
725
540
925
675
850
625
1075 800
M24
330
250
425
310
650
475
825
600
925
675
1150 850
1075
800
1350 1000
M27
490
360
625
450
950
700
1200 875
1350
1000 1700 1250 1600
1150 2000 1500
M30
675
490
850
625
1300 950
1650 1200 1850
1350 2300 1700 2150
1600 2700 2000
M33
900
675
1150 850
1750 1300 2200 1650 2500
1850 3150 2350 2900
2150 3700 2750
M36
1150
850
1450 1075 2250 1650 2850 2100 3200
2350 4050 3000 3750
2750 4750 3500
DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches.
When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated (yellow dichromate Specification JDS117) without any lubrication.
Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.
Tighten toothed or serrated-type lock nuts to the full torque value.
Reference: JDS - G200.
Specifications Fastener Torques - 7
SPECIFICATIONS FASTENER TORQUES Inch Fastener Torque Values 8
5.2
5.1
5
1 or 2b
SAE Grade and Head Markings
8.2
No Marks
5
2 SAE Grade and Nut Markings
8
No Marks
MIF
Grade 1
Grade 2b
Grade 5, 5.1 or 5.2
Grade 8 or 8.2
Lubricated a Dry a
Lubricated a Dry a
Lubricated a Dry a
Lubricated a Dry a
SIZE
N•m
lb-ft
N•m lb-ft N•m
lb-ft
N•m lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
1/4
3.7
2.8
4.7
3.5
6
4.5
7.5
5.5
9.5
7
12
9
13.5
10
17
12.5
5/16
7.7
5.5
10
7
12
9
15
11
20
15
25
18
28
21
35
26
3/8
14
10
17
13
22
16
27
20
35
26
44
33
50
36
63
46
7/16
22
16
28
20
35
26
44
32
55
41
70
52
80
58
100
75
1/2
33
25
42
31
53
39
67
50
85
63
110
80
120
90
150
115
9/16
48
36
60
45
75
56
95
70
125
90
155
115
175
130
225
160
5/8
67
50
85
62
105
78
135
100
170
125
215
160
215
160
300
225
3/4
120
87
150
110 190
140
240
175
300
225
375
280
425
310
550
400
7/8
190
140
240
175 190
140
240
175
490
360
625
450
700
500
875
650
1
290
210
360
270 290
210
360
270
725
540
925
675
1050 750
1-1/8
470
300
510
375 470
300
510
375
900
675
1150 850
1-1/4
570
425
725
530 570
425
725
530
1300 950
1-3/8
750
550
950
700 750
550
950
700
1700 1250 2150 1550 2700 2000 3400 2550
1-1/2
1000 725
1250 925 990
725
1250 930
2250 1650 2850 2100 3600 2650 4550 3350
DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
1300 975
1450 1075 1850 1350
1650 1200 2050 1500 2600 1950
head. Tighten toothed or serrated-type lock nuts to the full torque value. a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated (yellow dichromate Specification JDS117) without any lubrication.
Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.
b “Grade 2” applies for hex cap screws (Not Hex Bolts) up to 152 mm (6 in.) long. “Grade 1” applies for hex cap screws over 152 mm (6 in.) long, and for all other types of bolts and screws of any length.
When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt
Reference: JDS - G200
Specifications Fastener Torques - 8
SPECIFICATIONS GENERAL INFORMATION General Information Gasoline 4 - Cycle Engines
c CAUTION: Avoid Injury! Gasoline is
HIGHLY FLAMMABLE, handle it with care. DO NOT refuel machine while: indoors, always fill gas tank outdoors; machine is near an open flame or sparks; engine is running, STOP engine; engine is hot, allow it to cool sufficiently first; smoking. Help prevent fires: fill gas tank to bottom of filler neck only; be sure fill cap is tight after fueling; clean up any gas spills IMMEDIATELY; keep machine clean and in good repair - free of excess grease, oil, debris, and faulty or damaged parts; any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling:•ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter.
To avoid engine damage: •
DO NOT mix oil with gasoline;
MIF
IMPORTANT: Avoid damage! California Proposition 65 Warning: Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Gasoline Storage IMPORTANT: Avoid damage! Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked (“UNLEADED GASOLINE”) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing the machine or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container.
• ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher; • fill gas tank at the end of each day's operation to help prevent condensation from forming inside a partially filled tank; •
keep up with specified service intervals.
Use of alternative oxygenated, gasohol blended, unleaded gasoline is acceptable as long as: • the ethyl or grain alcohol blends DO NOT exceed 10% by volume or • methyl tertiary butyl ether (MTBE) blends DO NOT exceed 15% by volume RFG (reformulated) gasoline is acceptable for all machines designed for use of regular unleaded fuel. Older machines (that were designed for leaded fuel) may see some accelerated valve and seat wear.
Specifications General Information - 9
SPECIFICATIONS GENERAL INFORMATION 4 - Cycle Gasoline Engine Oil
Break-In Engine Oil - 4-Cycle Gasoline
Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure.
IMPORTANT: Avoid damage! ONLY use a quality break-in oil in rebuilt or remanufactured engines for the first 5 hours (maximum) of operation. DO NOT use oils with heavier viscosity weights than SAE 5W-30 or oils meeting specifications API SG or SH, these oils will not allow rebuilt or remanufactured engines to break-in properly.
The following John Deere oils are PREFERRED: •
PLUS - 4® - SAE 10W-40;
•
TORQ - GARD SUPREME® - SAE 5W-30.
The following John Deere oil is PREFERRED:
The following John Deere oils are also recommended, based on their specified temperature range: •
TURF - GARD® - SAE 10W-30;
•
PLUS - 4® - SAE 10W-30;
•
TORQ - GARD SUPREME® - SAE 30.
Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: •
SAE 10W-40 - API Service Classifications SG or higher;
•
SAE 5W-30 - API Service Classification SG or higher;
•
SAE 10W-30 - API Service Classifications SG or higher;
•
SAE 30 - API Service Classification SC or higher.
•
BREAK - IN ENGINE OIL.
John Deere BREAK - IN ENGINE OIL is formulated with special additives for aluminum and cast iron type engines to allow the power cylinder components (pistons, rings, and liners as well) to “wear-in” while protecting other engine components, valve train and gears, from abnormal wear. Engine rebuild instructions should be followed closely to determine if special requirements are necessary. John Deere BREAK - IN ENGINE OIL is also recommended for non-John Deere engines, both aluminum and cast iron types. The following John Deere oil is also recommended: •
TORQ - GARD SUPREME® - SAE 5W-30.
If the above recommended John Deere oils are not available, use a break-in engine oil meeting the following specification during the first 5 hours (maximum) of operation:
SAE 10W-30
SAE 30 SAE 5W-30
SAE 10W-40
•
SAE 5W-30 - API Service Classification SE or higher. IMPORTANT: Avoid damage! After the break-in period, use the John Deere oil that is recommended for this engine.
PREFERRED AIR TEMPERATURE MIF
Specifications General Information - 10
5W30 or 10W30
SAE 5W-30
BREAK-IN OIL
JDM J20C
SPECIFICATIONS GENERAL INFORMATION
PREFERRED
PREFERRED
AIR TEMPERATURE
AIR TEMPERATURE MIF
Hydrostatic Transmission and Hydraulic Oil Use the appropriate oil viscosity based on these air temperature ranges. Operating outside of these recommended oil air temperature ranges may cause premature hydrostatic transmission or hydraulic system failures. IMPORTANT: Avoid damage! Use only the oils recommended. HY-GARD® - JDM J20C can be mixed with 5W30 or 10W30 in this application. Do not use LOW VISCOSITY HY - GARD® oil. The following John Deere transmission and hydraulic oil is PREFERRED: •
HY-GARD® - JDM J20C.
The following John Deere oil is also recommended if above preferred oil is not available: •
5W30 or 10W30.
Other oils may be used if above recommended John Deere oils are not available, provided they meet one of the following specifications: •
John Deere Standard JDM J20C.
Specifications General Information - 11
MIF
SPECIFICATIONS GENERAL INFORMATION Gear Case Oil
Gear Transmission Grease
Use the appropriate oil viscosity based on the air temperature ranges. Operating outside of these recommended oil air temperature ranges may cause premature gear case failure.
Use the following gear grease based on the air temperature range. Operating outside of the recommended grease air temperature range may cause premature gear transmission failure. IMPORTANT: Avoid damage! ONLY use a quality gear grease in this transmission. DO NOT mix any other greases in this transmission. DO NOT use any BIO - GREASE in this transmission.
IMPORTANT: Avoid damage! ONLY use a quality oil in this gear case. DO NOT mix any other oils in this gear case. DO NOT use BIO-HY-GARD® in this gear case. The following John Deere gear case oil is PREFERRED: •
GL-5 GEAR LUBRICANT® - SAE 80W-90.
• NON-CLAY HIGH-TEMPERATURE EP GREASE® JDM J13E4, NLGI Grade 2.
The following John Deere gear case oil is also recommended if above preferred oil is not available: •
Other greases may be used if above preferred John Deere grease is not available, provided they meet the following specification:
GL-5 GEAR LUBRICANT® - SAE 85W-140.
Other gear case oils may be used if above recommended John Deere gear case oils are not available, provided they meet the following specification:
•
John Deere Standard JDM J13E4, NLGI Grade 2.
SAE 85W-140
JDM J13E4 NLGI Grade 2
API Service Classification GL - 5.
SAE 80W-90
•
The following John Deere gear grease is PREFERRED:
AIR TEMPERATURE
PREFERRED
MIF
AIR TEMPERATURE MIF
Alternative Lubricants Use of alternative lubricants could cause reduced life of the component. If alternative lubricants are to be used, it is recommended that the factory fill be thoroughly removed before switching to any alternative lubricant.
Specifications General Information - 12
SPECIFICATIONS COOLANT SPECIFICATIONS Synthetic Lubricants
Coolant Specifications
Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry classification and/or military specification) as shown in this manual. The recommended air temperature limits and service or lubricant change intervals should be maintained as shown in the operator’s manual, unless otherwise stated on lubricant label. Avoid mixing different brands, grades, or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.
Lubricant Storage
Gasoline Engine Coolant The engine cooling system when filled with a proper dilution mixture of anti-freeze and deionized or distilled water provides year-round protection against corrosion, cylinder or liner pitting, and winter freeze protection down to -37°C (-34°F). The following John Deere coolant is PREFERRED: • COOL-GARD® PRE-DILUTED SUMMER COOLANT (TY16036). This coolant satisfies specifications for “Automobile and Light Duty Engine Service” and is safe for use in John Deere Lawn and Grounds Care/Golf and Turf Division equipment, including aluminum block gasoline engines and cooling systems.
All machines operate at top efficiency only when clean lubricants are used. Use clean storage containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contamination. Store drums on their sides. Make sure all containers are properly marked as to their contents. Dispose of all old, used containers and their contents properly.
The above preferred pre-diluted anti-freeze provides:
Mixing of Lubricants
•
In general, avoid mixing different brands or types of lubricants. Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements. Mixing different lubricants can interfere with the proper functioning of these additives and lubricant properties which will downgrade their intended specified performance.
• compliance with ASTM D4656 (JDM H24C2) specifications
Oil Filters IMPORTANT: Avoid damage! Filtration of oils is critical to proper lubrication performance. Always change filters regularly. The following John Deere oil filters are PREFERRED:
•
adequate heat transfer
•
corrosion-resistant chemicals for the cooling system
•
compatibility with cooling system hose and seal material
• protection during extreme cold and extreme hot weather operations chemically pure water for better service life
If above preferred pre-diluted coolant is not available, the following John Deere concentrate is recommended: • COOL-GARD® CONCENTRATED SUMMER COOLANT CONCENTRATE™ (TY16034). If either of above recommended engine coolants are available use any Automobile and Light Duty Engine Service ethylene glycol base coolant, meeting the following specification: •
ASTM D4985 (JDM H24A2).
Read container label completely before using and follow instructions as stated.
• AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL FILTERS. Most John Deere filters contain pressure relief and antidrainback valves for better engine protection. Other oil filters may be used if above recommended John Deere oil filters are not available, provided they meet the following specification: •
ASTB Tested In Accordance With SAE J806.
Specifications Coolant Specifications - 13
SPECIFICATIONS COOLANT SPECIFICATIONS IMPORTANT: Avoid damage! To prevent engine damage, DO NOT use pure anti-freeze or less than a 50% anti-freeze mixture in the cooling system. DO NOT mix or add any additives/ conditioners to the cooling system in Lawn and Grounds Care/Golf and Turf Division equipment. Water used to dilute engine coolant concentrate must be of high quality - clean, clear, potable water (low in chloride and hardness - Table 1) is generally acceptable. DO NOT use salt water. Deionized or distilled water is ideal to use. Coolant that is not mixed to these specified levels and water purity can cause excessive scale, sludge deposits, and increased corrosion potential. Property
Requirements
Total Solids, Maximum
340 ppm (20 grns/gal)
Total Hardness, Maximum
170 ppm (10 grns/gal)
Chloride (as Cl), Maximum
40 ppm (2.5 grns/gal)
Sulfate (as SO4), Maximum 100 ppm (5.8 grns/gal) Mix 50 percent anti-freeze concentrate with 50 percent distilled or deionized water. This mixture and the pre-diluted mixture (TY16036) will protect the cooling system down to 37°C (-34°F) and up to 108°C (226°F). Certain geographical areas may require lower air temperature protection. See the label on your anti-freeze container or consult your John Deere dealer to obtain the latest information and recommendations.
Gasoline Engine Coolant Drain Interval When using John Deere Pre-Diluted (TY16036) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 36 months or 3,000 hours of operation, whichever comes first. When using John Deere Concentrate (TY16034) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 24 months or 2,000 hours of operation, whichever comes first. If above John Deere Automobile and Light Duty Engine Service coolants are not being used; drain, flush, and refill the cooling system according to instructions found on product container or in equipment operator’s manual or technical manual.
Specifications Coolant Specifications - 14
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Specifications - Trail Buck Engine Specifications - 500 Stroke (500 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 mm (2.5 in.) Displacement (500 cc Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498 cc (30.4 cu in.) Horsepower @ 7200 rpm (500 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.6 kW (37 hp)
Engine Specifications - 650 Stroke (650 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 mm (3.2 in.) Displacement (650 cc Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644 cc (39.3 cu in.) Horsepower @ 7100 rpm (650 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 kW (42 hp)
Engine Specifications - 500 and 650 General Specifications Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotax 4-TEC, 4 stroke Over Head Camshaft (OHC), Liquid cooled Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric with Optional Recoil Number of Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Number of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 valves Decompressor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Bore (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm (3.9 in.) Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5:1 Maximum HP RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7000 ± 100 rpm Lubrication . . . . . . . . Wet sump with replaceable oil filter (lubrication of engine and transmission simultaneously) Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow Air Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 stage foam filter Exhaust System Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nelson, stainless steel Exhaust System Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USDA approved Valves Intake Valve Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0° BTDC Intake Valve Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.0° ABDC Exhaust Valve Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.0° BBDC Exhaust Valve Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0° ATDC Intake Valve Stem Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.961 mm (0.2347 in.) Intake Valve Stem Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.975 mm (0.2352 in.) Intake Valve Stem Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.930 mm (0.2330 in.) Exhaust Valve Stem Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.946 mm (0.2341 in.) Exhaust Valve Stem Diameter (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.960 mm (0.2346 in.) Exhaust Valve Stem Diameter (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.930 mm (0.2330 in.) Valve Guide Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.060 mm (0.2386 in.) Valve Spring Free Length (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.45 mm (1.789 in.) Valve Spring Free Length (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.00 mm (1.693 in.) Intake Valve Seat Contact Width (New). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 to 1.30 mm (0.043 to 0.0051 in.) Intake Valve Seat Contact Width (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 mm (0.07 in.) Exhaust Valve Seat Contact Width (New). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 to 1.55 mm (0.049 to 0.061 in.) Exhaust Valve Seat Contact Width (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.078 in.)
Specifications Specifications - Trail Buck - 15
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Pistons Piston Measurement (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.951 to 99.969 mm (3.935 to 3.936 in.) Piston Measurement (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.80 mm (3.929 in.) Piston/Cylinder Clearance (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.031 to 0.059 mm (0.001 to 0.002 in.) Piston/Cylinder Clearance (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 mm (0.004 in.) Piston Ring Type 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rectangular Piston Ring Type 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taper-face Piston Ring Type 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Scraper Ring Piston Ring End Gap Rectangular (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Piston Ring End Gap Taper-face (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Piston Ring End Gap Oil Scraper Ring (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Piston Ring End Gap Rectangular (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.) Piston Ring End Gap Taper-face (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.) Piston Ring End Gap Oil Scraper Ring (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Piston Ring End Gap All (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in.) Piston/Ring Groove Clearance Rectangular (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 mm (0.001 in.) Piston/Ring Groove Clearance Taper-face (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in.) Piston/Ring Groove Clearance Oil Scraper Ring (New minimum). . . . . . . . . . . . . . . . . . . . . . . . 0.020 mm (0.0008 in.) Piston/Ring Groove Clearance Rectangular (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070 mm (0.0028 in.) Piston/Ring Groove Clearance Taper-face (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 mm (0.0024 in.) Piston/Ring Groove Clearance Oil Scraper Ring (New maximum) . . . . . . . . . . . . . . . . . . . . . . . 0.055 mm (0.0021 in.) Rocker Arm Rocker Arm Bore Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Bore Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Bore Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Shaft Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Shaft Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Shaft Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.007 mm (0.7877 in.) 20.020 mm (0.7881 in.) 20.035 mm (0.7887 in.) 19.980 mm (0.7866 in.) 20.007 mm (0.7877 in.) 19.965 mm (0.7860 in.)
Cylinder Cylinder Screw M11 (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.5 mm (8.524 in.) Cylinder Bore (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.00 mm (3.94 in.) Cylinder Taper (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.) Cylinder Taper (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 mm (0.004 in.) Cylinder Out of Round (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 mm (0.0004 in.) Cylinder Out of Round (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.) Camshaft and Cam Camshaft Bearing Journal PTO Side (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal PTO Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal PTO Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal Magneto Side (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal Magneto Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal Magneto Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bore PTO Side (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bore PTO Side (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bore PTO Side (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Specifications - Trail Buck - 16
24.967 mm (0.9829 in.) 24.980 mm (0.9835 in.) 24.960 mm (0.9827 in.) 39.927 mm (1.5719 in.) 39.935 mm (1.5722 in.) 39.920 mm (1.5716 in.) 24.987 mm (0.9837 in.) 25.000 mm (0.9842 in.) 25.020 mm (0.9850 in.)
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Camshaft Bore Magneto Side (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.984 mm (1.5742 in.) Camshaft Bore Magneto Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000 mm (1.5748 in.) Camshaft Bore Magneto Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.020 mm (1.5756 in.) Cam Lobe Intake (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.369 mm (1.235 in.) Cam Lobe Intake (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.569 mm (1.243 in.) Cam Lobe Intake (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.300 mm (1.232 in.) Cam Lobe Exhaust (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.147 mm (1.226 in.) Cam Lobe Exhaust (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.347 mm (1.234 in.) Cam Lobe Exhaust (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.100 mm (1.224 in.) Crankshaft Crankshaft Axial Clearance (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.0078 in.) Crankshaft Axial Clearance (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.0196 in.) Crankshaft Pin Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.017 mm (1.7723 in.) Crankshaft Pin Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.033 mm (1.7729 in.) Crankshaft Pin Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 mm (1.7710 in.) Crankshaft Journal Diameter MAG Side (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.976 mm (2.1644 in.) Crankshaft Journal Diameter MAG Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.995 mm (2.1651 in.) Crankshaft Journal Diameter MAG Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.950 mm (2.1634 in.) Crankshaft Journal Diameter PTO Side (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.974 mm (1.8099 in.) Crankshaft Journal Diameter PTO Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.990 mm (1.8102 in.) Crankshaft Journal Diameter PTO Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.940 mm (1.8086 in.) Crankshaft Radial Clearance MAG Side (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.0028 in.) Crankshaft Radial Clearance PTO Side (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.0028 in.) Connecting Rod Connecting Rod Big End Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.080 mm (1.774 in.) Connecting Rod Big End Clearance (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.0035 in.) Connecting Rod Big End Axial Play (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150 mm (0.06 in.) Connecting Rod Big End Axial Play (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.302 mm (0.01 in.) Connecting Rod Big End Axial Play (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.) Connecting Rod Small End Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.01 mm (0.9059 in.) Connecting Rod Small End Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.02 mm (0.9063 in.) Connecting Rod Small End Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.07 mm (0.9080 in.) Piston Pin Piston Pin Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.996 mm (0.9053 in.) Piston Pin Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.000 mm (0.9055 in.) Piston Pin Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.990 mm (0.9051 in.) Piston Pin Bore Clearance (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.080 mm (0.0035 in.) Drive Belt (New nominal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.00 mm (1.260 in.) Drive Belt (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.00 mm (1.181 in.) Governor Cup Roller Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.70 mm (0.539 in.) Governor Cup Roller Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.90 mm (0.547 in.) Governor Cup Roller Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.20 mm (0.519 in.) Centrifugal Lever Centrifugal Lever Pivot Bolt Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.078 mm (0.239 in.) Specifications Specifications - Trail Buck - 17
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Centrifugal Lever Pivot Bolt Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Pivot Bolt Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Bore Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Pivot Bolt Bore Diameter (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Pivot Bolt Bore Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Pivot Bolt Bore Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.100 mm (0.240 in.) 6.000 mm (0.236 in.) 6.200 mm (0.244 in.) 6.113 mm (0.241 in.) 6.171 mm (0.243 in.) 6.300 mm (0.248 in.)
Drive Pulleys Drive Pulley Sliding Half Large Bushing (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000 mm (2.165 in.) Drive Pulley Sliding Half Large Bushing (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.002 mm (2.166 in.) Drive Pulley Sliding Half Large Bushing (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.200 mm (2.173 in.) Drive Pulley Sliding Half Small Bushing (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.000 mm (1.181 in.) Drive Pulley Sliding Half Small Bushing (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.002 mm (1.182 in.) Drive Pulley Sliding Half Small Bushing (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.200 mm (1.189 in.) One-Way Clutch Bushing Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.990 mm (1.574 in.) One-Way Clutch Bushing Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.085 mm (1.578 in.) One-Way Clutch Bushing Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.100 mm (1.579 in.) Driven Pulley Sliding Half Bushing Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . 30.000 mm (1.181 in.) Driven Pulley Sliding Half Bushing Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . 30.002 mm (1.182 in.) Driven Pulley Sliding Half Bushing Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.200 mm (1.189 in.) Driven Pulley Fixed Half Bushing Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.000 mm (1.181 in.) Driven Pulley Fixed Half Bushing Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.002 mm (1.182 in.) Driven Pulley Fixed Half Bushing Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.200 mm (1.189 in.) Torque Gear On Driven Pulley (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.500 mm (.295 in.) Main Shaft MAG Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.990 mm (0.708 in.) Main Shaft PTO Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.950 mm (0.982 in.) Bevel Gear Shaft PTO Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.990 mm (0.984 in.)
Electrical Specifications Magneto/Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 W @ 6000 rpm Ignition system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.D.I. (Inductive Discharge Ignition) Ignition timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Adjustable Spark Plug Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Spark Plug Make and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NKG DCPR8E Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 - 0.7 mm (0.024 - 0.027 in.) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (159 lb-in.) Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 - 300 ohms Battery Charging Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 ± 0.01 ohms Ignition Coil Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 to 1.15 ohms @ 20° C (68° F) Ignition Coil Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 to 11.7 ohms @ 20° C (68° F) Engine RPM Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7400 Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrolyte Battery Type Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volts Nominal Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A•h Power Starter Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 kW
Specifications Specifications - Trail Buck - 18
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Lights Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 x 35 W Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/25 W Pilot Lamp Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEDS, 0.7 V approximately (each) Fuses Location no. 1 (spare 15 A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N.A. Location no. 2 (spare 15 A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N.A Location no. 3 (accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A (power outlet and auxiliary supply) Location no. 4 (fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 A Location no. 5 (main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 A Location no. 6 (charging system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 A
Carburation Specifications Carburetor Type . . . . . Mikuni constant depression type with manual choke and ECS (Enrichner Coasting System) Carburetor Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BSR42 Fuel Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mikuni Fuel Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External (vacuum operated) Engine Idle Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1100 ± 100 rpm Main Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.5 Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Needle Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DGY17-53 Clip Position Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Choke Plunger Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Choke Adjustment Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (.02 in.) Preliminary Pilot Screw Turn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Float Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 ± 0.5 mm (0.390 ± 0.020 in.) Fuel Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular Unleaded Gasoline Octane No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 (Ron + Mon)/2
Cooling Specifications CoolantEthyl Glycol/water mix (50% coolant, 50% water), Use coolant specifically designed for aluminum engines) Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostatic Fan Thermostat Switch ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95° C (203° F) Fan Thermostat Switch OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90° C (194° F) Engine Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75° C (167° F) Engine Thermostat Closing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (185° F) Radiator Cap Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 kPa (16 psi)
Specifications Specifications - Trail Buck - 19
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Drive Train Specifications Transmission Type . . . CVT (Continuous Variable Transmission), Dual Range (HI-LO) With Park Brake, Neutral and Reverse Engagement RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1450 ± 100 rpm Front Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Driven/Single Auto-Lock Differential (pump driven) Front Differential Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6:1 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shaft Driven/Solid Axle Rear Axle Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6:1
Steering Control Specifications Turning Radius 4-Wheel Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 mm (83 in.) Total Toe (vehicle on ground) Each Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ± 4 mm (0.315 ± 0.157 in.) Camber Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0° Tie-Rod Maximum Length Unengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 5 mm (0.787 ± 0.197 in.)
Suspension Specifications Front Suspension type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent Suspension - Double A-Arm Suspension Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 mm (7 in.) Shock Absorber Qty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Shock Absorber Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Spring Free Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 mm (11 in.) Spring Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Orange/Black/Black Front Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N.A. Rear Suspension type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rigid Swing Arm Suspension Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190.5 mm (7.5 in.) Shock Absorber Qty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Shock Absorber Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Spring Free Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 mm (6.3 in.) Spring Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red/Black Front Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Settings
Brakes Specifications Front Brake Qty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 discs Front Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Rear Brake Qty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 disc Rear Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Cable/Hydraulic Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Brake and Brake Lever Lock on LH Brake Lever Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floating Lining Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semi Metallic Minimum Pad Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.04 in.) Minimum Brake Disc Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 mm (0.18 in.) Maximum Brake Disk Warpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.01 in.)
Specifications Specifications - Trail Buck - 20
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Tires and Wheels Specifications Tires Pressure Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 kPa recommended; 35 kPa minimum (5.5 psi); (5 psi) Pressure Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 kPa recommended; 28 kPa minimum (4.5 psi); (4 psi) Tire Tread Depth (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 mm (0.16 in.) Size Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 x 8 x 12 Size Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 x 11 x 12 Wheels Size Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 x 6.5 Size Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 x 8
Dimension Specifications Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2071 mm (81.5 in.) Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1194 mm (47 in.) Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1143 mm (45 in.) Dry Weight 4-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 kg (745 lb) Wheel Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1296 mm (51 in.) Wheel Track Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 992 mm (39 in.) Wheel Track Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 940 mm (37 in.) Front and Under Engine Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 mm (9.6 in.) Rear Rigid Axle Ground Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 mm (7.4 in.)
Capacities Specifications Liquid Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8 L (5.8 U.S. gal) Fuel Tank Reserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 L (1.1 U.S. gal) Engine/Transmission Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L (3.17 qt) Engine/Transmission Oil Type . . . . . . . . . . . . .SAE 10W40, 4-stroke mineral based oil SG, SH or SJ or synthetic oil Differential Oil Capacity (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 ml (21 U.S. oz) Differential Oil Capacity (Rear) 75W90 or 80W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 ml (7 U.S. oz) Differential Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Synthetic Polyolester Oil 75W90 (API GL5) CV Joint Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEXACO, HTBJ Grease (M3014), ONLY Propeller Shaft Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHELL, Alvania EP-2, ONLY Hydraulic Brakes Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 ml (8.5 U.S. oz) Hydraulic Brakes Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Fluid DOT 4, ONLY Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (2.65 qt) Body and Frame Weight Distribution Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49/51% Front Storage Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 kg (22 lb) Rack Front (including front storage tray). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 kg (90 lb) Rack Rear (including tongue weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 kg (175 lb) Total Vehicle Load Allowed (including driver, all other loads and added accessories) . . . . . . . . . . . 220 kg (485 lb) Gross Vehicle Weight Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 kg (1200 lb) Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 kg (1100 lb)
Specifications Specifications - Trail Buck - 21
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Tongue (included with rear rack weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 kg (30 lb)
Torque Specifications Engine Torque Specifications Engine Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 N•m (35 lb-ft) Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (159 lb-in.) Oil Filter Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Dipstick Tube Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Magneto Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Starter Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Starter RED (+) Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.) Rotor Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 N•m (111 lb-ft) Stator Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Trigger Coil Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Cooling Torque Specifications Radiator Mount Screw/Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Thermostat Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Thermostat Bleeding Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (151 lb-in.) Water Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Fan Mount Screw/Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 N•m (40 lb-in.) Temperature Sender On Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) Exhaust Torque Specifications Exhaust Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) Heat Shield Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (89 lb-in.) Lubrication Torque Specifications Engine Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) Engine Oil Strainer Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Oil Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Oil Pressure Regulator Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Cylinder and Head Torque Specifications Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.) Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Rocker Arm Shaft Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (15 lb-ft) +90° rotation Cylinder Head Screw M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) Cylinder Head Screw M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft) +90° rotation Intake Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (16 lb-ft) Camshaft Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Chain Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Chain Tensioner Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Chain Tensioner Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (44 lb-in.)
Specifications Specifications - Trail Buck - 22
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Crankshaft Torque Specifications Crankcase Housing Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 N•m (33 lb-ft) +90° rotation Crankshaft Locking Access Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (16 lb-ft) Gearbox Torque Specifications Air Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bevel Gear Access Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Drive Pinion Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shifting Indicator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 N•m (80 lb-in.) 9 N•m (80 lb-in.) 21 N•m (16 lb-ft) 21 N•m (16 lb-ft) 9 N•m (80 lb-in.) 9 N•m (80 lb-in.) 4 N•m (35 lb-in.)
CVT Torque Specifications CVT Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Centrifugal Lever Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Drive Pulley (refer to CVT section for proper procedure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 N•m (74 lb-ft) Driven Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 N•m (44 lb-ft) Fuel Torque Specifications Carburetor Mounting Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 N•m (5.4 lb-in.) Drive Train Torque Specifications Front Wheel Hub Nut (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 N•m (103 lb-ft) Rear Wheel Hub Nut (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 N•m (103 lb-ft) Front Differential (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 N•m (49 lb-ft) Front Differential (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Rear Differential Socket Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 N•m (35 lb-ft) Propeller Shaft Screw (Engine Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (26 lb-ft) Propeller Shaft Screw (Differential Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft) Rear Differential Torx Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Rear Differential Protector (Torx Screw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Rear Differential Protector (Hexagonal Screw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Trailer Hitch Hexagonal Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 N•m (35 lb-ft) Differential Oil Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.) Front Differential Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 N•m (49 lb-ft) Wheel Torque Specifications Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Steering Control Torque Specifications Upper/Lower A-Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 N•m (41 lb-ft) Tie Rod Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Steering Arm (castellated nut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Ball Joint End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 N•m (46 lb-ft) Handlebar Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Steering Column Half Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Flanged Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (168 lb-in.)
Specifications Specifications - Trail Buck - 23
SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Handle Grip Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (35 lb-in.) Suspension Torque Specifications Shock Absorber Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 N•m (35 lb-ft) Rear Swing Arm RH Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 N•m (108 lb-ft) Rear Swing Arm LH Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) Rear Swing Arm LH Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 N•m (108 lb-ft) Brake Torque Specifications Caliper Brake Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Brake Disk Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft) Rear Master Cylinder Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (89 lb-in.) Rear Master Cylinder Banjo Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Front Master Cylinder Banjo Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Caliper Banjo Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Caliper Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 N•m (124 lb-in.) Rear Master Cylinder Rod Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (44 lb-in.) Rear Cable Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (89 lb-in.) Hydraulic Brake Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Body/Frame Torque Specifications Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Front Rack M6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 N•m (22 lb-in.) Front Rack M8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (133 lb-in.) Rear Rack M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (133 lb-in.) Rear Extension Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 N•m (35 lb-ft) Front Differential Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Seat Pivot Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Winch Plate Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Seat Latch Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 N•m (21 lb-ft) Seat Latch Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (35 lb-in.) Inner Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (44 lb-in.) A-Arm Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 N•m (22 lb-in.) Footrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Footpeg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 N•m (39 lb-in.) Removable Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) Engine Skid Plate M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (133 lb-in.) Engine Skid Plate M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (62 lb-in.) Headlight Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 N•m (5.4 lb-in.)
Specifications Specifications - Trail Buck - 24
ENGINE TABLE OF CONTENTS Engine
Table of Contents
Specifications .................................................27 Engine Specifications - 500..........................27 Engine Specifications - 650..........................27 Engine Specifications - 500 and 650............27 Required Tools .............................................30 Recommended Tools ...................................31 Diagnostics .....................................................32 Cooling System ............................................32 Magneto System ..........................................32 Lubrication....................................................33 Cylinder and Head........................................35 Gearbox........................................................36 CVT ..............................................................37 Engine General ............................................40 Tests and Adjustments ..................................44 Leak Test......................................................44 Repair...............................................................47 Component Location ....................................47 Engine Removal ...........................................47 Engine Installation ........................................51 Anti-Vibration System...................................52 Exhaust System ...........................................52 Shifting System ............................................54 Fuel Circuit ......................................................55 Fuel System Components ............................55 General.........................................................56 Fuel Lines.....................................................56 Fuel System Pressurization..........................56 Fuel Gauge...................................................56 Fuel Tank Draining .......................................57 Fuel Tank Strainer........................................57 Fuel Valve ....................................................58 Fuel Tank .....................................................59 Carburetor .......................................................61 Carburetor Components...............................61 Carburetor ....................................................62 Throttle Cable...............................................65 Choke Cable.................................................67 Fuel Pump ....................................................68 Fuel Circuit ......................................................70 Air Intake Components.................................70 Air Filter ........................................................71 Air Filter Cleaning/Draining ..........................71 Air Filter Box.................................................71
Rear Air Intake Adaptor ............................... 72 Cooling System.............................................. 73 Engine Side Components ............................ 73 Vehicle Side Components ........................... 74 General ........................................................ 74 Coolant Level............................................... 75 Cooling System Leak Test........................... 75 Draining The System ................................... 76 Coolant Replacement .................................. 76 Thermostat................................................... 77 Water Temperature Switch .......................... 78 Water Pump Housing................................... 78 Water Pump Impeller ................................... 79 Water Pump Shaft ....................................... 80 Radiator Cap................................................ 82 Radiator ....................................................... 82 Coolant Tank ............................................... 83 Cooling Fan ................................................. 83 Outlet Deflector............................................ 84 Temperature Sender.................................... 84 Ignition and Charging System ...................... 85 Charging Components................................. 85 General ........................................................ 85 Magneto Housing Cover .............................. 86 Seal.............................................................. 90 Bearing ........................................................ 91 Stator and Trigger Coil................................. 91 Vehicle Speed Sensor (VSS)....................... 92 Rotor ............................................................ 93 Oil System ...................................................... 94 Oil System Components .............................. 94 General ........................................................ 94 Engine Oil Pressure Test............................. 95 Oil Change................................................... 95 Oil Strainer................................................... 97 Engine Oil Pressure Regulator .................... 98 Oil Pump ...................................................... 99 Cylinder and Head ....................................... 104 Cylinder Head Components....................... 104 Piston and Rings Components .................. 105 General ...................................................... 105 Spark Plug ................................................. 106 Thermostat................................................. 106 Valve Cover ............................................... 106 Rocker Arm................................................ 107 Chain Tensioner ........................................ 110 Breather ..................................................... 111 Decompressor ........................................... 112
Engine Table of Contents - 25
ENGINE TABLE OF CONTENTS Camshaft Timing Gear ...............................114 Timing Chain ..............................................116 Cylinder Head.............................................116 Camshaft ....................................................118 Valve Spring ...............................................120 Valve ..........................................................121 Valve Guide Procedure ..............................123 Cylinder ......................................................125 Piston .........................................................127 Piston Rings ...............................................130 Crankshaft and Balancer .............................132 Crankshaft and Balancer Components ......132 Crankcase Components.............................133 General.......................................................133 Crankshaft Locking Procedure ...................134 Timing Chain ..............................................135 Chain Tensioner Guide ..............................135 Crankcase ..................................................136 Balancer Shaft............................................141 Crankshaft ..................................................142 Transmission - 650 .......................................148 Output Shaft and Transmission Components ...............................................148 Crankcase Components.............................149 General.......................................................149 Oil Seals .....................................................150 Output Shaft ...............................................151 Crankcase ..................................................155 Gearbox......................................................161 Shifting Indicator Switch .............................170 Starter Drive Pinion ....................................171 CVT Assembly - 500 .....................................173 Clutch Assembly Components ...................173 General.......................................................173 Belt Replacement .......................................174 Drive Pulley ................................................175 Driven Pulley ..............................................182
Engine Table of Contents - 26
ENGINE SPECIFICATIONS Specifications Engine Specifications - 500 Stroke (500 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 mm (2.5 in.) Displacement (500 cc Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498 cc (30.4 cu in.) Horsepower @ 7200 rpm (500 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.6 kW (37 hp)
Engine Specifications - 650 Stroke (650 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 mm (3.2 in.) Displacement (650 cc Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644 cc (39.3 cu in.) Horsepower @ 7100 rpm (650 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 kW (42 hp)
Engine Specifications - 500 and 650 General Specifications Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotax 4-TEC, 4 stroke Over Head Camshaft (OHC), Liquid cooled Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric with Optional Recoil Number of Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Number of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 valves Decompressor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Bore (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm (3.9 in.) Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5:1 Maximum HP RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7000 ± 100 rpm Lubrication . . . . . . . . Wet sump with replaceable oil filter (lubrication of engine and transmission simultaneously) Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow Air Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 stage foam filter Exhaust System Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nelson, stainless steel Exhaust System Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USDA approved Valves Intake Valve Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0° BTDC Intake Valve Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.0° ABDC Exhaust Valve Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.0° BBDC Exhaust Valve Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0° ATDC Intake Valve Stem Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.961 mm (0.2347 in.) Intake Valve Stem Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.975 mm (0.2352 in.) Intake Valve Stem Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.930 mm (0.2330 in.) Exhaust Valve Stem Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.946 mm (0.2341 in.) Exhaust Valve Stem Diameter (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.960 mm (0.2346 in.) Exhaust Valve Stem Diameter (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.930 mm (0.2330 in.) Valve Guide Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.060 mm (0.2386 in.) Valve Spring Free Length (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.45 mm (1.789 in.) Valve Spring Free Length (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.00 mm (1.693 in.) Intake Valve Seat Contact Width (New). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 to 1.30 mm (0.043 to 0.051 in.) Intake Valve Seat Contact Width (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 mm (0.07 in.) Exhaust Valve Seat Contact Width (New). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 to 1.55 mm (0.049 to 0.061 in.) Exhaust Valve Seat Contact Width (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.078 in.)
Engine Specifications - 27
ENGINE SPECIFICATIONS Pistons Piston Measurement (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.951 to 99.969 mm (3.935 to 3.936 in.) Piston Measurement (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.80 mm (3.929 in.) Piston/Cylinder Clearance (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.031 to 0.059 mm (0.001 to 0.002 in.) Piston/Cylinder Clearance (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 mm (0.004 in.) Piston Ring Type 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rectangular Piston Ring Type 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taper-face Piston Ring Type 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Scraper Ring Piston Ring End Gap Rectangular (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Piston Ring End Gap Taper-face (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Piston Ring End Gap Oil Scraper Ring (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Piston Ring End Gap Rectangular (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.) Piston Ring End Gap Taper-face (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.) Piston Ring End Gap Oil Scraper Ring (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Piston Ring End Gap All (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in.) Piston/Ring Groove Clearance Rectangular (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 mm (0.001 in.) Piston/Ring Groove Clearance Taper-face (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in.) Piston/Ring Groove Clearance Oil Scraper Ring (New minimum). . . . . . . . . . . . . . . . . . . . . . . . 0.020 mm (0.0008 in.) Piston/Ring Groove Clearance Rectangular (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070 mm (0.0028 in.) Piston/Ring Groove Clearance Taper-face (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 mm (0.0024 in.) Piston/Ring Groove Clearance Oil Scraper Ring (New maximum) . . . . . . . . . . . . . . . . . . . . . . . 0.055 mm (0.0021 in.) Rocker Arm Rocker Arm Bore Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Bore Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Bore Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Shaft Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Shaft Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Shaft Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.007 mm (0.7877 in.) 20.020 mm (0.7881 in.) 20.035 mm (0.7887 in.) 19.980 mm (0.7866 in.) 20.007 mm (0.7877 in.) 19.965 mm (0.7860 in.)
Cylinder Cylinder Screw M11 (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.5 mm (8.524 in.) Cylinder Bore (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.00 mm (3.94 in.) Cylinder Taper (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.) Cylinder Taper (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 mm (0.004 in.) Cylinder Out of Round (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 mm (0.0004 in.) Cylinder Out of Round (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.) Camshaft and Cam Camshaft Bearing Journal PTO Side (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal PTO Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal PTO Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal Magneto Side (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal Magneto Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Journal Magneto Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bore PTO Side (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bore PTO Side (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bore PTO Side (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications - 28
24.967 mm (0.9829 in.) 24.980 mm (0.9835 in.) 24.960 mm (0.9827 in.) 39.927 mm (1.5719 in.) 39.935 mm (1.5722 in.) 39.920 mm (1.5716 in.) 24.987 mm (0.9837 in.) 25.000 mm (0.9842 in.) 25.020 mm (0.9850 in.)
ENGINE SPECIFICATIONS Camshaft Bore Magneto Side (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.984 mm (1.5742 in.) Camshaft Bore Magneto Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000 mm (1.5748 in.) Camshaft Bore Magneto Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.020 mm (1.5756 in.) Cam Lobe Intake (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.369 mm (1.235 in.) Cam Lobe Intake (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.569 mm (1.243 in.) Cam Lobe Intake (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.300 mm (1.232 in.) Cam Lobe Exhaust (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.147 mm (1.226 in.) Cam Lobe Exhaust (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.347 mm (1.234 in.) Cam Lobe Exhaust (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.100 mm (1.224 in.) Crankshaft Crankshaft Axial Clearance (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.0078 in.) Crankshaft Axial Clearance (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.0196 in.) Crankshaft Pin Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.017 mm (1.7723 in.) Crankshaft Pin Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.033 mm (1.7729 in.) Crankshaft Pin Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 mm (1.7710 in.) Crankshaft Journal Diameter MAG Side (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.976 mm (2.1644 in.) Crankshaft Journal Diameter MAG Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.995 mm (2.1651 in.) Crankshaft Journal Diameter MAG Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.950 mm (2.1634 in.) Crankshaft Journal Diameter PTO Side (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.974 mm (1.8099 in.) Crankshaft Journal Diameter PTO Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.990 mm (1.8102 in.) Crankshaft Journal Diameter PTO Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.940 mm (1.8086 in.) Crankshaft Radial Clearance MAG Side (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.0028 in.) Crankshaft Radial Clearance PTO Side (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.0028 in.) Connecting Rod Connecting Rod Big End Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.080 mm (1.774 in.) Connecting Rod Big End Clearance (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.0035 in.) Connecting Rod Big End Axial Play (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150 mm (0.06 in.) Connecting Rod Big End Axial Play (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.302 mm (0.01 in.) Connecting Rod Big End Axial Play (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.) Connecting Rod Small End Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.01 mm (0.9059 in.) Connecting Rod Small End Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.02 mm (0.9063 in.) Connecting Rod Small End Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.07 mm (0.9080 in.) Piston Pin Piston Pin Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.996 mm (0.9053 in.) Piston Pin Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.000 mm (0.9055 in.) Piston Pin Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.990 mm (0.9051 in.) Piston Pin Bore Clearance (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.080 mm (0.0035 in.) Drive Belt (New nominal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.00 mm (1.260 in.) Drive Belt (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.00 mm (1.181 in.) Governor Cup Roller Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.70 mm (0.539 in.) Governor Cup Roller Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.90 mm (0.547 in.) Governor Cup Roller Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.20 mm (0.519 in.) Centrifugal Lever Centrifugal Lever Pivot Bolt Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.078 mm (0.239 in.) Engine Specifications - 29
ENGINE SPECIFICATIONS Centrifugal Lever Pivot Bolt Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Pivot Bolt Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Bore Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Pivot Bolt Bore Diameter (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Pivot Bolt Bore Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal Lever Pivot Bolt Bore Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.100 mm (0.240 in.) 6.000 mm (0.236 in.) 6.200 mm (0.244 in.) 6.113 mm (0.241 in.) 6.171 mm (0.243 in.) 6.300 mm (0.248 in.)
Drive Pulleys Drive Pulley Sliding Half Large Bushing (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000 mm (2.165 in.) Drive Pulley Sliding Half Large Bushing (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.002 mm (2.166 in.) Drive Pulley Sliding Half Large Bushing (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.200 mm (2.173 in.) Drive Pulley Sliding Half Small Bushing (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.000 mm (1.181 in.) Drive Pulley Sliding Half Small Bushing (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.002 mm (1.182 in.) Drive Pulley Sliding Half Small Bushing (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.200 mm (1.189 in.) One-Way Clutch Bushing Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.990 mm (1.574 in.) One-Way Clutch Bushing Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.085 mm (1.578 in.) One-Way Clutch Bushing Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.100 mm (1.579 in.) Driven Pulley Sliding Half Bushing Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . 30.000 mm (1.181 in.) Driven Pulley Sliding Half Bushing Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . 30.002 mm (1.182 in.) Driven Pulley Sliding Half Bushing Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.200 mm (1.189 in.) Driven Pulley Fixed Half Bushing Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.000 mm (1.181 in.) Driven Pulley Fixed Half Bushing Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.002 mm (1.182 in.) Driven Pulley Fixed Half Bushing Diameter (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.200 mm (1.189 in.) Torque Gear On Driven Pulley (Service limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.500 mm (0.295 in.) Main Shaft MAG Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.990 mm (0.708 in.) Main Shaft PTO Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.950 mm (0.982 in.) Bevel Gear Shaft PTO Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.990 mm (0.984 in.)
Required Tools Special or Required Tools Tool Name
Tool No.
Tool Use
Small Hose Pincher (Pack of 2)
295 000 076
Used during cooling system leak test.
Large Hose Pincher
529 032 500
Used during coolant replacement.
Magneto Puller (Flywheel Puller)
529 035 748
Used to remove rotor from crankshaft.
Crankshaft Protector
420 876 557
Protects crankshaft during rotor removal.
Crankshaft Locking Bolt
529 035 617
Used to lock crankshaft at TDC for removal and installation of rocker arm assemblies, camshaft, cylinder head, and drive pulley.
Bevel Gear Lock Pin/Driven Clutch Expander
529 035 747
Used to lock gearbox when measuring backlash.
Driven Clutch Puller
529 035 746
Used when removing fixed pulley, and locking camshaft to prevent timing chain stretching.
Drive Clutch Holding Tool
529 035 745
Used to block ring gear when removing and installing drive pulley.
Engine Specifications - 30
ENGINE SPECIFICATIONS Recommended Tools Special or Required Tools Tool Name Valve Spring Compressor
Tool No.
Tool Use
JDM70
Used to remove and install valve springs.
JT03502
Used for cylinder leakdown test
Hand-Held Digital Tachometer
JT05719
Used to check idle speed and starter performance.
Oil Pressure Gauge Assembly
JT03344
Used to read engine oil pressure.
Radiator Pressure Test Kit
JDG692
Used to test cooling system.
Cooling System Pressure Pump
DO5104ST
Used to test cooling system.
Vacuum Gauge
JT03503
Used to check engine crankcase vacuum.
Vacuum/Pressure Pump Leak Down Tester Multitester
Ring Compressor
Used to install pistons.
41 mm Socket Spark Tester
D-05351ST
Used to check overall condition of ignition system.
Engine Specifications - 31
ENGINE DIAGNOSTICS Diagnostics
Symptom: High Engine Operating Temperatures
Cooling System The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. This section pertains to engine mechanical components only. Some related problems can come from other systems such as ignition system, fuel system etc. and have an impact on the engine. Ensure to check the other systems prior to concluding that the engine is in fault.
Symptom: High Engine Operating Temperatures (1) Check coolant level. Coolant less than recommended level?
(8) Check condition of impeller located on the water pump shaft. Impeller wings broken and/or impeller thread is damaged? Yes - Replace. No - Go to next step. (9) Check coolant drain screw on water pump housing MAG side (marked “Drain”). Copper ring on drain screw leaks? Yes - Retighten screw and/or replace copper gasket ring. No - Go to next step. (10) Check cylinder head and/or cylinder base gasket. Worn out gasket(s) is (are) causing water leakage?
Yes - Refill (refer to “Cooling System”). No - Go to next step. (2) Check temperature sensor for electrical/ mechanical failure. Temperature sensor defective? Yes - Replace.
Yes - Replace gasket(s) and refill with coolant and oil (refer to “Cooling/Lubrication System” and Specifications" section). No - Go to next step.
No - Go to next step. (3) Check thermostat. Thermostat defective? Yes - Replace thermostat.
(11) Check intermediate gear(s) behind magneto cover. Worn out and/or broken gear(s) is (are) causing less coolant supply? Yes - Replace worn out and/or broken gear(s) (refer to “Lubrication/Magneto System”).
No - Go to next step. (4) Check gasket underneath water pump. Is there leakage in water pump cover area? Yes - Retighten screws or replace gasket.
Magneto System Symptom: No Spark
No - Go to next step. (5) Check leak indicator hole (water pump housing area MAG side) if coolant leaks. Coolant leaking from leak indicator hole means a damaged rotary seal inside magneto cover. Yes - Replace both rotary seal and oil seal (refer to “Cooling System” and “Magneto System”). No - Go to next step.
(1) Check engine stop switch position. Is engine stop switch in OFF position? Yes - Go to next step. No - Place engine stop switch to RUN position (2) Check battery. Is the battery charge level low, or has electrical failure? Yes - Charge or replace battery.
(6) Check coolant bleeding screw on thermostat housing. Screw loose/missing and/or gasket ring is missing/broken?
No - Go to next step. (3) Check condition of fuse(s). Are fuse(s) faulty?
Yes - Retighten/add screw and replace gasket ring.
Yes - Replace.
No - Go to next step.
No - Go to next step.
(7) Check condition of hoses and hose clamps fixation. Hoses are brittle and/or hard? Hose clamps are loose? Yes - Replace hoses, retighten clamps. No - Go to next step.
(4) Check ignition coil for damage and/or electrical failure. Ignition coil damaged? Connector is corroded or ignition coil shows electrical failure? Wire harness is brittle or hard (no connection)? Yes - Replace ignition coil. Clean spark plug area and replace ignition coil. Replace harness.
Engine Diagnostics - 32
ENGINE DIAGNOSTICS Symptom: No Spark
Symptom: No Spark
No - Go to next step. (5) Check spark plug electrode condition. Gap is too big or spark plug condition is bad? Yes - Readjust gap (refer to Specifications" section). Diagnose spark plug condition and replace it (refer to “Ignition System�). No - Go to next step. (6) Check spark plug cable and ignition wire. Cable and/or ignition wire is (are) damaged and/or shows electrical failure? Yes - Replace damaged part(s). No - Go to next step. (7) Check ignition coil for damage and/or electrical failure. Is ignition coil damaged and/or resistance value out of specification (refer to Specifications" section)? Is connector corroded or ignition coil shows electrical failure? Is wire harness brittle or hard (no connection)? Yes - Replace ignition coil. Clean connector area and/or replace ignition coil. Replace harness.
Yes - Replace electronic module. Clean and reconnect. Clean metal surface for good ground.
Lubrication Symptom: Low or No Oil Pressure/High Oil Consumption (1) Check oil level and search for leakage on crankcase and/or defective seals. Crankcase is leaking due to damage? Yes - Rebuild engine with new crankcase and gasket parts. Use a high quality oil (refer to Specifications" section). No - Go to next step. (2) Incorrect oil being used? Yes - Use a high quality oil (refer to Specifications" section). No - Go to next step. (3) Crankcase is leaking due to loose screws? Yes - Retighten screws with recommended torque.
No - Go to next step. (8) Check trigger coil on magneto for damage and/or electrical failure. Sensor shows electrical failure and/or damages? Connector is corroded? Resistance value is out of specification (refer to Specifications" section)? Yes - Replace magneto. Clean and reconnect. Replace magneto.
No - Go to next step. (4) Sealing rings, O-rings and/or gaskets are brittle and/or hard or damaged? Yes - Replace damaged parts No - Go to next step. (5) Check oil filter for contamination. Oil filter clogged?
No - Go to next step. (9) Check wire harness for cracks or other damages. Harness shows electrical failure and/or other damages? Yes - Replace wire harness and/or damaged wire section. No - Go to next step. (10) Check magneto for damage and/or electrical failure. Radial position of rotor wrong due to a broken woodruff key? Connector on magneto is damaged and/ or has electrical failure? Coating on stator winding is damaged? Resistance value is out of specification (refer to Specifications" section)? Yes - Replace woodruff key. Repair and clean contacts of connector. Replace magneto. (11) Check electronic module. Module shows electrical failure or damages? Connectors are corroded? Electronic module has bad ground to the vehicle frame?
Yes - Replace oil filter and oil at the same time. Use a high quality oil (refer to Specifications" section). No - Go to next step. (6) Check oil pressure regulator valve (spring) function. Valve spring damaged (valve always open)? Valve stays open in crankcase PTO due to contamination (metallic particles)? Yes - Replace spring. Clean and/or repair valve piston. No - Go to next step. (7) Check oil drain plug on engine bottom. Plug is loose and/or gasket ring is missing? Yes - Retighten the plug and/or place gasket ring. No - Go to next step.
Engine Diagnostics - 33
ENGINE DIAGNOSTICS Symptom: Low or No Oil Pressure/High Oil Consumption (8) Check oil strainer on engine bottom. Screw(s) is (are) loose and/or gasket is damaged, brittle or hard? Oil strainer is clogged due to contamination? Yes - Retighten screw and/or replace gasket. Clean or replace strainer and diagnose causes. Replace possible damaged parts. Use high quality oil (refer to Specifications" section). No - Go to next step. (9) Check leak indicator hole for oil leaks (water pump housing area MAG side). Oil leaking from leak indicator hole means a damaged oil seal inside magneto cover on water pump shaft. Yes - Replace both rotary seal and oil seal (refer to “Cooling System” and “Magneto System”)
Symptom: Low or No Oil Pressure/High Oil Consumption (16) Piston rings worn out (blue-colored engine exhaust emission)? Yes - Replace piston rings (refer to “Cylinder and Head”). No - Go to next step. (17) Piston rings are broken (low compression and bluecolored engine exhaust emission)? Yes - Replace piston rings (refer to “Cylinder and Head”). No - Go to next step. (18) Valve stem seal damaged and/or sealing lip is hard and/or brittle? Yes - Replace all valve stem seals.
No - Go to next step. (10) Check oil pressure switch function. Oil pressure switch damaged? Yes - Replace oil pressure switch. No - Go to next step. (11) Check oil orifice(s) on the oil pump suction side. Oil orifice(s) is (are) clogged? Yes - Clean from contamination. Replace oil and oil filter if necessary (refer to “Maintenance” or “Lubrication”). No - Go to next step. (12) Check oil pump operation. Oil pump rotor is out of wear limit? Yes - Replace oil pump shaft (refer to “Lubrication”). No - Go to next step. (13) Oil pump seized due to oil leakage and/or air inclusion? Yes - Replace oil pump (refer to “Lubrication”). No - Go to next step. (14) Gears driving oil pump are broken or damaged? Yes - Replace gears. No - Go to next step. (15) Check plain bearings in crankcase for heavy wear. Plain bearings out of specification (increased clearance)? Yes - Replace all plain bearings at the same time (refer to “Crankshaft”).
Symptom: Oil Contamination (White Appearance) (1) Check leak indicator hole (water pump housing area MAG side) if coolant and oil leaks. Leakage of oil/ coolant mixture from leak indicator hole means damaged oil seal and rotary seal inside magneto cover on water pump shaft. Coolant or oil leaks? Yes - Replace both rotary seal and oil seal and refill with recommended oil and/or coolant (refer to “Cooling System” and “Magneto System”). No - Go to next step. (2) Check cylinder head and/or cylinder base gasket. Gasket damaged or leaking? Yes - Retighten cylinder head with recommended torque and/or replace gasket. No - Go to next step. (3) Check screws for torque. Screws not fixed? Yes - Retighten screws with recommended torque and/or replace oil. No - Go to next step. (4) Check oil for particles (may indicate possible damages inside the engine). Oil contamination due to metal or plastic particles? Yes - Replace possibly damaged part(s) including oil and oil filter. Use a high quality oil (refer to Specifications" section).
No - Go to next step.
Engine Diagnostics - 34
ENGINE DIAGNOSTICS Cylinder and Head Symptom: Unusual Engine Noise and/or Vibration In Idle Speed (1) Check operation of decompressor located on camshaft. Decompressor shaft is stuck and/or torsion spring is damaged? Yes - Replace spring and/or decompressor mechanism.
Symptom: Oil Contamination on Cylinder and/or Head Yes - Clean spark plug area and replace spark plug tube.
Symptom: Unusual Engine Noise and/or Vibration (1) Check for possible plain bearing failure. Oil pressure is out of specified values?
No - Go to next step. (2) Check chain tensioner operation. Faulty chain tensioner?
Yes - Replace damaged parts (refer to “Lubrication”). No - Go to next step. (2) Connecting rod small end bearing is damaged and/ or out of specification?
Yes - Replace spring and/or mechanism.
Symptom: Unusual Engine Noise and/or Vibration While Operating (1) Check items 1 and 2 of “Unusual Engine Noise and/or Vibration in Idle Speed”. Check Noise coming from cylinder head area. Chain guide worn out?
Yes - Replace damaged and/or worn out part(s). No - Go to next step. (3) Connecting rod big end clearance is out of specification? Yes - Replace damaged and/or worn out part(s). No - Go to next step.
Yes - Replace chain guide. No - Go to next step. (2) Stretched chain and/or worn out sprocket? Yes - Replace chain and sprocket at the same time. No - Go to next step.
(4) Crankshaft plain bearing MAG/PTO side is damaged and/or out of specification? Yes - Replace crankshaft and plain bearing MAG/ PTO at the same time (refer to “Crankshaft”). No - Go to next step.
(3) Sprocket screw got loose? Yes - Retighten screw with recommended torque.
(5) Check ball bearing(s) on balancer shaft end(s). Ball bearing(s) do(es) not move freely? Yes - Replace bearing(s).
No - Go to next step. (4) Hydraulic element inside rocker arm(s) is (are) worn out (valve adjustment)? Yes - Replace rocker arm(s).
Symptom: Oil Contamination on Cylinder and/or Head (1) Check screws for torque. Loose screws?
No - Go to next step. (6) Check that mark on balancer shaft is aligned with crankshaft position mark. Mark on balancer shaft and crankshaft are not aligned? Yes - Readjust position of balancer shaft and crankshaft (refer to “Crankshaft/Balancer Shaft”). No - Go to next step.
Yes - Retighten screws with recommended torque. No - Go to next step. (2) Gaskets are brittle, hard, worn out or damaged? Yes - Replace damaged gasket(s).
(7) Check thrust washer(s) on crankshaft MAG/PTO side. Thrust washer(s) is (are) missing on MAG and/or PTO side? Yes - Fit thrust washer(s).
No - Go to next step. (3) Spark plug in the contact area to ignition coil fouled by oil?
Engine Diagnostics - 35
ENGINE DIAGNOSTICS Gearbox
Symptom: Gear Indication Fails
Symptom: Unusual Engine Noise and/or Vibrations (1) Check oil level in engine. Oil leakage from engine? Yes - Replace damaged gasket(s) and/or oil seal(s), torque screws and refill with oil up to specified level (refer to Specifications" section).
(5) Wire harness has broken cables? Yes - Replace wire harness.
Symptom: Gear(s) Is (Are) Hard To Shift (1) Check engine idle speed (choke in use). Choke is in use and increases the engine RPM? Yes - Go to next step.
No - Go to next step. (2) Check bearings in the gearbox for free movement. Bearing(s) do(es) not move freely?
No - Adjust or repair choke. (2) Idle speed is too high (CVT engages)?
Yes - Replace bearing(s).
Yes - Adjust idle speed.
No - Go to next step.
No - Go to next step.
(3) Check for knocking noise. Tooth of gears are damaged and/or worn? Yes - Replace respective gears. No - Go to next step. (4) Check backlash on the output shaft. Backlash exceeds service limit? Yes - Perform bevel gear adjustment and replace distance shims.
Yes - Readjust indexation of shifting lever in accordance with side panel. No - Go to next step. (4) Shifting lever is bent? Yes - Replace lever. No - Go to next step.
Symptom: Gear Indication Fails (1) Check wire harness connector pins (gear indicator) and/or electronic system. Connector pins are corroded and/or damaged? Yes - Clean connector and/or replace wire harness if damaged. No - Go to next step. (2) Electronic system failed and/or damaged? Yes - Repair and/or replace damaged part(s). No - Go to next step. (3) Check contact screws on PTO side (behind CVT driven pulley) for damage and/or wear. Shifting indicator switch(es) pin(s) is (are) worn and/or damaged?
(5) Check drive pulley one-way clutch. Bearing inside one-way clutch does not move freely? Yes - Replace one-way clutch (refer to CVT). No - Go to next step. (6) Shifting lever is bent? Yes - Replace lever. No - Go to next step. (7) Check shift shaft spline and/or shift forks for wear and/or damages. Shifting indicator switch(es) pin(s) is (are) worn out (no roundings on top of pin)? Yes - Replace shifting indicator switch(es). No - Go to next step. (8) Shift shaft is worn out and/or shows damaged splines?
Yes - Replace shifting indicator switch(es). No - Go to next step. (4) Contact(s) is (are) corroded and/or contact screw for wire harness got loose? Yes - Clean contact surface and retighten contact screw(s) with recommended torque. No - Go to next step.
(3) Check indexation of shifting lever on vehicle side panel. Lever is not aligned with vehicle side panel indexation?
Yes - Replace shift shaft. No - Go to next step. (9) Shift drum track(s) and/or splines is (are) worn out or damaged? Yes - Replace shift drum and damaged part(s). No - Go to next step.
Engine Diagnostics - 36
ENGINE DIAGNOSTICS Symptom: Gear(s) Is (Are) Hard To Shift (10) Isolating washer located on the shift drum is worn and/or damaged? Yes - Replace isolating washer.
No - Go to next step. (6) Check drive pulley sliding half for free axial movement. Sliding half is stuck (refer to CVT)?
No - Go to next step. (11) Shift fork(s) is (are) worn out and/or engagement pins are damaged? Yes - Replace shift fork(s). No - Go to next step. (12) Shift fork(s) is (are) worn out and/or fork(s) is (are) damaged?
Yes - Replace damaged part(s). No - Go to next step. (7) Check condition of drive/driven pulley spring. Drive pulley spring tension is too smooth and/or damaged (refer to CVT)? Yes - Replace spring. No - Go to next step.
Yes - Replace shift fork(s).
(8) Driven pulley spring tension is too stiff (refer to CVT)?
No - Go to next step. (13) Shift gear(s) is (are) worn out?
Yes - Replace spring.
Yes - Replace shift gear(s).
No - Go to next step.
CVT Symptom: The UATV Accelerates Slowly, Especially When It Is Stopped (1) Check for possible water/dirt intrusion. Water/dirt inside CVT area? Yes - Unscrew drain screw and/or remove CVT cover and clean CVT area from contamination. No - Go to next step. (2) Oil leakage out of crankcase PTO and/or oil seal(s) (slipping belt)? Yes - Replace damaged part(s) (refer to “Gearbox”). No - Go to next step. (3) Check drive belt condition. Belt is too narrow (drive belt engagement RPM is higher than normal)? Yes - Replace belt if width is less than specified (refer to “CVT” and/or Specifications" section). No - Go to next step. (4) Check roller(s) on governor cup and/or lever condition on drive pulley sliding half. Roller(s) is (are) worn and/or damaged (refer to CVT)? Yes - Replace governor cup assembly.
(9) Check carburetor adjustment and/or high altitude calibration. Carburetor is not adjusted according to specified values and/or high altitude calibration? Yes - Readjust carburetor/
Symptom: Engine Maximum RPM Is Too High And Top Speed Is Not Reached (1) Check items 1 to 4 of “The UATV Accelerates Slowly, Especially When It Is Stopped”. Check drive/driven pulley spring tension. Drive pulley spring tension is too stiff? Yes - Replace spring (recommended spring). No - Go to next step. (2) Driven pulley spring tension is too smooth and/or damaged (refer to CVT)? Yes - Replace spring.
Symptom: Drive Pulley Noise In Idle Speed (1) Check slider shoes (drive pulley). Worn slider shoes (increased clearance between governor cup and drive pulley sliding half)? Yes - Replace all slider shoes at the same time (slider shoes kit). No - Go to next step.
No - Go to next step. (5) Lever(s) on drive pulley sliding half is (are) worn and/or damaged (refer to CVT)? Yes - Replace governor cup assembly.
Symptom: The UATV Accelerates Slowly, Especially When It Is Stopped
(2) Check drive pulley sliding mechanism (between drive pulley outer and inner half). Mechanism is stuck and/or damaged? Yes - Replace drive pulley assembly.
Engine Diagnostics - 37
ENGINE DIAGNOSTICS Symptom: Drive Pulley Noise In Idle Speed No - Go to next step. (3) Check roller(s) and/or levers for wear (located on sliding half of drive pulley). Roller(s) on governor cup is (are) worn out and/or damaged (refer to CVT)?
Symptom: Drive Pulley Noise When Accelerating/Decelerating No - Go to next step. (3) Check drive/driven pulley screw for torque. Loose screw on drive and/or driven pulley?
Yes - Replace governor cup assembly.
Yes - Retighten screw with recommended torque.
No - Go to next step.
No - Go to next step.
(4) Lever(s) on drive pulley sliding half is (are) worn out and/or damaged (refer to CVT)? Yes - Replace all levers at the same time (lever kit).
(4) Check cam and driven pulley fixed half for wear. Cam and/or drive pulley fixed half out of wear limit and/ or damaged? Yes - Replace damaged part(s).
No - Go to next step. (5) Check drive pulley screw for torque. Loose screw? Yes - Retighten screw with recommended torque. No - Go to next step. (6) Check one-way clutch condition on drive pulley sliding half. Bearing(s) do(es) not move freely? Yes - Replace damaged part(s) and lubricate inside of one-way clutch (refer to CVT). No - Go to next step. (7) Spring sleeve(s) inside one-way clutch is (are) worn out? Yes - Replace both sleeves and springs and lubricate inside of one-way clutch (refer to CVT). No - Go to next step. (8) Spring(s) inside one-way clutch is (are) worn out? Yes - Replace both pins and springs and lubricate inside of one-way clutch (refer to CVT).
Symptom: Drive Pulley Noise When Accelerating/Decelerating (1) Check items 1 to 5 of “Drive Pulley Noise In Idle Speed�. Check if belt runs in dry conditions. Drive pulley area is wet/contaminated due to water/dirt intrusion? Yes - Clean driven pulley area and/or drain water our of CVT cover. No - Go to next step. (2) Check for foreign particles in CVT area (stones, dirt, etc.). Small particles damaged belt and/or pulley surface(s)? Yes - Clean system and replace damaged parts (refer to CVT).
No - Go to next step. (5) Check torque gear fixed in driven pulley sliding half for wear. Torque gear out of wear limit and/or damaged? Yes - Replace torque gear (refer to CVT).
Symptom: Vibrations Originating From Drive Pulley (1) Check tightening torque of drive pulley nut. Moving sliding half? Yes - Retighten nut. No - Go to next step. (2) Check fixed half bushings. Excessive gap between bushings and fixed half shaft, thus restraining sliding half movements? Yes - Replace fixed half assembly. No - Go to next step. (3) Check starter ring gear condition. Starter ring gear loosened? Yes - Retighten ring gear and/or mount it in original position (balanced system) No - Go to next step. (4) Check if slider shoes are present and/or placed in correct position. Slider shoe(s) is (are) missing and/or damaged? Yes - Replace all slider shoes at the same time (slider shoes kit).
Symptom: Vibrations Originating From Driven Pulley (1) Check fixed and sliding half bushings on driven pulley. Excessive gap between bushings and CVT shaft, thus restraining sliding half movements?
Engine Diagnostics - 38
ENGINE DIAGNOSTICS Symptom: Vibrations Originating From Driven Pulley Yes - Replace fixed and/or sliding half of driven pulley, polish CVT shaft area with fine emery cloth and wipe clean with a cloth.
Symptom: Pulleys Do Not Down/Up Shift Properly (1) Check roller levers for wear and groove on running surface. Levers are worn out? Yes - Replace lever kit (refer to “CVT”).
Symptom: Belt Glazed Excessively Or Having Baked Appearance No - Go to next step. (3) Check misuse due to keeping the vehicle uphill by throttling. Belt glazed due to overload? Yes - Clean CVT area and replace belt with proper type of belt (refer to Specifications" section). No - Go to next step. (4) Check if pulley halves are clean. Oil on pulley surfaces? Yes - Clean pulley halves and replace belt.
No - Go to next step.
No - Go to next step.
(2) Rollers are worn out in diameter? Yes - Replace governor cup (refer to “CVT”). No - Go to next step. (3) Check drive pulley bushings (cleanliness, wear, etc.). Bushings stick to fixed half pulley shaft? Yes - Clean or replace.
(5) Water intrusion in CVT area? Yes - Find root cause and repair. Drain water and replace belt.
Symptom: Belt Worn Excessively In Top Width (1) Check drive belt width. Considerable wear?
No - Go to next step. (4) Spring seat sticks to sliding half pulley bushing? Yes - Clean system and/or replace sliding half pulley. No - Go to next step. (5) One-way clutch does not operate properly? Yes - Clean system and/or replace damaged part(s). No - Go to next step. (6) Check driven pulley spring tension. Driven pulley spring tension is too weak and/or broken? Yes - Replace.
Yes - Replace belt if narrower than specified (refer to “CVT” or Specifications" section). No - Go to next step. (2) Check drive belt identification number. Improper belt angle (wrong type of belt)? Yes - Replace belt with an appropriate drive belt. No - Go to next step. (3) Check for localized belt wear caused by belt slippage. Localized wear? Yes - Replace belt.
Symptom: Belt Disintegration
No - Go to next step. (7) Driven pulley cam is worn or damaged?
(1) Check drive belt identification number. Using unspecified type of belt?
Yes - Replace.
Yes - Replace belt with proper type of belt.
Symptom: Belt Glazed Excessively Or Having Baked Appearance (1) Check if CVT air intake and/or outlet is clogged. CVT area heats up due to contamination? Yes - Clean air intake and/or outlet from contamination.
No - Go to next step. (2) Check if pulley halves are clean. Oil on pulley surfaces? Yes - Clean pulley surfaces with fine emery cloth and wipe clean. No - Go to next step.
No - Go to next step. (2) Fans located on drive pulley fixed half (underneath ring gear) are clogged?
(3) Drive/driven pulley halves are damaged through stones inside CVT area?
Yes - Clean from contamination.
Engine Diagnostics - 39
ENGINE DIAGNOSTICS Symptom: Belt Disintegration
Symptom: Engine Backfires
Yes - Clean pulley surfaces with fine emery cloth, wipe clean with a cloth or replace drive/driven pulley halves and belt.
Symptom: Flex Cracks Between Cogs
(7) Check calibration of carburetor. Wrong carburetor adjustment (engine to lean)? Yes - Clean and readjust carburetor.
Symptom: Engine Suddenly Turns Off
(1) Check drive belt condition. Considerable use, belt wearing out? Yes - Replace.
(1) Check spark plug cap contact and/or cable. Spark plug cap loose? Yes - Replug cap.
No - Go to next step.
No - Go to next step.
(2) Brittle belt condition through aging?
(2) Spark plug cable melted and/or damaged?
Yes - Replace.
Yes - Replace spark plug cable. No - Go to next step.
Engine General
(3) Check condition of spark plug (blue spark ideal). Red, jumping spark means a damaged spark plug.
Symptom: Engine Backfires (1) Check spark plug and/or electrical system. Carbon accumulation caused by defective spark plug? Yes - Clean carbon accumulation and replace spark plug. No - Go to next step.
Yes - Replace spark plug with appropriate heat range (refer to Specifications" section). No - Go to next step. (4) Spark plug in poor condition? Yes - Readjust carburetor and/or replace spark plug.
(2) Electrical system has failure?
No - Go to next step.
Yes - Replace defective part(s).
(5) Check fuel supply to engine intake. Fuel valve is switched off?
No - Go to next step. (3) Check leakage on intake manifold/air filter box. Air leak on intake system? Yes - Retighten screws and/or replace intake manifold/air filter box.
Yes - Turn on fuel valve. No - Go to next step. (6) Run out of fuel? Yes - Turn fuel valve to “RES� position and refill.
No - Go to next step. (4) Check exhaust air leaking. Exhaust gasket is leaking?
No - Go to next step. (7) Poor quality and/or wrong fuel?
Yes - Retighten screws and/or replace exhaust gasket.
Yes - Clean from contamination and use appropriate fuel.
No - Go to next step.
No - Go to next step.
(5) Check intake valve(s) for leaking. Intake valve(s) is (are) leaking? Yes - Repair or replace valve(s).
Yes - Clean fuel supply from contamination. No - Go to next step.
No - Go to next step. (6) Check if fuel supply is insufficient at high RPM. Fuel line is contaminated and/or bent (engine gets lean)? Yes - Clean and/or replace defective part(s). No - Go to next step.
(8) Fuel supply insufficient at high RPM?
(9) Carburetor contaminated? Yes - Clean jets and carburetor float chamber from contamination. No - Go to next step. (10) Fuel line clogged and/or bent?
Engine Diagnostics - 40
ENGINE DIAGNOSTICS Symptom: Engine Suddenly Turns Off
Symptom: Engine Suddenly Turns Off
Yes - Clean fuel supply from contamination and/or replace defective part(s).
Yes - Clean from contamination and use appropriate fuel.
No - Go to next step.
No - Go to next step.
(11) Perform engine leak test. Refer to “Engine Leak Test” procedure. Check for possible piston seizure. Damaged head gasket and/or seal and/or leaking inlet/ exhaust valve(s)?
(20) Cracked or broken piston. Cracked or broken piston due to excessive piston/cylinder clearance or engine overreving?
Yes - Replace and/or repair defective parts.
Yes - Replace piston. Check piston/cylinder clearance (refer to “Cylinder and Head”).
No - Go to next step.
No - Go to next step.
(12) Piston seizure (piston ring(s) damaged and/or cylinder shows grooves). Spark plug heat range is too low?
(21) Check connecting rod, crankshaft, rocker arm rollers movement. Connecting rod failure due to lack of oil?
Yes - Replace damaged parts and install spark plug with appropriate heat range.
Yes - Repair and replace defective parts and use a high quality oil.
No - Go to next step.
No - Go to next step.
(13) Compression ratio is too high?
(22) Crankshaft failure due to lack of oil?
Yes - Install genuine parts.
Yes - Repair and replace defective parts and use a high quality oil.
No - Go to next step.
No - Go to next step.
(14) Poor oil quality?
(23) Oil contamination due to clogged oil filter?
Yes - Use a high quality oil.
Yes - Replace oil filter and oil at the same time, replace defective part(s).
No - Go to next step. (15) Leaks at air intake manifold (engine gets too lean)? Yes - Retighten screws or replace air intake manifold. No - Go to next step. (16) Contamination (like sand) through engine intake? Yes - Replace defective part(s) and use new air filter. (17) Melted and/or perforated piston dome; melted section at ring end gap. Spark plug heat range is too low?
Yes - Replace defective part(s) and do the valve adjustment.
(25) Check for water intrusion through intake system into combustion chamber. Water in intake system and/ or combustion chamber? Yes - Replace defective part(s).
Yes - Install recommended spark plug.
Symptom: Engine Turns Over But Fails To Start
No - Go to next step. (18) Coolant less than recommended level (engine gets too hot)? Yes - Repair cooling circuit and/or refill with recommended liquid.
(19) Poor quality and/or wrong fuel?
(24) Check valve springs exhaust/inlet. Broken valve spring damages the cylinder head, valve(s), rocker arm(s)/piston?
No - Go to next step.
No - Go to next step.
No - Go to next step.
No - Go to next step.
(1) Check items of “Engine Does Not Start - No Spark At Spark Plug”. Check battery power. Battery shows a lack of power? Yes - Charge or replace battery. No - Go to next step. (2) Check spark plug. Inspect spark plug (no spark) or wrong spark plug gap?
Engine Diagnostics - 41
ENGINE DIAGNOSTICS Symptom: Engine Turns Over But Fails To Start Yes - Readjust gap and clean spark plug or replace. No - Go to next step. (3) Check for fuel on spark plug and inside carburetor. Flooded engine (spark plug wet when removed)? Yes - Do not overchoke. Remove wet spark plug, turn ignition switch to OFF and crank engine several times. Install clean dry spark plug. Start engine following usual starting procedure. No - Go to next step. (4) Flooded engine because of contaminated/defective floater inside carburetor float chamber? Yes - Clean and/or replace defective part(s). No - Go to next step. (5) Check engine compression. Insufficient engine compression? Yes - Replace defective part(s) (ex.: piston, ring(s), etc.).
(6) Valve seat worn and/or damaged? Yes - Repair by performing valve guide procedure (refer to “Cylinder and Head”). Readjust valve clearance.
Symptom: Engine Does Not Offer Maximum Power and/or Does Not Reach Maximum Operating RPM (1) Check items of “Engine Suddenly Turns Off”. Check air intake system. Air filter is clogged due to contamination?
Yes - Replace and/or repair defective parts. No - Go to next step. (5) Worn piston and/or piston ring(s)? Yes - Replace (refer to “Cylinder and Head”). No - Go to next step. (6) Check for water in fuel (wrong fuel). There is water in fuel or wrong fuel? Yes - Drain fuel system, search for leakage and refill it with appropriate fuel. No - Go to next step. Yes - Replace belt if width is less than specified (refer to CVT).
Symptom: High Engine Operating Temperature (1) Check if cooling system shows any failure (see “Cooling System”). System is leaking? Yes - Repair and/or replace damaged part(s). No - Go to next step. (2) Check oil level. Oil level is to high? Yes - Drain and refill with appropriate oil. No - Go to next step.
Yes - Replace air filter. No - Go to next step. (2) Check spark plug condition and/or gap. Fouled spark plug or wrong spark plug gap? Yes - Readjust gap and clean spark plug or replace. No - Go to next step. (3) Check spark plug type. Improper spark plug heat range?
No - Go to next step.
(4) Check engine compression and perform engine leak test. Refer to “Engine Leak Test” procedure. Check for possible piston seizure. Damaged head gasket and/or seal and/or leaking inlet/exhaust valve(s)?
(7) Check drive belt. Worn belt?
No - Go to next step.
Yes - Install recommended spark plug.
Symptom: Engine Does Not Offer Maximum Power and/or Does Not Reach Maximum Operating RPM
(3) Check condition and heat range of spark plug. Melted spark plug tip or inadequate heat range? Yes - Install recommended spark plug. No - Go to next step. (4) Check air inlet and outlet of the CVT cover. Air circulation is clogged (overheating)? Yes - Clean air circulation from contamination. No - Go to next step. (5) Drive belt worn and/or damaged? Yes - Replace belt with an appropriate drive belt. No - Go to next step.
Engine Diagnostics - 42
ENGINE DIAGNOSTICS Symptom: High Engine Operating Temperature (6) Check calibration of carburetor. Wrong carburetor adjustment (engine too lean)? Yes - Clean and readjust carburetor.
Symptom: Starter Turns, But Engine Does Not Crank (1) Check starter drive condition on electric starter. Worn and/or damaged starter drive?
Symptom: Engine Does Not Start - No Spark At Spark Plug (See Magneto System) (5) Metallic particles caused a short circuit between the soldered connections? Yes - Clean connector and trigger coil from metallic dust. No - Go to next step. (6) Check magneto for damage and/or electrical failure. Windings of stator have electrical failure?
Yes - Replace electric starter and/or starter drive.
Yes - Replace magneto.
No - Go to next step.
No - Go to next step.
(2) Check condition of starter drive pinion gear. Worn and/or damaged starter pinion and/or ring gear? Yes - Replace starter drive and/or drive pulley fixed half.
(7) Check electronic module for damage and/or electrical failure. Electronic module shows visual damage and/or electrical failure? Yes - Replace electronic module.
No - Go to next step. (3) Check battery power. Battery shows a lack of power? Yes - Charge or replace battery.
Symptom: Engine Does Not Start - No Spark At Spark Plug (See Magneto System) (1) Verify spark plug condition. Defective, improperly set, worn out, fouled? Yes - Identify source of problem and correct. Replace spark plug. No - Go to next step. (2) Verify condition of ignition coil and resistance with an ohmmeter. Mechanically damaged part, vibration problem, electrically damaged part? Yes - Replace ignition coil. No - Go to next step. (3) Verify condition of trigger coil and resistance with an ohmmeter and connector condition. Defective trigger coil and/or corroded connector terminal? Yes - Replace trigger coil. Clean terminals and apply silicone dielectric grease. No - Go to next step. (4) Mechanically damaged part, vibration problem, electrically damaged part? Yes - Tighten mounting screw(s) and/or replace magneto. No - Go to next step.
Engine Diagnostics - 43
ENGINE TESTS AND ADJUSTMENTS Tests and Adjustments
Remove spark plug from cylinder head. NOTE: Ignition coil can help to remove spark plug.
Leak Test
1
Verification:
2
Before performing the cylinder leak test, verify the following: IMPORTANT: Avoid damage! If a piston ring and/or valve is replaced, always clean the whole engine and replace oil and oil filter. • intake port/air filter contamination (clogged) from dirt, sand, etc. (leads to worn valves, piston rings and finally to lack of power) •
blue exhaust gas indicates damaged/worn piston rings
•
clamp(s) tightness
•
radiator and hoses
R610motr03A
R610motr03a2.EPS
A - Ignition Coil (1) B - Spark Plug (2)
• oily contamination on leak indicator hole (speed sensor area) means a damaged oil seal on water pump shaft
Remove valve cover.
2
• coolant out of leak indicator hole means a damaged rotary seal on water pump shaft (refer to COOLING SYSTEM)
1
• coolant flowing out from water pump housing means damaged gasket(s) and/or loosened screws (refer to COOLING SYSTEM). NOTE: For all the checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine. Leak Test Procedure: NOTE: The following procedures should be done with a cold engine.
R610motr04A
R610motr04a2.EPS
Preparation:
A - Ratchet Wrench (1) B - Valve Cover (2)
Disconnect battery.
c CAUTION: Avoid Injury! Always respect this
order for disassembly; disconnect BLACK (-) cable first. Electrolyte or fuel vapors can be present in engine compartment and a spark may ignite them and possibly cause personal injuries.
Rotate crankshaft until piston is at TDC. To place piston at TDC, there are three possible procedures. First procedure: •
Remove CVT cover. Refer to CVT section.
•
Turn the drive pulley until piston is at TDC.
Remove:
Second procedure:
•
vehicle seat
•
•
radiator cap
•
inlet hose of CVT cover.
• Install a 8 x 1.25 x 50 mm bolt and a nut on the MAG side of the crankshaft.
Unplug and remove ignition coil.
Remove the RH engine side panel.
Lock bolt with the help of the nut then turn bolt until piston
Engine Tests and Adjustments - 44
ENGINE TESTS AND ADJUSTMENTS is at TDC.
Lock crankshaft performing crankshaft locking procedure (refer to CRANKSHAFT/BALANCER SHAFT).
1
V04C0YA
1
2 V04c0ya2.EPS
A - Bolt M8 x 1.25 x 50 mm (1) B - Nut M8 (2)
R610motr202A
2 R610motr202a2.EPS
Third procedure: • Use rewind starter (if so equipped) and rotate the crankshaft until piston is at ignition TDC. To secure the piston at ignition TDC, there are two possible procedures.
A - Vehicle Front Side (1) B - Position for Crankshaft Locking Pin Bolt (P/N JDG 529 035 746 Test: Connect tester to adequate air supply. Set needle of measuring gauge to zero.
First possible procedure: Lock camshaft using drive pulley puller (P/N JDG 529 035 746) (refer to CYLINDER AND HEAD). IMPORTANT: Avoid damage! When removing camshaft screw always lock camshaft using drive pulley puller (P/N JDG 529 035 746) to avoid stretching the timing chain.
NOTE: Each tester will have specific instruction on the gauge operation and required pressure. Install gauge adapter into previously cleaned spark plug hole. Supply combustion chamber with air pressure.
1
1
V04C0ZA
R610motr06A
3
V04c0za2.EPS
R610motr06a2.EPS
A - Cylinder Pin for TDC Position of Camshaft (1) Second possible procedure:
2
A - Leak Tester (1) B - Adequate Adaptor for Spark Plug Hole C - Air Supply Hose
Engine Tests and Adjustments - 45
ENGINE TESTS AND ADJUSTMENTS Note the amount of leaking or percentage (depending on tester). Leakage percentage
Engine condition
0% to 7%
Excellent condition
8% to 15%
Fair condition; proceed with tuned up or adjustment
16% to 30%
Poor condition; engine will run and performance might be down in some cases.
31% and higher
Very poor condition, diagnose and repair engine.
Diagnose: Listen for air leaks. • air escaping on intake port/carburetor means leaking intake valve(s) • air escaping on exhaust port means leaking exhaust valve(s) • air bubbles out of radiator means leaking cylinder head gasket • air/oil escaping from crankcase means damaged gasket and/or loosened screws (refer to GEARBOX) • air/coolant escaping from cylinder/head means damaged gasket(s) and/or loosened screws (refer to CYLINDER AND HEAD) • air escaping into crankcase area means excessively worn cylinder and/or broken piston rings. NOTE: For all the checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine. installation: NOTE: At reassembly, use the torque values and Loctite products from the exploded views (refer to particular engine sections). For installation, reverse the preparation procedure.
Engine Tests and Adjustments - 46
ENGINE REPAIR Repair
Component Location
26
10 N m 21 (89 lbf in)
26 22
11 N m (97 lbf in) 24
5
23
6
4
13 N m (115 lbf in) 19 20 13 N m (115 lbf in)
18 24 N m (18 lbf ft)
13 N m 19 (115 lbf in) 48 N m (35 lbf ft)
10 N m (89 lbf in)
24 N m (18 lbf ft) 25
13 15
24 N m 11 (18 lbf ft) 1
13
27 10 N m (89 lbf in)
Synthetic grease 16
10 17 48 N m (35 lbf ft)
14 Synthetic grease
11 24 N m (18 lbf ft)
17 16
2
17
10 N m (89 lbf in)
10 N m (89 lbf in) 28 V04C0VS
24 N m (18 lbf ft)
8
3
10 N m 29 (89 lbf in) V04c0vsa2.EPS
9 48 N m (35 lbf ft)
11 24 N m (18 lbf ft)
vehicle by doing the following. Remove seat.
Engine Removal
Disconnect BLACK (-) cable from battery, then RED (+) cable.
Vehicle and Engine Preparation: Place vehicle at workstation that will have access to an engine-lifting hoist. Then start with initial preparation of
Engine Repair - 47
ENGINE REPAIR
c CAUTION: Avoid Injury! Always disconnect
battery or starter cables exactly in the specified order, BLACK (-) cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines.
•
transmission lever no. 2
•
dipstick tube
•
plastic transmission lever locator no. 3
Remove skid plate. Drain engine oil and engine coolant.
3 1
2
1
V04C0EA
V04c0Ea2.EPS
A - Transmission Lever (1) B - Dipstick Tube (2) C - Plastic Transmission Lever Locator (3)
V04C07A
V04c07A3.EPS
A - Oil Drain Plug (1)
• rear exhaust shield no. 4 (this will provide easier access to exhaust spring)
1
1
V04C0FA
V04c0fa2.EPS
A - Rear Exhaust Shield (1) V04C0AA
V04c0Aa3.EPS
A - Cooling Drain Plug (1)
•
seat support bracket
•
exhaust springs no. 5
•
exhaust pipe no. 6.
Remove console. Refer to BODY/FRAME.
Disconnect:
On right side of vehicle, remove the following:
•
wires to starter
• transmission lever handle no. 1 (refer to Transmission Lever Handle)
•
water temperature sensor
•
oil pressure sensor
• RH engine side panel and footrest (Refer to BODY/ FRAME)
•
lower coolant hose from engine
•
large CVT breather hose.
Engine Repair - 48
ENGINE REPAIR 1
2
1
V04C0IA
V04c0ia2.EPS
V04C0GA
2
3
A - Fuel Valve (1) B - Fuel Valve Bracket (2)
4
V04c0ga2.EPS
A B C D
- Water Temperature Sensor (1) - Oil Pressure Sensor (2) - Lower Coolant Hose (3) - CVT Breather Hose (4)
Disconnect magneto, gear box and speed sensor connectors.
On left side of vehicle, remove the following: •
LH engine side panel (Refer to BODY/FRAME)
•
CVT breather box
V04C0JA
3
2
1 V04c0ja2.EPS
A - Magneto Connector (1) B - Gear Box Connector (2) C - Speed Sensor Connector (3) From the top side, do the following: 1 MX30887
A - Breather Box (1) •
footrest (Refer to BODY/FRAME)
•
CVT cover (refer to CVT)
•
drive and driven pulleys (refer to CVT).
Remove carburetor (refer to CARBURETOR AND FUEL PUMP). Disconnect: •
the ignition coil and remove it
•
upper coolant hose.
Disconnect hose from fuel valve to fuel pump. Remove fuel valve bracket from frame and place valve and hoses off to one side.
Engine Repair - 49
ENGINE REPAIR
4
1 3
2 V04C0KA
V04B01A
V04c0ka2.EPS
A B C D
- Carburetor (1) - Ignition Coil (2) - Upper Coolant Hose (3) - Breather Hose (4)
V04b01a2.EPS
From bottom side, do the following: Remove front and rear propeller shaft bolts. Loosen only the two (2) lower engine mount bolts no. 9 and no. 10.
Remove cylinder head breather hose. Refer to CYLINDER AND HEAD. Remove upper engine mount assembly no. 7 and no. 8.
V04C0MA
1 V04c0ma2.EPS
A - Engine Mounting Bolts (1) V04C0LA
V04c0La2.EPS
Remove the eight (8) engine bracket nuts no. 11 from the four (4) lower engine brackets no. 12 and no. 13.
Install engine lifting tool onto exhaust mounting studs.
Engine Repair - 50
ENGINE REPAIR into the frame area.
1
Start lifting the rear of engine up as you lower the rear down until complete engine has entered frame area. Turn engine 90°, front towards right side of vehicle. Install rear propeller shaft. Lift engine a little more to clear rear mounting brackets from frame and tilt rear brackets down towards their locating holes. Tilt both front lower engine brackets down. Install front propeller shaft onto engine output shaft.
2
Lower engine into its place. Remove the engine lifting tool. From bottom side, do the following: Install front and rear propeller shaft bolts. Reinstall the eight (8) engine bracket bolts from the four(4) lower engine brackets. Tighten the two (2) lower engine mount bolts.
V04C0NA
V04c0na2.EPS
A - Rear Lower Engine Brackets (1) B - Front Lower Engine Brackets (2)
Reinstall upper engine-mount assembly but do not tighten the three (3) top nuts at this time. This will be done when the seat bracket is installed. From the top side, install the following:
Engine Removal: Lift engine approximately 25.4 to 38 mm (1 to 1-1/2 in.). Pull front propeller shaft out of engine output shaft splines. Tilt both front lower engine brackets up towards the rear. Turn front of the engine towards left side of vehicle and pull rear propeller shaft off.
•
carburetor
•
breather and its hose
•
upper coolant hose
•
ignition coil and connect it.
On left side of vehicle, install the following:
Lift engine a little more to clear rear mounting brackets from frame and tilt brackets up towards the front of the engine.
•
CVT breather box
•
magneto, gear box and speed sensor connectors
Turn engine 90°, front towards left side of vehicle.
• fuel valve bracket and reconnect hose from fuel valve to fuel pump
NOTE: Place a protective mat on the footrest support.
•
drive and driven pulleys
•
CVT cover
Rest engine onto footrest support and relocate lifting chain to opposite side of frame.
•
LH footrest
•
LH engine side panel.
Lift engine and move away from vehicle.
On right side of vehicle, do the following:
Engine Installation
Connect: •
large CVT outlet hose
Engine Installation:
•
lower coolant hose to engine
Lift engine and move towards vehicle.
•
oil pressure sensor
Rest engine onto footrest support, cylinder side down and relocate lifting chain to opposite side of frame.
•
water temperature sensor
•
wires to starter.
Lift front of engine up as you lower the cylinder end of engine down while pulling out of the frame.
Hold front of engine up as you enter the rear end of engine
Install:
Engine Repair - 51
ENGINE REPAIR •
exhaust pipe and mounting bolts
•
exhaust springs
•
exhaust shield
•
seat support bracket
push support bushing no. 16 and anti-vibration bushing out of the housing. Use punch to remove the other bushing. IMPORTANT: Avoid damage! Do not use a screwdriver when removing anti-vibration bushing.
• plastic transmission lever locator (do not tighten at this time) •
Anti-Vibration System Installation:
transmission lever
NOTE: Place the transmission lever in NEUTRAL position and place the plastic transmission lever locator so that the notch is in the center of the transmission lever handle holder. •
dipstick tube
•
RH footrest
•
RH engine side panel
•
transmission lever handle.
Insert support bushing in engine support. Apply synthetic grease on anti-vibration bushings and insert them in engine support, one on each side.
Exhaust System Heat Shield Removal:
c CAUTION: Avoid Injury! Never touch exhaust system components immediately after the engine has been run because these components are very hot.
Final assembly procedure: Install console. Confirm coolant and oil drain plugs are reinstalled and tight.
1
Fill cooling system. Refer to COOLING SYSTEM. Fill engine with appropriate amount of oil and recommended viscosity. Install skid plate. Reconnect battery.
c CAUTION: Avoid Injury! Connect RED (+) cable then BLACK (-) cable. Always connect RED (+) cable in first.
Before starting the engine, remove spark plug and ground it on engine or frame. Run starter about thirty seconds. This operation will activate the oil pump. Reinstall spark plug.
V04C0QA
3
2 V04c0qa2.EPS
Start vehicle.
A - Front Exhaust Shield (1) B - Rear Exhaust Shield (2) C - Muffler Shield (3)
Set carburetor. Stop engine and reverify coolant and oil levels are correct. Install seat.
Front Exhaust Shield:
Test drive to confirm all is working well.
To take off the front exhaust shield no. 18, remove:
Anti-Vibration System
• console and RH engine side panel (Refer to BODY/ FRAME)
Anti-Vibration System Removal:
•
plastic transmission lever locator
Remove engine mounting bolt no. 9 or no. 10, elastic nut no. 14 or no. 15 and engine brackets no. 12 or no. 13.
•
screws no. 19.
Anti-Vibration System
Rear Exhaust Shield:
Remove front exhaust shield.
Insert a punch in hole of anti-vibration bushing no. 17 and Engine Repair - 52
ENGINE REPAIR To reach the rear exhaust shield no. 4, remove the RH engine side panel and the plastic transmission lever locator no. 3. Unscrew bolts no. 20 retaining rear exhaust shield then remove shield. Muffler Shield: Remove: •
rear fender (Refer to BODY/FRAME)
•
screws no. 21 retaining muffler shield no. 22.
Heat Shield Inspection: Check all shields for cracks or other damages. Replace if necessary.
V04C0SA
1 V04c0sa2.EPS
A - Exhaust Pipe Bracket Screw (1)
Heat Shield Installation: For installation, reverse the removal procedure.
Push muffler backwards and remove exhaust pipe.
NOTE: Be sure to verify alignment of muffler and exhaust pipe or an air leak could occur and cause a backfire.
Pull exhaust pipe forward. Exhaust Pipe Installation: For installation, reverse the removal procedure, paying attention to the following details.
Exhaust Pipe Removal: Remove exhaust pipe shields no. 4 and no. 18. Remove springs no. 5 retaining exhaust pipe and muffler no. 23. Remove the exhaust pipe nuts no. 24.
Use a new exhaust pipe gasket and make sure that it is properly installed. With muffler secured in its rubber mounts, fit exhaust pipe on cylinder head. Tighten nuts, making sure exhaust pipe is properly aligned inside muffler ball socket then install retaining springs after pushing muffler forward over exhaust pipe flange. Tighten exhaust pipe support bolt. Muffler Removal: Remove exhaust pipe no. 6. Pull muffler no. 23 forward, pull out retaining rod from supports and remove muffler. Muffler Inspection:
V04C0RA
Check muffler for cracks or other damages. Replace if necessary.
1 V04c0ra2.EPS
A - Exhaust Pipe Nuts (1) Remove screw from exhaust pipe bracket no. 25.
Muffler Installation: For the installation, reverse the removal procedure. NOTE: Check rubber bushings no. 26 for cracks or other damages, change if necessary.
Engine Repair - 53
ENGINE REPAIR Shifting System Transmission Lever Handle Removal: Place transmission lever on NEUTRAL position. Unscrew transmission lever handle bolt no. 27. Remove transmission lever handle no. 1. Transmission Lever Handle Installation: The installation is the reverse of removal procedure. Plastic Transmission Lever Locator Removal: V04C0TA
Remove the transmission lever handle.
V04c0ta2.EPS
Unscrew the bolts no. 28 then remove the locator. Plastic Transmission Lever Locator Installation: Install the plastic transmission lever locator no. 3 but do not torque bolts yet. Place the transmission lever on NEUTRAL position and place the plastic transmission lever locator so that the notch is in the center of the transmission lever handle holder.
Transmission Lever Installation: For installation, reverse the removal procedure, paying attention to the following detail. Align the center of the transmission lever handle holder in front of the NEUTRAL position notch.
2 2
1 1 V04C0UA
V04c0ua2.EPS V04C0UA
V04c0ua2.EPS
A - Transmission Lever (1) B - Notch Indicating NEUTRAL Position
A - Transmission Lever (1) B - Notch Indicating NEUTRAL Position (2) Torque bolts then install the transmission lever handle. Transmission Lever Removal: Remove transmission lever handle. Unscrew transmission lever retaining bolt no. 29 and pull lever.
Engine Repair - 54
ENGINE FUEL CIRCUIT Fuel Circuit
Fuel System Components
3 4
5 11
8 12
7
10 1 6 9
2
V04F0FT
V04f0fT2.EPS
Engine Fuel Circuit - 55
ENGINE FUEL CIRCUIT General
Fuel System Pressurization
c CAUTION: Avoid Injury! Always disconnect
battery exactly in the specified order, BLACK () cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines.
Fill up fuel tank no. 1. Remove seat and LH engine side panel. Install on fuel tank, the special cap for leak testing. Install hose pinchers (P/N JDG 295 000 076) on fuel pump outlet hose no. 2 at carburetor, as shown in the following photo.
c CAUTION: Avoid Injury! When draining a fuel
tank or whenever a fuel line is disconnected, obstruct line with a hose pincher (P/N JDG 295 000 076) or equivalent device. Fuel is flammable and explosive under certain conditions. Ensure work area is well ventilated. Do not smoke or allow open flames or sparks in the vicinity.
During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a thread locker.
V04F04A
IMPORTANT: Avoid damage! Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
1 V04f04a2.EPS
A - Install hose pincher on this hose (1) Using air pump inject air into fuel tank. Pressurize fuel system to 21 kPa (3 PSI). That pressure must not drop during 3 minutes. If pressure drops, locate fuel leak(s) and repair/ replace leaking component(s). To ease locating leak(s) at fuel tank vent fitting, fuel gauge or fuel cap spray soapy water on components; bubbles will indicate leak location(s).
Fuel Lines IMPORTANT: Avoid damage! Whenever working on fuel system, always verify for water or dust infiltration in reservoir. Replace any damaged, leaking or deteriorated fuel lines.
Fuel Gauge
IMPORTANT: Avoid damage! Use of improper fuel lines could compromise fuel system integrity.
Removal:
NOTE: The gauge shows an approximate amount of the fuel in tank.
Remove console. Refer to BODY/FRAME. Pull out fuel gauge no. 3 from fuel tank. At the same time, remove the fuel gauge gasket.
Engine Fuel Circuit - 56
ENGINE FUEL CIRCUIT V04f06A2.EPS
1
Typical A - Reserve Fuel Hose (1) B - Main Fuel Hose (2) Disconnect the reserve fuel hose no. 4 from fuel tank. Place an approved fuel container under engine then bring the reserve fuel hose into the container. Remove the hose pincher to drain the fuel tank. NOTE: To accelerate fuel tank draining and ensure complete draining, remove cap no. 5.
Fuel Tank Strainer V04F05A
2
3 V04f05A2.EPS
Typical
NOTE: The fuel tank has two fuel hose strainers. Use the following procedure for both fuel lines. Removal:
A - Fuel Gauge (1) B - Fuel Tank (2) C - Fuel Gauge Gasket (3)
Close fuel valve no. 6. Remove:
Installation: The installation is the reverse of the removal procedure. NOTE: Check gasket for crack or other damage. Change if necessary.
•
console
•
RH and LH engine side panels
•
RH foot rest.
Drain fuel tank, refer to FUEL TANK DRAINING. Manually pull grommet no. 7 out of fuel tank.
Fuel Tank Draining
NOTE: In the case that grommet is too tight, use a flat screwdriver and carefully pull out grommet, as shown in the next photo.
Turn fuel valve OFF. Remove: •
Engine skid plate
•
LH engine side panel.
Install hose pincher (P/N JDG 295 000 076) on reserve fuel hose.
V01N02A
V01n02a2.EPS
1
Typical - Use screwdriver only if grommet is too tight
2
V04F06A
Inspection: Ensure that fuel tank strainer no. 8 and fuel line are clean and not damaged, as per following photo.
Engine Fuel Circuit - 57
ENGINE FUEL CIRCUIT 1
Fuel Valve
2
Removal: NOTE: To ease reinstallation, mark all hoses before removing fuel valve no. 6. Remove the LH engine side panel, refer to BODY/FRAME. Remove plastic cap from fuel valve. Unscrew valve nut, as shown in the next photo.
A31I03A
A31i03a.eps
Typical A - Fuel Tank Strainer (1) B - Fuel Line (2) Installation: NOTE: To ease grommet insertion, apply lubricant. Position grommet on fuel line, as shown in the next photo then insert grommet in tank hole.
V04F07A
V04f07A2.EPS
Typical - Unscrew valve nut Unplug all 3 hoses from fuel valve. Remove valve. Installation: Reinstall fuel valve by positioning rubber washer inside and nut outside vehicle. See next photo.
4 3
V01N03A
2
2
1
1 V01n03a2.EPS
Typical A - Grommet properly positioned for insertion (1) B - Fitting recess (2) Once grommet is inserted in tank hole, push fitting until its recess properly sits in grommet. Refuel tank and ensure there are no leaks.
V04F08A
V04f08A2.EPS
A - Internal Rubber Washer (1) B - External Rubber Washer (2) C - Metallic Washer (3)
Engine Fuel Circuit - 58
ENGINE FUEL CIRCUIT D - Fuel Valve Nut (4) Replug all hoses according to the following illustration.
3
5
•
dipstick tube
•
CVT breather inlet hose
•
RH inner fender bracket.
1 2 5 4
V04F09A
1
2
4 V04f09A2.EPS
3
Typical A B C D E
6
- Fuel Tank Top Hose (main) (1) - To Fuel Pump (2) - Fuel Tank Bottom Hose (reserve) (3) - Fuel Pump (4) - Carburetor (5)
V04F0AA
V04f0aA2.EPS
Fuel Tank Inspection: Visual: Inspect fuel tank for any damage or cracks which may result in fuel leaks. If so, replace tank with new one.
A B C D E F
- Plastic Transmission Lever Locator Bracket (1) - Removal Brace (2) - Brake Cable Bracket (3) - Dipstick Tube (4) - CVT Breather Inlet Hose (5) - Inner Fender Bracket (6)
Drain fuel tank no. 1, refer to FUEL TANK DRAINING.
Pressure Test: Refer to FUEL SYSTEM PRESSURIZATION for complete detailed procedure.
Unplug fuel hoses from fuel valve. Remove the front propeller shaft. Refer to FRONT DRIVE. Unscrew the fuel tank support no. 9 then remove the bottom fuel tank screw no. 10.
Removal: Remove: •
console
•
RH and LH engine side panels
•
RH foot rest
•
front fender
•
RH and LH inner fenders
•
engine skid plate
•
plastic transmission lever locator and its bracket
•
RH removable brace
•
brake cable bracket
Engine Fuel Circuit - 59
ENGINE FUEL CIRCUIT shown in the next photo.
1
6
3
3
2
V04F0CA
V04F0BA
5
V04f0bA2.EPS
A - Bottom Screw (1) B - Fuel Tank Support (2) C - CVT Cover (3)
4
2
1 V04f0ca2.EPS
Typical
Remove both fuel tank top screws no. 11, as shown in the next photo.
1
A B C D E F
- Nut (1) - Frame Bracket (2) - Fuel Tank Holding Tab (3) - Spacer (4) - Washer (5) - Screw (6)
Perform fuel system pressurization as described in the FUEL SYSTEM PRESSURIZATION section.
F04F0GA
1 V04f0gA2.EPS
A - Remove both top and bottom screws (1) Remove fuel tank support then remove fuel tank. Installation: Reverse removal procedure, however pay attention to the following: Ensure that main fuel tank hose no. 12 and reserve fuel tank hose no. 4 are not inverse. Refer to FUEL VALVE table. Position all fuel tank screws, nuts, washers and spacers as
Engine Fuel Circuit - 60
ENGINE CARBURETOR Carburetor
Carburetor Components
V04F0HS
V04f0HS2.EPS
Engine Carburetor - 61
ENGINE CARBURETOR Carburetor IMPORTANT: Avoid damage! Although some jets can be replaced by other jets from other carburetors, such modifications shouldn’t be performed. They can greatly affect engine calibration and can cause severe damage to engine. Use only recommended jetting specific for this carburetor. Modifications may also be performed on the CTV drive clutch.
c CAUTION: Avoid Injury! Always disconnect
battery exactly in the specified order, BLACK () cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines.
Disconnect ignition coil connector. Install hose pincher (P/N JDG 295 000 076) on engine outlet hose then unplug hose.
Vehicle operation at sea level AFTER high level carburetor modifications have been made may create performance problems and possible internal engine damage. Carburetor modifications for high altitude operation should be changed to factory setting for sea level operation.
1
Carburetor Jets:
4 2
Trail Buck 500 Carburetion Calibration
1200 m (4000 ft)
2400 m (8000 ft)
Qty
152.5
150
147.5
1
Needle Jet
O-6
O-4
O-0
1
Pilot Jet
35
27.5
27.5
1
Pilot Screw
**
**
**
-
1300
1300
1300
-
Main Jet
Sea Level
3
V04F0QA
Idle RPM (±100)
Trail Buck 640EX and 650 EXT Carburetion Calibration
1200 m (4000 ft)
2400 m (8000 ft)
Qty
152.5
147.5
145
1
Needle Jet
O-6
O-2
O-2
1
Pilot Jet
40
32.5
32.5
1
Pilot Screw
**
**
**
-
1200
1200
1200
-
Main Jet
Idle RPM (±100)
Sea Level
Carburetor Removal: Turn fuel valve OFF. Remove seat. Disconnect BLACK (-) cable from battery.
V04f0qa2.EPS
Typical A B C D
- Outlet Hose with Hose Pincher (1) - Ignition Coil (2) - Throttle Cable (3) - Choke Cable (4)
Loosen both carburetor and air box clamps. Loosen air box bolts and move backward. Unscrew choke cable then remove the choke plunger from the throttle body. To unscrew the choke plastic nut from carburetor, use the special choke nut tool (P/N JDG 529 035 660). NOTE: Take care do not loose the choke plunger. If so, check plunger for damages and replace it if necessary. Unplug air box breather hose and fuel hose. Unscrew carburetor bracket (if so equipped). Turn carburetor to place the throttle cable housing on the top then remove the throttle cable. See Throttle Cable further in this section. Pull out carburetor.
Engine Carburetor - 62
ENGINE CARBURETOR Cleaning and Inspection:
2
The entire carburetor should be cleaned with a general solvent and dried with compressed air before disassembly. IMPORTANT: Avoid damage! Heavy duty carburetor cleaner may be harmful to the float material and to the rubber parts, O-rings, etc. Therefore, it is recommended to remove those parts prior to cleaning.
A
Carburetor body and jets should be cleaned in a carburetor cleaner following manufacturer’s instructions.
c CAUTION: Avoid Injury! Solvent with a low
flash point such as gasoline, naphtha, benzol, etc., should not be used as they are flammable and explosive.
Carburetor Float Level Adjustment: Correct fuel level in float chamber is vital toward maximum engine efficiency. To check for correct float level proceed as follows: •
Remove float bowl and gasket from carburetor.
•
Make sure that float arm is symmetric, not distorted.
F04F0IA
1 V04f0iA2.EPS
Typical A - Gauge Tips (1) B - “L” Arm (2) C - Height (A)
With carburetor chamber up side down: • Measure height between bowl seat and the top edge of float arm. Use float level gauge (P/N JDG 529 035 520). • Keep float level gauge perfectly vertical and in line with main jet hole. Ensure that both float level gauge tips are properly positioned on carburetor body and that “L” arm is leaning on float while compressing valve spring.
90°
Refer to following photos for proper float level gauge positioning. Float level should be 10 mm ± 0.5 mm.
V04F0JA
V04f0jA2.EPS
Typical - Gauge Aligned with Main Jets To adjust height, bend the contact tab of float arm until the specified height is reached. IMPORTANT: Avoid damage! When adjusting contact tab, do not pry on. This would apply pressure on needle and damage valve seat/needle. NOTE: On the AUTOSHIFT model, the TPS sensor
Engine Carburetor - 63
ENGINE CARBURETOR calibration is necessary. Adjust the idle speed in first, then, calibrate the TPS sensor. Refer to ELECTRIC SHIFT SYSTEM.
1
Installation: To install carburetor on engine, inverse removal procedure, as described: • Inspect throttle and choke cable housing prior to installation. • Reinstall throttle and choke cables, at the same time adjust the throttle cable, then install the side cover. Refer to CARBURETOR ADJUSTMENTS below in this section. •
Reinstall carburetor on engine.
2
When reinstalling carburetor on engine, pay attention to the following: IMPORTANT: Avoid damage! The rubber flanges must be checked for cracks and/or damage. At assembly, the rubber flanges must be perfectly matched with the air box, carburetor and engine or severe engine damage will occur. Do not use screwdriver or other tool to install the rubber flanges. Install rubber flange on air box side so that its recess aligns with air box notch, as shown in the next photo.
3 V04F0KA
V04f0kA2.EPS
Bottom View A - Idle Speed Screw (1) B - Pilot Screw (2) C - Drain Plug and Screw (3) Idle Speed Preliminary Adjustment:
Callout
Adjust idle speed to specifications in “Carburetor” tables. See “Carburetor” on page 61.
V04F0RA
V04f0ra2.EPS
Typical - Air Box Side - Rubber Flange Installation Carburetor Adjustments:
V04F0LA
1 V04f0lA2.EPS
Typical A - Bypass Hole Closes to Halfway
Engine Carburetor - 64
ENGINE CARBURETOR Throttle Cable
Idle Speed Adjustment: Start engine and allow it to warm then adjust idle speed to specifications by turning idle speed screw clockwise to increase engine speed or counterclockwise to decrease it. NOTE: Use the digital induction tachometer. IMPORTANT: Avoid damage! Do not attempt to set the idle speed by using the pilot screw.
Removal: Carburetor Side:
c CAUTION: Avoid Injury! Ensure the key is
turned OFF, prior to performing the throttle cable removal.
Refer to specifications.
NOTE: To ease reinstallation, take note cable routing.
Pilot Screw Adjustment:
Remove carburetor side cover.
NOTE: The pilot screw is factory pre-set. Warm up the engine to operating temperature. Adjust idle speed to specifications in “Carburetor” tables. See “Carburetor” on page 61. Unscrew the pilot screw until engine starts to miss (too rich mixture), then back in just enough to avoid engine missing. If idle speed changes after adjusting the pilot screw, readjust the idle speed screw to specification. Diaphragm Installation: Carefully, install diaphragm in its original position. Make sure spring is located properly in carburetor cover before screwing. NOTE: Check and locate properly the indexation lob. The diaphragm must be installed correctly into the groove on the edge of carburetor housing.
V04F0MA
1 V04f0mA2.EPS
Typical A - Remove This Cover (1) Using thumb, release tension on throttle lever. With long nose pliers, rotate cable end bushing so that cable aligns with throttle lever recess, then lift cable end. See next photo.
V04F0SA
V04f0sa2.EPS
Engine Carburetor - 65
ENGINE CARBURETOR Slide cable in clip slot and remove the end of cable from clip. Lubrication: The throttle cable must be lubricated with cable lubricant.
c CAUTION: Avoid Injury! Using another
lubricant could cause sticking or stiffness of throttle lever/cable.
Open the throttle lever housing. Separate the housing. Slide rubber protector back to expose throttle cable adjuster. Unscrew the locking nut of the cable adjuster then screw in the adjuster to release the cable tension. V04F0TA
1
3
2 V04f0ta2.EPS
Typical A - Release Tension On Throttle Lever (1) B - Cable End Bushing (2) C - Throttle Lever Recess (3) Separate cable end bushing from throttle cable end. Keep bushing. Loosen throttle cable nut, as shown in the next photo.
1
V07I0GA
1
2
3
4 V07i0gA3.EPS
A B C D
- Cable Protector (1) - Throttle Cable Adjuster (2) - Lock Nut (3) - Throttle Lever Housing (4)
Remove:
V04F0NA
2 V04f0na2.EPS
A - Loosen This Nut (1) B - Side Cover Removed (2) Pull cable out of carburetor. Throttle Lever Side: Remove both screws under throttle lever then open it. Remove throttle cable from housing. V07I0HA
Engine Carburetor - 66
1
ENGINE CARBURETOR V07i0hA3.EPS
Inner Housing Protector (1) •
inner housing protector
•
the cable from the throttle lever housing.
(preliminary adjustment) and choke. Slide rubber protector back to expose throttle cable adjuster.
NOTE: Slide cable in clip slot and remove the end of cable from clip.
Loosen lock nut then turn the adjuster to obtain correct throttle lever free play. NOTE: Measure throttle free play at the tip of throttle lever. Tighten lock nut and reinstall protector.
A
V01I1VA
1 V01i1VA3.EPS
V07I0IA
V07i0iA3.EPS
Remove the carburetor side cover. Insert the needle of spray can in the end of throttle cable adjuster.
c CAUTION: Avoid Injury! Always wear eye
protection and gloves when lubricating cables.
NOTE: NOTE: Place a rag around cable luber to prevent lubricant splash. Put lubricant until it passes through the cable.
A - Throttle Lever (1) B - 3 to 6 mm (1/8 to 7/32 in.) (A) With the transmission lever on PARK position, start the engine. Check if the throttle cable is adjusted correctly by turning handlebar fully right then fully left. If the engine RPM increases, readjust the throttle lever free play. Before readjusting, check the cable routing.
Choke Cable Removal: NOTE: To ease reinstallation, take note cable routing. Carburetor Side:
Clean lubricant surplus in carburetor housing. Reinstall carburetor cover and cable in throttle housing. Adjust cable, see below.
Remove the LH side panel. Unscrew choke plastic nut from carburetor. Pull choke cable to remove choke plunger from carburetor.
Installation:
Remove the choke plunger and its spring.
For installation, reverse the removal procedure. Adjustment:
c CAUTION: Avoid Injury! Ensure the key is
turned OFF, prior to perform the throttle cable adjustment.
Before adjusting the throttle cable, adjust idle speed
Engine Carburetor - 67
ENGINE CARBURETOR
2
3 1
V07F0CA
2
1 V07F0EA
V07F0Ca2.EPS
V07F0ea2.EPS
Typical
A - Retaining Spring (1) B - Choke Cable (2) C - Choke Cable Housing (3)
A - Choke Plunger (1) B - Choke Plunger Spring (2) Handlebar Side:
Steering Cover Side:
Push the choke lever on FULL position. Underneath multi-function switch, align the choke cable end with the lever slot then remove the cable.
Remove: •
Allen screw on the side of knob
•
rubber bellows.
Unscrew the plastic jam nut. Unscrew slit nut under steering cover. Pull cable away from frame. Installation: The installation is the reverse of removal procedure.
Fuel Pump Removal: Turn off fuel valve. Lift coolant tank. Unplug fuel hose coming from fuel valve.
V07F0DA
V07F0da2.EPS
Typical Remove the retaining spring to remove the choke cable from housing.
NOTE: It may be easier to unplug fuel hose coming from fuel valve at fuel valve location. Unplug fuel hose going to carburetor. Disconnect impulse hose.
Engine Carburetor - 68
ENGINE CARBURETOR Installation:
1
V01F0NA
To install fuel pump, reverse removal procedure. However, pay attention to fuel hose position. Refer to arrows on fuel pump.
2
3 V01f0na2.EPS
A - Fuel Hose Coming From Fuel Valve (1) B - Fuel Hose Going To Carburetor (2) C - Impulse Hose (3) Remove fuel pump. Verification: Connect a clean plastic tubing to the inlet nipple and alternately apply pressure and vacuum with pump. The inlet valve should release with pressure and hold under vacuum. Repeat the same procedure at the outlet nipple. This time the outlet valve should hold with pressure and release under vacuum. Check impulse diaphragm and gasket on high-supply fuel pump with twin outlets as follows: Connect a clean plastic tubing to the impulse nipple and plug vent hole on top cover. Either apply pressure or vacuum. The diaphragm/gasket must not leak. Cleaning and Inspection: The exterior of the assembled pump should be cleaned with general purpose solvent before disassembly. Fuel pump components should be cleaned in general purpose solvent and dried with compressed air.
c CAUTION: Avoid Injury! Solvent with a low
flash point such as gasoline, naphtha, benzol, etc., should not be used as each is flammable and explosive.
Inspect diaphragm. The pumping area should be free of holes, tears or imperfections. Replace pump as needed.
Engine Carburetor - 69
ENGINE FUEL CIRCUIT Fuel Circuit
Air Intake Components 19
3
1
10 N m (89 lbf in) 5
17
10
6
8 9
V04F01T
V04f01TA2.EPS
Engine Fuel Circuit - 70
ENGINE FUEL CIRCUIT Air Filter
3
1
2
Removal: IMPORTANT: Avoid damage! Never remove or modify any component in the air box. Otherwise, engine performance degradation or damage can occur. The engine carburation is calibrated to operate specifically with these components. Remove seat. Release clamps and remove air filter box cover no. 1. V04C16A
Loosen clamp and remove air filter no. 3.
V04c16a3.EPS
1
2
Typical A - Air Filter Box (1) B - Drain Tube (2) C - Clamp (3) NOTE: If vehicle is used in dusty area, inspect more frequently than specified in maintenance chart. If liquid/deposits are found, squeeze and remove the clamp. Pull drain tube no. 9 out and empty it. IMPORTANT: Avoid damage! Do not start engine when liquid or deposits are found in the drain tube. If there is oil in the air box, check engine oil level, it may be too high.
V01F1LA
V01f1La3.EPS
Typical
Remove air filter. NOTE: When liquid/deposits are found, the air filter must be inspected/dried/replaced depending on its condition.
A - Clamp (1) B - Air Filter (2) Installation:
Clean inside the air box.
Properly reinstall removed parts in the reverse order of their removal.
Rinse the filter with warm water until all cleaning solution disappears.
NOTE: Apply air filter oil on air filter.
NOTE: If the air filter foam is still dirty or damaged, replace it with a new one.
Air Filter Cleaning/Draining
Then, let the filter dry completely.
Periodically inspect air filter box drain tube no. 9 for liquid or deposits.
When the filter is dried, re-oil with air filter oil.
Air Filter Box Removal: Remove seat. Remove radiator access plug.
Engine Fuel Circuit - 71
ENGINE FUEL CIRCUIT Rear Air Intake Adaptor Removal: Remove: •
seat
•
radiator access plug
•
air filter box cover.
Unsnap the rigid intake tube no. 19 from the rear fender.
V04F02A
V04f02A2.EPS
Unsnap the rigid intake tube no. 19 from the rear fender.
V04F03A
V04f03A2.EPS
Press the air intake adaptor no. 17 to make it come out of air filter box. Installation: For installation, reverse the removal procedure.
V04F03A
V04f03A2.EPS
Remove: •
air filter box cover no. 1
•
air filter no. 3.
Detach: • rear air intake adaptor no. 17 (refer to REAR AIR INTAKE ADAPTOR) •
engine breather hose no. 6
•
intake adaptor no. 8from carburetor.
Unfasten bolts no. 5 retaining air filter box no. 10 to the frame. Installation: For installation, reverse the removal procedure.
Engine Fuel Circuit - 72
ENGINE COOLING SYSTEM Cooling System
Engine Side Components
10 N m (89 lbf in) 14
10 N m (89 lbf in) 3 5 Multi-purpose grease 2.5 N m (22 lbf in) 6 7
15
10 N m 1 (89 lbf in) 2
13 4 10 N m (89 lbf in)
12 Engine oil
R610motr258S
R610motr258sa2.EPS
Engine Cooling System - 73
10 11
9 8
ENGINE COOLING SYSTEM Vehicle Side Components 19 23 9 N m (80 lbf in)
18
27 26
24 11 N m (97 lbf in)
28
25
4.5 N m (40 lbf in)
20 17 21 16
22 V04C22S
V04c22sa2.EPS
General During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a thread locker.
Engine Cooling System - 74
ENGINE COOLING SYSTEM
c CAUTION: Avoid Injury! Torque wrench
tightening specifications must strictly be adhered to.Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
c CAUTION: Avoid Injury! To avoid potential
burns, do not remove the radiator cap or loosen the cooling drain plug if the engine is hot.
V04B0VA
1
2 V04b0Va2.EPS
A - Radiator Plug (1) B - Small Hose Pincher (2) Using a pump, pressurize all system to 103 kPa (15 PSI).
Coolant Level Place the vehicle on a level surface and check the coolant in the coolant tank no. 16. The coolant level should be between MIN. and MAX. level marks of the coolant tank. NOTE: When checking level at temperature lower than 20°C (68°F), it may be slightly lower than MIN. mark. If the level in the tank is lower than the MIN. mark, remove the coolant tank cap no. 17 and add coolant up to MAX. mark. Reinstall the tank cap then check the level in the radiator no. 18. The radiator must be completely full. Add coolant if necessary. NOTE: A cooling system that frequently requires coolant is the indication of leaks or engine problems. Perform a cooling system leak test and inspect the components of cooling system.
V01C09A
V01c09a2.EPS
NOTE: The rear fender removal is not necessary.The fender has been removed for a better comprehension. Inspection:
Cooling System Leak Test
Check all hoses, radiator no. 18 and cylinder/base for coolant leaks. Spray a soap/water solution and look for air bubbles.
Procedure:
Check general condition of hoses and clamp tightness.
To perform the leak test on the cooling system, remove the protective cap on the rear fender or tilt the cargo box to allow an access to the radiator cap no. 19.
Check the leak indicator hole if there is oil or water.
Install a radiator plug instead of the radiator cap then pinch the overflow hose no. 20 with a small hose pincher (P/N JDG 295 000 076).
NOTE: Flowing water indicates a damaged ceramic seal no. 7. Oil out of the leak indicator hole indicates a faulty oil seal no. 12.
Engine Cooling System - 75
ENGINE COOLING SYSTEM IMPORTANT: Avoid damage! If the drain plug is removed completely, pay attention to the gasket ring no. 2. Never use the gasket ring a second time. Always install a new one. When cooling system is drained completely, screw the cooling drain plug and torque it to 10 N•m (89 lb-in.).
Coolant Replacement Recommended Coolant: Use Premixed Coolant or a blend of 50% antifreeze with 50% distilled water.
R610motr23A
1 R610motr23a2.EPS
A - Leak Indicator Hole (1)
Draining The System To drain cooling system, partially unscrew cooling drain plug no. 1 on the engine MAG side and remove radiator cap no. 19
IMPORTANT: Avoid damage! To prevent rust formation or freezing condition, always replenish the system with Premixed Coolant or with 50% antifreeze and 50% distilled water. Pure antifreeze without water thickens and does not have the same efficiency. Always use ethylene glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines. System Capacity: Refer to "Specifications" section. Replacement Procedure: Drain the system completely. Pinch engine outlet hose no. 21 between radiator and thermostat housing with a large hose pincher (P/N JDG 529 032 500).
1
R610motr25A
R610motr25a2.EPS R610motr24A
R610motr24a2.EPS
A - Coolant Drain Plug (1)
Unscrew bleeding screw on top of thermostat housing.
Engine Cooling System - 76
ENGINE COOLING SYSTEM
R610motr26A
1 R610motr26a2.EPS
A - Bleeding Screw (1) With vehicle on a flat surface, engine cold, refill radiator no. 18. When the coolant comes out by the thermostat housing hole, install the bleeding screw and remove the hose pincher. Install the radiator cap.
R610motr27A
1 R610motr27a2.EPS
A - 3 Screws (1) •
thermostat with gasket out of the hole.
NOTE: Do not forget gasket ring when bleeding screw is installed. Torque bleeding screw to 10 N•m (89 lbin.). Refill coolant tank no. 16 up to cold level mark. Install the coolant tank cap. Run engine until thermostat opens then stop engine. When engine has completely cooled down, recheck coolant level in radiator and coolant tank and top off if necessary. Every 100 hours or once a year, check coolant concentration (freezing point) with proper tester.
Thermostat The thermostat is a single action type and it is located on top of cylinder head, on intake side. R610motr28A
Removal:
1 R610motr28a2.EPS
Remove:
A - Thermostat with Gasket (1)
•
bleeding screw on thermostat cover
•
thermostat housing screws and pull thermostat cover.
Test: To check thermostat, put in water and heat water. Thermostat should open when water temperature reaches 85°C (185°F). Check if the gasket is not brittle, hard or damaged. If so, replace thermostat and gasket. Installation: For installation, reverse the removal procedure, paying attention to the following details. Install the thermostat cover then torque screws to 10 N•m (89 lb-in.).
Engine Cooling System - 77
ENGINE COOLING SYSTEM Check coolant level in radiator and coolant tank and top up if necessary.
Water Pump Housing
Water Temperature Switch
Removal:
Removal:
Drain cooling system and engine oil.
NOTE: The temperature switch is located on the top of cylinder head, on intake side.
Remove: •
engine inlet hose no. 12
Install a hose pincher on both radiator hoses.
•
oil filter (refer to Operator Manual)
Unplug the water temperature switch then remove it.
• screws no. 3 and no. 4 retaining water pump housing no. 5
It is located on the engine MAG side.
2 1 2
1
R610motr259A
2
1
1 R610motr259a2.EPS
A - Water Temperature Switch (1) B - Intake Port (2)
1 1
Test: Remove the water temperature switch from engine then put the switch in coolant and heat up. R610motr29A
Place a multimeter lead on each switch terminals.
R610motr29a2.EPS
The water temperature switch should operate when coolant temperature reaches 115°C (239°F). Replace water temperature switch if necessary. Installation:
A - Screws M6 x 35 (1) B - Screws M6 x 85 (2) •
water pump housing no. 5.
Inspection:
For installation, reverse the removal procedure. IMPORTANT: Avoid damage! Never use the gasket ring a second time. Always install a new one.
Check if gaskets are brittle, hard or damaged and replace as necessary.
Torque temperature switch to 16 N•m (142 lb-in.). Check coolant level in radiator and coolant tank and top off if necessary.
Engine Cooling System - 78
ENGINE COOLING SYSTEM R610motr29b2.EPS
IMPORTANT: Avoid damage! Prior to reinstall oil filter cover check if O-rings no. 14 and no. 15 are correctly in place.
R610motr30A
1
2 R610motr30a2.EPS
A - Gasket for the Oil Area (1) B - Gasket to Avoid Coolant Leak (2) Installation:
R610motr260A
2
1
The installation is the opposite of the removal procedure.
R610motr260a2.EPS
A - O-ring on Mating Surface (1) B - O-ring Inside Groove (2)
NOTE: For installation use the torque values in the exploded view. IMPORTANT: Avoid damage! To prevent leaking, take care that the gaskets are exactly in groove when you reinstall the water pump housing. Do not forget to place O-ring no. 13. Tightening sequence for screws on water pump housing is as per following illustration.
Water Pump Impeller Removal: Remove: •
water pump housing no. 5
•
impeller no. 6.
1 4 7 6
1
2
R610motr31A
R610motr31a2.EPS
3
A - Impeller (1)
5
R610motr29B
IMPORTANT: Avoid damage! Water pump shaft no. 7 and impeller no. 6 have left-hand threads. Remove by turning clockwise and install by turning counterclockwise.
Engine Cooling System - 79
ENGINE COOLING SYSTEM Inspection: Check impeller for cracks or other damage. Replace impeller if damaged. Installation: The installation is the opposite of the removal procedure. Pay attention to the following detail. IMPORTANT: Avoid damage! Be careful not to damage impeller wings during installation (hand torque only).
Water Pump Shaft
1
R610motr33A
Removal:
R610motr33a2.EPS
A - Water Pump Gear (1)
Remove: •
•
water pump housing no. 5
•
impeller no. 6
•
magneto housing cover (refer to MAGNETO SYSTEM)
needle pin no. 10 and thrust washer no. 11.
1
R610motr34A
2
1
R610motr34a2.EPS
R610motr32A
3
2 R610motr32a2.EPS
A - Retaining Ring (1) B - Water Pump Gear (2) C - Thrust Washer (3) •
A - Needle Pin (1) B - Thrust Washer (2) IMPORTANT: Avoid damage! When removing water pump shaft, always replace ceramic seal with water pump shaft no. 7 and oil seal no. 12 (behind ceramic seal).
retaining ring no. 8 with appropriate pliers IMPORTANT: Avoid damage! Never use the retaining ring a second time. Always install a new one.
•
water pump gear no. 9
NOTE: The water pump gear is held by a needle pin on the water pump shaft.
Engine Cooling System - 80
ENGINE COOLING SYSTEM
1
R610motr35A
R610motr35a2.EPS
A - Water PUmp Shaft with Ceramic Seal (1)
2
1
R610motr37A
R610motr37a2.EPS
Inspection: Inspect water pump gear for wear and damage on the snap mechanism to the needle pin. Replace if damaged. Water pump shaft with ceramic seal must rotate freely. Otherwise, replace it. Installation: R610motr36A
R610motr36a2.EPS
For installation, reverse the removal procedure. If the water pump shaft has been removed, install a new ceramic seal, a new oil seal and a new retaining ring.
A - Oil Seal Behind Ceramic Seal (1) B - Ceramic Seal Bore (2) Extract the water pump shaft with ceramic seal no. 7 with oil seal no. 12 from inside magneto housing cover with a pusher. IMPORTANT: Avoid damage! Be careful not to damage the surface of the ceramic seal bore in magneto housing cover.
NOTE: Never put oil in the press fit area of the oil seal and ceramic seal. Push water pump shaft oil seal in place by using an oil seal pusher.
Engine Cooling System - 81
ENGINE COOLING SYSTEM 2
water pump shaft bore.
3
Tighten screws in the following sequence.
4 7 6
1
2
1
R610motr38A
R610motr38a2.EPS
3
A - Oil Seal for the Water Pump Shaft (1) B - Oil Seal Pusher (2) C - Handle for Insertion Jig (3)
5
Install the water pump shaft assembly using a water pump ceramic seal installer. R610motr29B
IMPORTANT: Avoid damage! Never use a hammer for the ceramic seal installation. Only use a press to avoid damaging the ceramic component.
R610motr29b2.EPS
Radiator Cap Using a suitable tester, check if radiator cap pressurizes the system. If not, install a new 110 kPa (16 PSI) cap (do not exceed this pressure).
2
Radiator Removal: Drain cooling system. Remove:
R610motr39A
•
rear fender (Refer to BODY/FRAME)
•
engine inlet no. 22 and engine outlet no. 21 hoses
1 R610motr39a2.EPS
A - Water PUmp Shaft with Ceramic Seal (1) B - Water Pump Ceramic Seal Installer (2) NOTE: For installation use the torque values in the exploded view. Ensure to use Multi-purpose grease in
Engine Cooling System - 82
ENGINE COOLING SYSTEM Pull coolant tank no. 16 upward.
1
Empty coolant tank. Installation: The installation is the reverse of the removal procedure.
Cooling Fan Test: NOTE: No key required for this test. Unplug the temperature sender connector. Install a jumper wire end in connector. Replace the cooling fan no. 25 if it does not work.
2
V01C0AA
V01c0aa2.EPS
Typical A - Engine Outlet Hose (1) B - Engine Inlet Hose (2) •
overflow hose no. 20
•
mounting bolts no. 23 on top of radiator.
Unplug temperature sender no. 24. R610dvrs01A
Inspection:
R610dvrs01a2.EPS
Check radiator air passage for clogging or damage. Remove insects, mud or other obstructions with compressed air or low pressure water.
Removal: Remove rear fender. Refer to BODY/FRAME.
Check for any coolant leakage from radiator and hoses.
Unplug cooling fan connector.
Installation:
Remove bolts no. 26 and cooling fan supports no. 27.
For installation, reverse the removal procedure. Pay attention to the following detail.
1
2
1
Fill up the radiator. Refer, at the beginning of this section, to the COOLANT REPLACEMENT PROCEDURE.
Coolant Tank Overflow Coolant Tank: The coolant expands as the temperature (up to 100 110°C (212 - 230°F)) and pressure rise in the system. If the pressure limit the radiator cap is reached 110 kPa (16 PSI), the pressure relief valve in the radiator cap is lifted from its seat and allows coolant to flow through the overflow hose into the overflow coolant tank. V01G0AA
Removal:
1
2
1 v01g0aa2.EPS
Remove overflow hose no. 20. Engine Cooling System - 83
ENGINE COOLING SYSTEM A - Remove Bolts (1) B - Fan Support (2)
Typical A - Temperature Sender Connector (1) B - Engine Inlet Hose (2)
Remove the cooling fan. Installation:
Unscrew temperature sender no. 24.
For the installation, reverse the removal procedure.
Installation:
Outlet Deflector
The installation is the reverse of the removal procedure, paying attention to the following detail.
Removal:
Check O-ring and change if necessary.
Remove cooling fan no. 25.
IMPORTANT: Avoid damage! Do not apply any product on the threads or on the O-ring.
Remove radiator. Pull outlet deflector upward no. 28. Installation: The installation is the reverse of the removal procedure.
Temperature Sender Test: Remove temperature sender, see below for procedure. Put the sender in water and heat water. Using a multimeter, check the resistance of temperature sender. Place a multimeter lead on each terminal of temperature sender. Temperature sender should open when water temperature reaches the following degree. Water temperature
95°C (203°F)
Change temperature sender if the resistance is over 1â„Ś. Removal: Unplug temperature sender connector.
R610motr40A
2
1 R610motr40a2.EPS
Engine Cooling System - 84
ENGINE IGNITION AND CHARGING SYSTEM Ignition and Charging System
Charging Components
10 N m (89 lbf in) Multi-purpose grease 7 N m (62 lbf in)
5
4 Loctite 5910 19
18
10 14
8
25 N m (19 lbf ft) 4
10 N m (89 lbf in) Loctite 243
12
150 N m 11 (111 lbf ft) 15
Engine oil
10 N m 3 (89 lbf in) 7 6 25 N m (19 lbf ft)
1
9
10 N m (89 lbf in) Engine 2 oil Multi-purpose grease
10 N m (89 lbf in)
Multi-purpose grease
13
17
Loctite 5910 Loctite 243
16
Degreased
R610motr203S
R610motr203sa2.EPS
General The engine removal is not necessary to work on magneto components.
installing whatever component. For installation, use the torque values and Loctite products from the exploded views. Clean threads before using Loctite when installing the screws. Clean threads before applying a thread locker.
Always perform the electric tests before removing or
Engine Ignition and Charging System - 85
ENGINE IGNITION AND CHARGING SYSTEM
c CAUTION: Avoid Injury! Torque wrench
tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
Magneto Housing Cover Removal: Disconnect BLACK negative cable from battery, then RED positive cable.
1
R610motr10A
c CAUTION: Avoid Injury! Always disconnect
battery or starter cables exactly in the specified order, BLACK (-) cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines.
Remove: •
electric starter no. 1
•
water pump housing (refer to COOLING SYSTEM)
•
screws nos. 2, 3, 4, 5 and 6.
R610motr10a2.EPS
A - Gasket Ring (1) Withdraw magneto housing cover no. 7. NOTE: Lift the magneto housing cover from the provided area using two flat screwdrivers prying equally at the same time.
IMPORTANT: Avoid damage! Be careful not to lose the gasket ring on the screws nos. 2 and 5. NOTE: Only remove the two front screws no. 6. To ease lifting the magneto cover it is recommended to loosen the screws behind.
1
R610motr11A
1 R610motr11a2.EPS
A - Special Area for Removal of MAgneto Housing Cover (1)
R610motr09A
R610motr09a2.EPS
A - Gasket Ring (1)
Engine Ignition and Charging System - 86
ENGINE IGNITION AND CHARGING SYSTEM 1
R610motr17A
1 R610motr17a2.EPS
A - Special Area for Removal of MAgneto Housing Cover (1) IMPORTANT: Avoid damage! Ensure to use prying lugs to separate magneto housing cover to prevent damaging contact surface. During lifting be careful that splines on the shifter shaft do not damage the oil seal no. 8. Use grease on the splines.
R610motr16A
2
3 R610motr16a2.EPS
A - O-ring for Water Circulation (1) B - O-ring for Oil Circulation (2) C - Sealing Ring for Oil Circulation (3) Inspection: Check magneto housing cover for cracks or other damages. Replace if necessary. NOTE: Output shaft and cylinder holes are machined while crankcase MAG/PTO and magneto housing cover are assembled. In case of a damage, the whole crankcase assembly must be replaced. Installation: NOTE: Clean all metal component in a non-ferrous metal cleaner. Use gasket remover, or suitable equivalent. To remove remaining Loctite 5910 on the contact surface, use a copper brush.
R610motr18A
R610motr18a2.EPS
Grease splines to avoid future leaking on the shifter shaft IMPORTANT: Avoid damage! Be careful not to lose the sealing rings located on the crankcase mag side.
c CAUTION: Avoid Injury! Wear safety glasses
and work in a well ventilated area when working with strong chemical products. Also wear suitable non-absorbent gloves to protect your hands.
For installation, reverse the removal procedure. However, pay attention to the following. IMPORTANT: Avoid damage! When beginning the application of the crankcase sealant, the assembly and the first torquing should be done within 10 minutes. It is suggested to have all you need on hand to save time. NOTE: It is recommended to apply this specific sealant as described here to get a uniform application without lumps. If you do not use the roller method, you may
Engine Ignition and Charging System - 87
ENGINE IGNITION AND CHARGING SYSTEM use your finger to uniformly distribute the sealant (unlike the Drei Bond sealing compound, using a finger will not affect the adhesion).
1
Use the silicone-based Loctite 5910 on mating surfaces. NOTE: The sealant curing time is similar to the Loctite 518 without using the Primer N. IMPORTANT: Avoid damage! Do not use Loctite 515 or 518 to seal crankcase. Do not use Loctite Primer N with the Loctite 5910. Using these products or non silicone- based sealant over a previously sealed housing with Loctite 5910 will lead to poor adhesion and possibly a leaking housing. These products are chemically incompatible. Even after cleaning, the Loctite 5910 would leave incompatible microscopic particles. Use a Plexiglas plate and apply some sealant on it. Use a soft rubber roller (50 - 75 mm (2 - 3 in.)) (available in arts products suppliers for print making) and roll the sealant to get a thin uniform coat on the plate (spread as necessary). When ready, apply the sealant on magneto mating surfaces.
2
R610motr204A
R610motr204a2.EPS
A - Mating Surface on the Magneto Housing Cover (1) B - Do not apply Loctite 5910 here (2) IMPORTANT: Avoid damage! Ensure the sealing rings are present on the crankcase mag side.
1
F12R17A
F12r17A2.EPS
Do not apply in excess as it will spread out inside crankcase. NOTE: Do not use Loctite Primer N with this sealant. The sealant curing time is similar to the Loctite 518 without Primer N, from 4 to 24 hours. NOTE: Apply Loctite 5910 all around the crankcase MAG mating surface, except on the areas shown below.
R610motr16A
2
3 R610motr16a2.EPS
A - O-ring for Water Circulation (1) B - O-ring for Oil Circulation (2) C - Sealing Ring for Oil Circulation (3) IMPORTANT: Avoid damage! Use oil seal protector to avoid damaging the oil seal during reinstallation of the magneto housing cover.
Engine Ignition and Charging System - 88
ENGINE IGNITION AND CHARGING SYSTEM 1
1
R610motr207A
R610motr207a2.EPS
A - Failed Spring Inside Oil Seal (1) R610motr206A
1
R610motr206a2.EPS
2
A - Stator Wire Harness (1) Refer to the following illustration for proper installation of screws. IMPORTANT: Avoid damage! Ensure to reinstall the sealing ring on the screws nos. 2 and 5. Never use those gasket rings a second time. Always install new ones.
2
6
2
2
4 R610motr205A
3
R610motr205a2.EPS
A - Oil Seal Protector (1) B - Crankshaft MAG Side (2) IMPORTANT: Avoid damage! Do not damage stator wire harness during reinstallation of magneto housing cover.
3
5
3
5
R610motr19A
1
7
1
3
1
R610motr19a2.EPS
A B C D E F G
- Screws M6 x 130 (1) - Screws M6 x 45 (2) - Screws M6 x 65 (3) - Screws M6 x 25 (4) - Screws M8 x 25 (5) - Screws M6 x 45 with Sealing Ring (6) - Screws M6 x 130 with Sealing Ring (7)
Tightening sequence for screws on magneto housing cover is as per following illustration.
Engine Ignition and Charging System - 89
ENGINE IGNITION AND CHARGING SYSTEM 7
9
5
C - Handle for Insertion Jig (3)
12
3
1
4 15
3
16
2
2 R610motr19B
11
10
8
6
13
14 R610motr19b2.EPS
Seal R610outi01A
1
Remove magneto housing cover no. 7.
R610outi01a2.EPS
Inspection: Check the oil seal no. 8 and no. 9 on the magneto housing cover. If brittle, hard or damaged, replace.
A - Oil Seal (1) B - Oil Seal Installer (2) C - Handle for Insertion Jig (3) Reinstall other removed parts in the reverse order.
Removal:
NOTE: Rotate water pump impeller to ease placing the magneto cover in final position.
Pry out oil seals with a screwdriver. IMPORTANT: Avoid damage! Be careful not to damage the oil seal bore when using a screwdriver. Installation: NOTE: Never use oil in the press fit area of oil seal.
3
IMPORTANT: Avoid damage! Always use the oil seal protector to avoid damaging the oil seal during magneto housing cover installation. Apply grease on spline of shift shaft. Without Magneto Housing Cover Removed: Using a suitable tube, with the proper diameter, install the oil seals as per following illustration. IMPORTANT: Avoid damage! Use the oil seal protector to avoid damaging the oil seal during installation.
R610outi02A
1
2 R610outi02a2.EPS
A - Oil Seal (1) B - Oil Seal Installer (2)
Engine Ignition and Charging System - 90
ENGINE IGNITION AND CHARGING SYSTEM 3
2
1
Bearing Inspection: Ball bearing no. 10 must rotate freely. Otherwise, replace it. Removal: • Heat up the magneto housing cover to about 100°C (212°F) for an easy ball bearing removal.
1
R610motr208A
R610motr208a2.EPS
A - Oil Seal (1) B - Oil Seal Protector (2) C - Tube (min. 50 mm long) (3) IMPORTANT: Avoid damage! Apply grease on shift shaft splines to avoid damaging the oil seal.
3
2
1
R610motr12A
R610motr12a2.EPS
A - Ball Bearing (1) Installation: For installation also heat the magneto housing up to about 100°C (212°F) to put the ball bearing in place. Place new ball bearing in freezer for 10 minutes approximately. Reinstall other removed parts in the reverse order.
Stator and Trigger Coil Removal: Remove:
R610motr209A
R610motr209a2.EPS
A - Oil Seal (1) B - Grease on Spline of Shift Shaft (2) C - Tube (min. 70 mm long) (3)
•
magneto housing cover no. 7
•
screws no. 11 and 12
•
stator with trigger coil no. 13.
Engine Ignition and Charging System - 91
ENGINE IGNITION AND CHARGING SYSTEM 4
3 4
2
R610motr12B
1 R610motr12b2.EPS
R610motr20A
1
2 R610motr20a2.EPS
A B C D
- Stator (1) - Stator Screws (2) - Trigger Coil (3) - Trigger Coil Screws (4)
A - Cable Cover (1) B - Notch for Stator (2)
Vehicle Speed Sensor (VSS) The VSS is located on the top of magneto housing cover, behind the oil dipstick. Removal:
Inspection: Check stator and trigger coil condition. If damaged replace the faulty part.
Remove the LH side panel. Unscrew the VSS screw no. 19.
For electrical inspection, refer to CHARGING SYSTEM for the stator and IGNITION SYSTEM for the trigger coil.
3
2
1
Installation: For installation, reverse the removal procedure. However, pay attention to the following. IMPORTANT: Avoid damage! When installing the stator, make sure the cable cover no. 14 runs between the two threaded posts for trigger coil (guide for the wire). NOTE: There is only one position for the stator (notch in the magneto housing cover).
R610motr210A
R610motr210a2.EPS
A - VSS (1) B - Screw (2) C - Oil Dipstick (3) Lift sensor no. 18. Inspection: Check VSS condition and replace it, if necessary. Installation: For installation, reverse the removal procedure.
Engine Ignition and Charging System - 92
ENGINE IGNITION AND CHARGING SYSTEM Rotor Removal: Lock crankshaft with locking bolt (P/N JDG 529 035 617). Refer to CRANKSHAFT/BALANCER SHAFT. Remove: •
magneto housing cover no. 7
•
nut no. 15 retaining rotor no. 16
•
friction washer no. 17.
2
1
R610motr15A
R610motr15a2.EPS
A - Nut (1) B - Friction Washer (2) Install magneto puller (P/N JDG 529 035 748) and crankshaft protector (P/N JDG 420 876 557) then remove rotor. NOTE: Use grease to place protector on crankshaft end prior to screw on the magneto puller. Inspection: Check woodruff key and keyway on the crankshaft and the friction washer for wear or damages. Replace as necessary. Installation: For installation, reverse the removal procedure. However, pay attention to the following. IMPORTANT: Avoid damage! When installing the rotor, take care that the tapers are clean and degreased. Friction washer no. 17 must be installed correctly.
Engine Ignition and Charging System - 93
ENGINE OIL SYSTEM Oil System
Oil System Components
10 N m (89 lbf in)
30 Engine oil 21
29 26
25
19
24 27
4
11 N m 14 N m (97 lbf in) (124 lbf in) 23 Loctite 243 32 22 1 15 14
20
13 17 18 16 28 Engine 31 oil
5 6
2 3 30 N m (22 lbf ft)
7 8 9
Engine oil
10 11
10 N m 12 (89 lbf in)
R610motr261S
R610motr261sa2.EPS
General Prior to change the oil, ensure vehicle is on a level surface. Oil and oil filter must be replaced at the same time and oil strainer must be cleaned too. Oil change, oil filter
replacement and oil strainer cleaning should be done with a warm engine.
c CAUTION: Avoid Injury! The engine oil can be very hot. Wait until engine oil is warm.
During assembly/installation, use the torque values and
Engine Oil System - 94
ENGINE OIL SYSTEM service products as in the exploded views. Clean threads before applying a thread locker.
c CAUTION: Avoid Injury! Torque wrench
tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
Pressure/RPM
1300 rpm
6000 rpm
Minimal
70 KPa (10 PSI)
250 KPa (36 PSI)
Nominal
300 KPa (44 PSI)
500 KPa (73 PSI)
Maximal
600 KPa (87 PSI)
700 KPa (102 PSI)
If the engine oil pressure is out of specifications, check the points described in troubleshooting section.
Dispose oil and filter as per your local environmental regulations.
To install oil pressure switch, reverse the removal procedure.
Engine Oil Pressure Test
Oil Change
NOTE: The engine oil pressure test should be done with a warm engine and the recommended oil.
Removal:
Remove the oil pressure switch no. 1 in the area of the cylinder head (exhaust side), mounted on the crankcase MAG side and install an oil pressure gauge.
Clean the magnetic drain plug area.
Place a drain pan under the engine magnetic drain plug area. Unscrew magnetic drain plug no. 3 then remove dipstick. NOTE: Pay attention not to lose the O-ring located on dipstick.
2
1
R610motr41A
1 R610motr41a2.EPS
A - Oil Pressure Switch (1) R610motr262A
R610motr262a2.EPS
NOTE: Oil pressure switch works between 30 KPa (4 PSI) and 60 KPa (9 PSI). The engine oil pressure should be within the following values. NOTE: Oil pressure test has to be done at 80°C (176 °F).
A - O-ring (1) B - Dipstick (2) •
Wait a while to allow oil to flow out of oil filter.
Inspection: Oil condition gives information about the engine condition. See troubleshooting section. Clean the magnetic drain plug from metal shavings and dirt. Presence of debris gives an indication of failure inside
Engine Oil System - 95
ENGINE OIL SYSTEM B C D E
the engine. Check engine to correct the problem. Installation: The installation is the reverse of removal procedure. IMPORTANT: Avoid damage! Never use the gasket ring no. 2 a second time. Always replace by a new one.
Inspection: Check oil filter cover O-rings no. 5 and no. 6, replace if necessary. Check and clean the oil filter inlet and outlet area for dirt and other contaminations.
2
R610motr42A
- Oil Filter Cover (2) - Oil Filter (3) - O-ring Inside Groove (4) - O-ring Placed on Mating Surface (5)
1 R610motr42a2.EPS
A - Magnetic Drain Plug (1) B - Gasket Ring (2) R610motr44A
1
System Capacity:
R610motr44a2.EPS
A - Inlet Bore from the Oil Pump to the Oil Filter (1) B - Outlet Bore to the Engine Oil Providing System (2)
Refer to "Specifications" section. Oil Filter Removal: Remove: •
engine oil (refer to OIL CHANGE)
•
oil filter screw no. 4
•
oil filter cover
•
oil filter.
2
Installation: The installation is the opposite of the removal procedure. Pay attention to the following details. Install O-rings on oil filter cover as per following illustration.
4 3
3
5
2
2
1
1 R610motr263A
R610motr267A
R610motr263a2.EPS
R610motr267a2.EPS
A - Oil Filter Screw (1)
A - O-ring Inside Groove (1)
Engine Oil System - 96
ENGINE OIL SYSTEM B - O-ring Placed on Mating surface (2) C - Oil Filter Cover (3)
Cleaning and Inspection: Clean oil strainer with a part cleaner then use an air gun to dry it.
Torque oil filter screw to 10 N•m (89 lb-in.).
c CAUTION: Avoid Injury! always wear eye
Oil Strainer
protector. Chemicals can cause a rash break out and an injury to your eyes.
Removal: Remove:
Inspect O-ring no. 8 and rubber ring no. 10.
•
engine oil (refer to OIL CHANGE)
•
engine skid plate (Refer to BODY/FRAME)
•
screws no. 12 retaining oil strainer cover no. 11
If O-ring and rubber ring are brittle, cracked or hard, replace them.
2
Clean both contact surfaces (oil strainer cover and crankcase). Check and clean the oil inlet and outlet area for dirt and other contaminations.
2
R610motr46A
1
1
2 R610motr46a2.EPS R610motr48A
A - Oil Strainer Cover (1) B - 5 Screws (2)
3 R610motr48a2.EPS
•
oil collector no. 9 and O-ring no. 8
•
oil strainer no. 7.
2
A - Oil Inlet to the Oil Pump (1) B - Oil Return from the Oil Pressure Regulator System (2) C - Oil Return from the Engine Oil Circulation (3)
1
Installation: For installation, reverse the removal procedure. Reinstall oil strainer with sealing edge towards engine.
R610motr47A
R610motr47a2.EPS
A - Oil Collector with O-ring (1) B - Oil Strainer (2) Engine Oil System - 97
ENGINE OIL SYSTEM
2
1
R610motr266A
R610motr49A
1
R610motr266a2.EPS
A - Sealing Edge (1) B - Direction of Reinstallation (2)
A - Oil Pressure Regulator Plug (1)
Torque oil strainer cover screws as per following sequence.
1
R610motr49a2.EPS
NOTE: The oil pressure regulator system works when the oil pressure exceeds 500 kPa (73 PSI). Removal:
5
Remove: • water pump housing (refer to COOLING SYSTEM) • magneto housing cover (refer to MAGNETO SYSTEM) • oil pressure regulator plug no. 20, compression spring no. 22 and valve piston no. 21.
c CAUTION: Avoid Injury! Oil pressure regulator plug on oil pump housing is spring loaded.
1 R610motr46B
4
2
2
3
3 R610motr46b2.EPS
Refill engine at the proper level with the recommended oil. Refer to "Specifications" section for capacity. Start engine and let idle for a few minutes. Ensure oil filter and magnetic drain plug areas are not leaking. Stop engine. Wait a while to allow oil to flow down to crankcase then check oil level. Refill as necessary.
Engine Oil Pressure Regulator The oil pressure regulator is located on the engine MAG side (behind magneto housing cover).
R610motr264A
R610motr264a2.EPS
A - Valve Piston (1)
Engine Oil System - 98
ENGINE OIL SYSTEM B - Compression Spring (2) C - Oil Pressure Regulator Plug (3)
3
1
2
Inspection: Inspect valve piston for scoring or other damages. Check compression spring for free length. Compression Spring Free Length New Nominal
64 mm (2.519 in.)
Service Limit
62 mm (2.441 in.)
Replace both parts if important wear or damage are present. Clean bore and threads in the oil pump housing from metal shavings and other contaminations. Installation: R610motr51A
For installation, reverse the removal procedure.
R610motr51a2.EPS
A - Thrust Washer (1) B - Pin (2) C - Intermediate Gear with Needle Bearing (3)
Oil Pump The oil pump is located on the engine MAG side (refer to ENGINE OIL PRESSURE REGULATOR).
•
thrust washer no. 32
Removal: Remove: • engine from vehicle (refer to REMOVAL AND INSTALLATION) •
water pump housing (refer to COOLING SYSTEM)
•
magneto housing cover (refer to MAGNETO SYSTEM)
NOTE: The following steps to remove the drive gears (no. 13 to no. 19) are not necessary to replace only the oil pump. •
retaining ring no. 15 then drive gear no. 14 IMPORTANT: Avoid damage! Never use the retaining ring a second time. Always replace by a new one.
NOTE: Drive gear is snapped on a needle pin. This needle pin passes through the balancing shaft. R610motr52A
•
needle pin no. 13
•
distance sleeve no. 19
•
thrust washer no. 17
•
screws no. 29
•
pin no. 16
•
oil pump cover no. 26
•
intermediate gear no. 18
1 R610motr52a2.EPS
A - Thrust Washer (1)
Engine Oil System - 99
ENGINE OIL SYSTEM 1
2
1
1
R610motr54A
R610motr54a2.EPS
A - Dowel Pins (1) •
R610motr49B
1
oil pump gear no. 28
NOTE: Oil pump gear is snapped on needle pin. This needle pin passes through the oil pump shaft. Use screwdrivers to remove this gear.
3 R610motr49b2.EPS
1
A - 4 Screws (1) B - Oil from the Pump to the Oil Filter in the Magneto Housing Cover (2) C - Oil Pump Cover (3) NOTE: To remove oil pump system, lift the dowel pins no. 25 a bit. The oil pump housing with oil pump shaft assembly will be easier to remove. IMPORTANT: Avoid damage! Pay attention not to drop the dowel pins inside the engine.
1
R610motr55A
R610motr55a2.EPS
A - Flat Screwdriver (1)
2
R610motr53A
3
2
4
1 R610motr53a2.EPS
5
A - Oil Pump System (1)
1
R610motr56A
R610motr56a2.EPS
Engine Oil System - 100
ENGINE OIL SYSTEM A B C D E
- Oil Pump Gear (1) - Dowel Pins (2) - Suction Side of the Oil Pump - Oil Outlet to the Bypass of the Oil Filter (4) - Outlet from the Engine Oil Pressure Regulator Valve (5)
•
needle pin no. 27
•
oil pump shaft assembly no. 24
•
oil pump housing no. 20.
1
R610motr58A
R610motr58a2.EPS
A - Pittings on the Teeth (1) Using a feeler gauge, measure the clearance between inner and outer rotors.
1 2 R610motr57A
1
2 R610motr57a2.EPS
B
A - Oil Pump Shaft Assembly (1) B - Oil Pump Housing (2)
A
Inspection: Inspect oil pump shaft assembly, housing and cover for marks or other damages. R610motr59A
Replace O-ring no. 30 if brittle or hard. This O-ring is located on the oil pump housing.
R610motr59a2.EPS
A - Outer Rotor (1) B - Inner Rotor (2)
Replace gasket no. 31 if brittle or hard. This gasket is located on the crankcase MAG side behind intermediate gear no. 18. Check inner rotor for corrosion pin-holes or other damages. If so, replace oil pump shaft assembly. Ensure to also check oil pump housing and cover. If damaged, replace the complete oil pump assembly.
C
Outer And Inner Rotors Clearance Mm (in.) Service Limit A
0.25 mm (0.009 in.)
B C If clearance between inner and outer rotors exceeds the tolerance, replace oil pump shaft assembly. Ensure to also check oil pump housing and cover. If damaged, replace the complete oil pump assembly. If clearance between outer rotor and its bore in oil pump exceeds the tolerance, replace the complete oil pump assembly. Engine Oil System - 101
ENGINE OIL SYSTEM Using a dial indicator, measure side wear as shown.
2
3
2
R610motr60A
1
R610motr265A
1
R610motr265a2.EPS R610motr60a2.EPS
A - Oil Pump Housing Surface (1) B - Dial Indicator (2)
2
A - Oil Inlet to the Oil Pump (1) B - Oil Return From the Oil Pressure Regulator System (2) C - Oil Distribution Through the Engine (3) Installation: For installation, reverse the removal procedure. IMPORTANT: Avoid damage! The punch mark on the oil pump housing must be the same side as the punch mark on the shaft assembly. 1
R610motr60B
1 R610motr60b2.EPS
A - Oil Pump Outer Rotor Surface (1) B - Dial Indicator (2) Difference between pump housing and outer rotor should not exceed 0.1 mm (0.004 in.). If so, replace the complete oil pump assembly. NOTE: When the axial clearance of the oil pump shaft assembly increases, the oil pressure decreases. Check the inside of oil pump housing and its cover for scoring or other damages. If so, change the complete oil pump assembly.
P0008504
A - Both Marks on the Same Side (1) Tightening oil pump housing screws as per following sequence.
Clean oil ducts from contaminations. Engine Oil System - 102
ENGINE OIL SYSTEM 1
R610motr62A
4
3
2 R610motr62a2.EPS
NOTE: To keep the O-ring no. 30 in place it is recommended to apply multi purpose grease. Final Test: After engine is completely reassembled, start engine and make sure oil pressure is within specifications.
Engine Oil System - 103
ENGINE CYLINDER AND HEAD Cylinder and Head
NOTE: For cylinder head, cylinder and piston removal, it is not necessary to remove engine from vehicle.
Cylinder Head Components
1
3
10 N m (89 lbf in)
4 10 N m (89 lbf in)
Engine oil
5
11
Engine oil 20
20 N m + 90° (15 lbf ft + 90°) 8
10 23
21
7
6
4 N m (35 lbf in) 10 19 Loctite 243
Multipurpose grease
Engine oil
22
29 26
24
25 10 N m 28 (89 lbf in) Loctite 243
38
30 36 27
16 N m (142 lbf in)
38
37 32 42
Engine oil 31 20 N m + 90° (15 lbf ft + 90°) 25 N m (18 lbf ft) Engine 33 oil
Engine oil Loctite 243
10 N m (89 lbf in)
Multipurpose grease
35
10 N m (89 lbf in) 42
10 N m (89 lbf in)
Engine oil 9
39
Engine oil
Engine oil 40
R610motr227S
R610motr227sa2.EPS
Engine Cylinder and Head - 104
Engine oil
20 N m (15 lbf ft) 2
34
41
43
Anti-seize lubricant
ENGINE CYLINDER AND HEAD Piston and Rings Components
Loctite 243 Engine oil
17
7 N m (62 lbf in) 14 12 4.5 N m (40 lbf in) 18
13 16 0.4 N m (3.5 lbf in)
15
Engine oil
44
46 45
Engine oil
47 49 Engine oil
48 47 Engine oil
R610motr228S
R610motr228sa2.EPS
General NOTE: When diagnosing an engine problem, always perform a cylinder leak test. This will help pin-point a problem. Refer to the instructions included with your leak tester and LEAK TEST section for procedures.
Always place the vehicle on level surface. NOTE: For a better understanding, the following illustrations are taken with engine out of vehicle. To perform the following instructions, it is not necessary to remove engine from vehicle. Always disconnect BLACK (-) cable from the battery, then RED (+) cable before working on the engine.
Engine Cylinder and Head - 105
ENGINE CYLINDER AND HEAD
c CAUTION: Avoid Injury! Always disconnect
1
2
battery or starter cables exactly in the specified order, BLACK (-) cable first.
Even if the removal of many parts is not necessary to reach another part, it is recommended to remove these parts in order to check them. During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a thread locker.
c CAUTION: Avoid Injury! Torque wrench
tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
When disassembling parts that are duplicated in the engine, (e.g.: valves), it is a strongly recommended to note their position (PTO, MAG side) and to keep them as a “group”. If you find a defective component, it would be much easier to find the cause of the failure among its group of parts (e.g.: you found a worn valve guide. A bent spring could be the cause and it will be easy to know which one among the springs is the cause to replace it if you grouped them at disassembly). Besides, since used parts have matched together during the engine operation, they will keep their matched fit when you reassemble them together within their “group”. Intake port/air filter contaminated (clogged) with dirt, sand, etc. (leads to worn valves, piston rings and finally to lack of power). IMPORTANT: Avoid damage! In case of piston rings and/or valve replacement, always clean the whole engine and change oil and oil filter.
R610motr87A
R610motr87a2.EPS
A - Ignition Coil (1) B - Spark Plug (2)
Inspection: Check spark plug and ignition coil condition (refer to IGNITION SYSTEM). NOTE: To check spark, place connected spark plug with threads against crankcase to simulate electrical ground and crank the engine. Installation: For installation, reverse the removal procedure. Pay attention to the following details. Check spark plug gap (refer to "Specifications" section). Place spark plug into ignition coil, screw spark plug then remove the ignition coil. Torque spark plug to 20 N•m (15 lb-ft). Reinstall the ignition coil.
Thermostat Refer to COOLING SYSTEM.
Valve Cover
Spark Plug
Removal:
Removal:
Remove:
Unplug the ignition coil connector. Remove the ignition coil no. 1.
•
valve cover shield no. 3
•
valve cover screws no. 4
Clean spark plug and ignition coil area before disassembly. Unscrew spark plug no. 2 then use the ignition coil to take spark plug out of spark plug hole.
Engine Cylinder and Head - 106
ENGINE CYLINDER AND HEAD Rocker Arm
1
Removal: Lock crankshaft with crankshaft locking bolt (P/N JDG 529 035 617), refer to CRANKSHAFT AND BALANCER SHAFT. Remove: •
spark plug
•
valve cover
•
spark plug tube no. 7
R610motr88A
R610motr88a2.EPS
A - Valve Cover Screws (1) •
valve cover no. 5 and profile sealing ring no. 6.
R610motr90A
1
2 R610motr90a2.EPS
A - Cylinder Head (1) B - Spark Plug Tube (2) •
rocker arm shaft screws no. 8 (discard screws)
1 R610motr89A
2
1 R610motr89a2.EPS
A - Valve Cover (1) B - Profile Sealing Ring (2) Inspection: Check the profile sealing ring on the valve cover and the rubber bushing on the valve cover screws if they are brittle, cracked or hard. If so, replace the profile sealing ring or the valve cover screw accordingly. Installation: For installation, reverse the removal procedure. NOTE: Tighten the valve cover screws in a criss-cross sequence.
R610motr91A
2 R610motr91a2.EPS
A - Rocker Arm Shaft Screws (1) B - Rocker Arms (2) • rocker arm shaft no. 9 with rocker arm assembly (exhaust side no. 10 and intake side no. 11).
Engine Cylinder and Head - 107
ENGINE CYLINDER AND HEAD 2
3 R610motr94A
2
1
3 R610motr94a2.EPS
R610motr92A
2
A - Spark Plug Tube (1) B - Seal to the Valve Cover (2) C - Seal to the Cylinder Head (3)
1 R610motr92a2.EPS
Rocker Arm: Inspect each rocker arm for cracks and scored friction surfaces. If so, replace rocker arm assembly.
A - Rocker Arm Shaft (1) B - Rocker Arms (exhaust side) (2) C - Rocker Arm (intake side) (3)
Check the rocker arm rollers for free movement, wear and excessive radial play. Replace rocker arm assembly as necessary.
1
A
R610motr93A
R610motr93a2.EPS
A - Oil supply from the camshaft to the rocker arm shaft, then to the rocker arms and finally to the valve adjustment (1) Inspection: Spark Plug Tube: Check seals on spark plug tube. If seals are brittle, cracked or hard, replace spark plug tube.
1
R610motr95A
2
R610motr95a2.EPS
A - Rocker Arm (intake side) (1) B - Roller (2) C - Bore for Rocker Arm Shaft (A)
Engine Cylinder and Head - 108
ENGINE CYLINDER AND HEAD Check for scored friction surfaces, if so, replace parts.
A
Measure rocker arm shaft diameter. Rocker Arm Shaft Diameter
R610motr96A
2
Minimum (new)
19.980 mm (0.7866 in.)
Maximum (new)
20.007 mm (0.7877 in.)
Service Limit
19.965 mm (0.7860 in.)
1 R610motr96a2.EPS
A - Rocker Arm (exhaust side) (1) B - Roller (2) C - Bore for Rocker Arm Shaft (A)
A
R610motr98A
R610motr98a2.EPS
Measure rocker arm bore diameter. If diameter is out of specification, change the rocker arm assembly.
A - Measure Rocker Arm Diameter Here (A) Any area worn excessively will require parts replacement. Installation:
Rocker Arm Bore Diameter Minimum (new)
20.007 mm (0.7877 in.)
Maximum (new)
20.020 mm (0.7881 in.)
Service Limit
20.035 mm (0.7887 in.)
For installation, reverse the removal procedure. Pay attention to the following details. Apply engine oil on rocker arm shaft. Position the rocker arm shaft with the notches on top.
Press the hydraulic lifter with your thumb. If the hydraulic lifter groove disappears inside rocker arm casting, replace rocker arm assembly. Lifter must turn freely in rocker arm bore. Otherwise, replace.
2
R610motr99A
1 R610motr99a2.EPS
A - Rocker Arm Shaft (1) B - Rocker Arm Shaft Notches (2) R610motr97A
Install NEW rocker arm shaft screws no. 8. Torque as per following procedure:
1 R610motr97a2.EPS
A - Hydraulic Lifter Groove (1) Rocker Arm Shaft:
Engine Cylinder and Head - 109
ENGINE CYLINDER AND HEAD IMPORTANT: Avoid damage! This assembly uses stretch screws. As the screws have been stretched from the previous installation, it is very important to use new screws at assembly. Failure to replace screws and to strictly follow the torque procedure may cause screws to loosen and lead to engine damage.
•
carburetor (refer to CARBURETOR AND FUEL PUMP)
•
chain tensioner plug no. 12
• torque screws at half of the recommended torque value in the exploded view •
torque screws at the recommended torque value
• finish tightening screws turning an additional 90° rotation with a torque angle gauge.
2
1
R610motr101A
R610motr101a2.EPS
A - Chain Tensioner Plug (1) •
O-ring no. 18 mounted on chain tensioner plug
•
spring no. 13
1 R610motr100A
2
1
3
R610motr100a2.EPS
A - Rocker Arm Shaft Screw (1) B - Torque Angle Gauge (2)
Chain Tensioner Removal:
c CAUTION: Avoid Injury! Chain tensioner is
R610motr229A
spring loaded.
R610motr229a2.EPS
c CAUTION: Avoid Injury! Never perform this
operation immediately after the engine has been run because the exhaust system can be very hot. Wait until exhaust system is warm or cold.
• unscrew chain tensioner plunger no. 16 with a screwdriver •
Remove: •
A - Chain Tensioner Plug (1) B - O-ring (2) C - Spring (3)
screws no. 14
RH engine cover (Refer to BODY/FRAME) Engine Cylinder and Head - 110
ENGINE CYLINDER AND HEAD Installation: For installation, reverse the removal procedure. Pay attention to the following details. IMPORTANT: Avoid damage! Do not forget to place O-rings no. 17 and no. 18. Screw the plunger until it touches the chain guide and torque to 0.4 N•m (3.5 lb-in.). Install torsion spring end in plunger groove and the other in the plug groove.
1
2 R610motr102A
1 R610motr102a2.EPS
A - Chain Tensioner Screw (1) •
chain tensioner housing no. 15.
R610motr231A
R610motr231a2.EPS
Inspection: Check general condition of chain tensioner area. Using a flat screwdriver, unscrew chain tensioner plunger no. 16. Check chain tensioner plunger for free movement in the threads of chain tensioner housing. NOTE: Excessively worn chain tensioner plunger shows possible failure.
A - Groove In Plunger (1) B - Torsion Spring End (2) Screw plug and torque to 4.5 N•m (40 lb-in.).
Breather Removal: Remove RH engine cover. Refer to BODY/FRAME. Unscrew upper engine support nuts.
R610motr103A
R610motr103a2.EPS
Check chain guides for wear. Replace as necessary. Check spring condition. Replace if broken or worn. Replace O-rings no. 17 and no. 18, if brittle, cracked or hard.
R610motr104A
1 R610motr104a2.EPS
A - Engine Support Nuts (1) Remove breather hose then unscrew breather screws no. 19.
Engine Cylinder and Head - 111
ENGINE CYLINDER AND HEAD Push, with your hand, the top of engine toward the LH side of vehicle. At the same time, remove the breather no. 20.
A - Washer Properly Installed (1) Properly slide new “V” ring on its seat.
IMPORTANT: Avoid damage! Do not let the thrust washer no. 23 or anything else fall into the chain pit.
2
4
2 1
3
P0004442
A - New “V” Ring on its Seat (1) B - Apply Engine Oil (2) Apply engine oil on V-ring mating surface.
1 R610motr232A
R610motr232a2.EPS
A B C D
Install breather assembly all the way in until it reaches its normal position.
- Breather (1) - O-ring (2) - V-ring (3) - Thrust Washer Mounted Inside Camshaft Cover (4)
1
Inspection: Check O-ring no. 21 and V-ring no. 22 on breather. If they are brittle, cracked or hard, replace them. Installation: For installation, reverse the removal procedure. Make sure thrust washer is properly installed inside cover.
P0004440
A - Apply Engine Oil on Mating Surfaces (1) Check if the sealing lips are sealing properly against washer.
1
Decompressor Removal: Remove:
P0004437
•
breather no. 20
•
notched washer no. 23
•
camshaft timing gear cover no. 24
•
centrifugal weight no. 25
•
decompressor shaft no. 26.
Engine Cylinder and Head - 112
ENGINE CYLINDER AND HEAD Inspection:
B - Edge of Centrifugal Weight (2)
Check decompressor shaft for service limit, replace if it out of specifications.
B
R610motr105B
1
A
A R610motr105b2.EPS
A - Decompressor Shaft B - Measure Here (A) C - Measurement on top end of decompressor shaft (B) Decompressor Shaft Measurement A Minimum (new)
6.015 mm (0.2368 in.)
Maximum (new)
6.027 mm (0.2373 in.)
Service Limit
5.900 mm (0.2323 in.)
Decompressor Shaft Measurement B Minimum (new)
5.830 mm (0.230 in.)
Maximum (new)
5.870 mm (0.231 in.)
Service Limit
5.500 mm (0.217 in.)
Check torsion spring and edge of the centrifugal weight for visible wear. If so, replace them together.
2
R610motr106A
1 R610motr106a2.EPS
A - Centrifugal Weight with Torsion Spring (1)
Engine Cylinder and Head - 113
ENGINE CYLINDER AND HEAD Installation:
the timing gear.
The installation is essentially the reverse of the removal procedure but, pay attention to the following details. 1
Engage the edge of centrifugal weight into the decompressor shaft groove then put the parts in place.
2 P0004443
2
3
A - Pin in Cover with Large Hole in Timing Gear (1) B - Hole in Cover with Small Hole in Timing Gear (2)
1 R610motr107a2.EPS
A - Decompressor Shaft Groove (1) B - Centrifugal Weight (2) C - Torsion Spring (3) Place the torsion spring end under socket screw head.
1
R610motr109A
2
1 R610motr109a2.EPS
A - Hole in Cover (1) B - Hole in Camshaft Timing Gear (2) IMPORTANT: Avoid damage! Take care before and after cover installation that the centrifugal system works properly.
Camshaft Timing Gear
R610motr108A
R610motr108a2.EPS
A - Position of Torsion Spring End (1) Install the camshaft timing gear cover. Position the cover on the timing gear so that the holes are aligned. NOTE: The hole in the timing gear cover must be in line with the small hole in the gear. The pin inside the timing gear cover must be in line with the large hole in
NOTE: Although it is not necessary to position crankshaft to TDC for disassembly, it is a good practice to do it, as a troubleshooting step, to know before disassembly if valve timing was appropriate. Removal: Lock crankshaft at the TDC compression position to have the crankshaft position defined for reassembly (refer to
Engine Cylinder and Head - 114
ENGINE CYLINDER AND HEAD CRANKSHAFT AND BALANCER SHAFT). Remove: •
valve cover
•
chain tensioner
1
Using the drive pulley puller (P/N JDG 529 035 746), lock the camshaft at TDC compression position to prevent timing chain stretching.
2 1
R610motr110A
2
R610motr110a2.EPS
A - Drive Pulley Puller (1) B - Camshaft on TDC Position (2) R610motr233A
R610motr233a2.EPS
Install the camshaft timing gear with the writing toward cylinder head.
A - Drive Pulley Puller (1) B - Allen Screws (2) •
decompressor
•
chain guide no. 27
•
Allen screws no. 28
•
camshaft timing gear no. 29.
1
NOTE: Secure timing chain no. 30 with a retaining wire. Inspection: Check camshaft timing gear for wear or deterioration.
2
If gear is worn or damaged, replace it as a set (camshaft timing gear and timing chain). For crankshaft timing gear, refer to CRANKSHAFT AND BALANCER SHAFT. Installation: For installation, reverse the removal procedure. Pay attention to the following details. Using the drive pulley puller (P/N JDG 529 035 746), lock camshaft on TDC position. R610motr113A
R610motr113a2.EPS
A - Good (1) B - Never (2)
Engine Cylinder and Head - 115
ENGINE CYLINDER AND HEAD IMPORTANT: Avoid damage! Crankshaft and camshaft must be locked on TDC compression cycle to place camshaft timing gear and timing chain in the proper position. Double-check position of timing gear with drive pulley puller (P/N JDG 529 035 746), when chain tensioner is reinstalled.
A - Timing Chain (1) If chain is excessively worn or damaged, replace it as a set (camshaft timing gear and timing chain). Further details refer to CRANKSHAFT AND BALANCER SHAFT section.
Cylinder Head
Timing Chain
Removal:
Inspection: Measure depth from chain tensioner plug mating surface down to chain tensioner guide.
Lock crankshaft with crankshaft locking bolt (P/N JDG 529 035 617), refer to CRANKSHAFT AND BALANCER SHAFT.
Use a suitable pin and mark with a scratch awl.
Drain coolant (refer to COOLING SYSTEM).
2 A
1
NOTE: Before removing cylinder head, blow out remaining coolant by air pressure. During cylinder head removal, the remaining coolant in cylinder head could overflow into the engine and a little quantity of coolant could drop into the engine. In this case, the engine oil will be contaminated. Disconnect temperature switch. Remove:
R610motr230A
R610motr230a2.EPS
A - Scratch Awl (1) B - Measuring Point (2) C - Pin Diameter Approximately 12 mm (A) Depth of Chain tensioner guide
•
RH side cover
•
seat support
• exhaust pipe and upper engine support (refer to REMOVAL AND INSTALLATION) •
engine outlet hose
•
carburetor and pulse line
•
tensioner
•
valve cover shield
Nominal (New)
55.0 mm (0.1805 ft)
• valve cover and profile sealing ring (see Valve cover above)
Service Limit
61.0 mm (0.1969 ft)
•
breather and notched washer
•
decompressor
•
camshaft timing gear
•
cylinder head screws M6 no. 32
If depth exceeds service limit, replace timing chain, camshaft timing gear, chain guide and chain tensioner guide at the same time. Check timing chain on camshaft timing gear for excessive radial play. Check chain condition for wear and rollers condition.
R610motr201A
1 R610motr201a2.EPS
Engine Cylinder and Head - 116
ENGINE CYLINDER AND HEAD • Check oil supply through the cylinder head for contamination.
1
2
3 1
R610motr114A
R610motr114a2.EPS
A - Cylinder Head Screws M6 (1) • cylinder head screws M11 no. 31 retaining cylinder head and cylinder to cylinder base.
R610motr234A
R610motr234a2.EPS
A - Oil Supply to Camshaft Bearing Journal MAG Side (1) B - Oil Supply to Camshaft Bearing Journal PTO Side (2) C - Oil Backflow Through Chain Compartment to Engine Bottom (3) Installation: For installation, reverse the removal procedure. Pay attention to the following details. Ensure dowel pins are in place.
1
R610motr115A
R610motr115a2.EPS
A - Cylinder Head Screws M11 (1) Disconnect the temperature switch. Pull up cylinder head no. 33. Remove: •
chain guide no. 27
•
gasket no. 34.
Install cylinder head screws M11 no. 31. Torque screws as per following procedure. IMPORTANT: Avoid damage! This assembly use stretch screws. As the screws have been stretched from the previous installation, it is very important to measure each screw at assembly. If screw is out of specification, replace by a new one. Failure to replace screws and to strictly follow the torque procedure may cause screws to loosen and lead to engine damage. Cylinder Head Screw M11 Service Limit
Inspection:
216.5 mm (8.524 in.)
• Check for cracks between valve seats, if so, replace cylinder head.
Torque screws in criss-cross sequence at half of the recommended torque value in the exploded view.
•
Torque screws no. 31 criss-cross with the recommended values in the exploded view.
Check gasket for cracks or other damages.
• Check mating surface between cylinder and cylinder head for contamination. If so, clean both surfaces.
Finish tightening screws turning an additional 90° rotation
Engine Cylinder and Head - 117
ENGINE CYLINDER AND HEAD with a torque angle gauge then, torque screws no. 32 with the recommended values in the exploded view.
Camshaft Removal: Remove:
2
•
valve cover
•
rocker arms
•
chain tensioner
•
decompressor
•
camshaft timing gear
•
camshaft lock no. 35
•
camshaft no. 36.
1
1
R610motr116A
R610motr116a2.EPS
A - Cylinder Screws M11 (1) B - Angle Torque Wrench (2) Check chain guide no. 27 for movement. IMPORTANT: Avoid damage! Chain guide has to be inserted in the provided groove.
R610motr117A
2 R610motr117a2.EPS
A - Camshaft Lock (1) B - Camshaft (2)
2
Cleaning:
1
Remove carbon deposits from combustion chamber, exhaust port and piston top. Inspection: R610motr233B
R610motr233b2.EPS
A - Chain Guide (placed between cylinder head and timing chain) (1) B - Chain Tensioner Guide (mounted in crankcase MAG) (2)
Check each lobe and bearing journal of camshaft for scoring, scuffing, cracks or other signs of wear. Measure camshaft bearing journal diameter and lobe height using a micrometer.
Remove crankshaft locking bolt then install plug with sealing ring.
Engine Cylinder and Head - 118
ENGINE CYLINDER AND HEAD D
A
B
A
C
Maximum (new)
39.935 mm (1.5722 in.)
Service Limit
39.920 mm (1.5716 in.)
Camshaft Bearing Journal - PTO Side 24.967 mm (0.9829 in.)
Maximum (new)
24.980 mm (0.9835 in.)
Service Limit
24.960 mm (0.9827 in.)
Camshaft Bore - Mag Side Measured In Diameter
R610motr118A
R610motr118a2.EPS
A B C D
Minimum (new)
- Camshaft Lobe (exhaust valves) (A) - Camshaft Lobe (intake valves) (B) - Camshaft Bearing Journal MAG Side (C) - Camshaft Bearing Journal PTO Side (D)
Measure clearance on both ends of camshaft and into cylinder head bores.
Minimum (new)
39.984 mm (1.5742 in.)
Maximum (new)
40.000 mm (1.5748 in.)
Service Limit
40.020 mm (1.5756 in.)
Camshaft Bore - PTO Side Measured In Diameter Minimum (new)
24.987 mm (0.9837 in.)
Maximum (new)
25.000 mm (0.9842 in.)
Service Limit
25.020 mm (0.9850 in.)
Replace parts that are not within specifications. Installation:
2
For installation, reverse the removal procedure. Pay attention to the following details.
1
Install camshaft then place the drive pulley puller (P/N JDG 529 035 746) in the slot.
1
R610motr235A
R610motr235a2.EPS
A - Cylinder Head (camshaft bore MAG side) (1) B - Cylinder Head (camshaft bore PTO side) (2) Camshaft Lobe - Exhaust Valve Minimum (new)
31.147 mm (1.226 in.)
Maximum (new)
31.347 mm (1.234 in.)
Service Limit
31.100 mm (1.224 in.)
Camshaft Lobe - Intake Valve Minimum (new)
31.369 mm (1.235 in.)
Maximum (new)
31.569 mm (1.243 in.)
Service Limit
31.300 mm (1.232 in.)
R610motr119A
R610motr119a2.EPS
A - Camshaft Lock Position (1) For other parts, refer to proper installation procedure.
Camshaft Bearing Journal - Mag Side Minimum (new)
39.927 mm (1.5719 in.) Engine Cylinder and Head - 119
ENGINE CYLINDER AND HEAD Valve Spring
the valve Remove valve cotters no. 38.
Removal:
Withdraw valve spring compressor, valve spring retainer no. 39 and valve spring.
Remove: •
rocker arms (see ROCKER ARM above)
•
cylinder head (see CYLINDER HEAD above).
Inspection: Check valve spring for rust, corrosion or other visible damages. If so, replace valve spring.
Compress valve spring no. 37, use valve spring compressor clamp and valve spring compressor cup.
Check valve spring for free length and straightness.
c CAUTION: Avoid Injury! Always wear safety
Replace valve springs if not within specifications.
glasses when disassembling valve springs. Be careful when unlocking valves. Components could fly away because of the strong spring preload.
2
A R610motr122A
R610motr122a2.EPS
1
A - Valve Spring Length (A) Valve Spring Free Length Nominal (New)
45.45 mm (1.789 in.)
Service Limit
43 mm (1.693 in.)
Installation:
R610motr120A
R610motr120a2.EPS
A - Valve Spring Compressor Clamp (1) B - Valve Spring Compressor Cup (2)
For installation, reverse the removal procedure. Pay attention to the following details. Colored area of the valve spring must be placed on top. NOTE: Valve cotter must be properly engaged in valve stem grooves.
R610motr121A
R610motr121a2.EPS
Locate valve spring compressor clamp in center of Engine Cylinder and Head - 120
ENGINE CYLINDER AND HEAD 2
1
R610motr123A
R610motr123a2.EPS
A - Position of the Valve Spring (1) B - Valve Cotters (2)
Valve
R610motr125A
R610motr125a2.EPS
Removal� Remove valve spring. Push valve stem then pull valves no. 40 and no. 41 out of valve guide.
IMPORTANT: Avoid damage! Do not remove valve stem seal with a screwdriver to avoid damaging the thrust surface on cylinder head.
1
R610motr240A
R610motr240a2.EPS R610motr124A
1
2 R610motr124a2.EPS
A - Intake Valve 38 mm (1) B - Exhaust Valve 31 mm (2)
A - Thrust surface damage due to wrong stem seal disassembly (1) Inspection: Valve Stem Seal:
Remove valve stem seal with integrated thrust washer no. 42 with special pliers such as Snap-ON YA 8230.
Inspection of valve stem seals is not needed because new seals should always be installed whenever cylinder head is removed. Valve: Inspect valve surface, check for abnormal stem wear and bending. If so, replace by a new one.
Engine Cylinder and Head - 121
ENGINE CYLINDER AND HEAD Exhaust
Valve Out Of Round
Intake
Nominal (New) Exhaust
5.93 mm (0.233 in.)
0.005 mm (0.0002 in.)
Intake
Replace valve guide if it is out of specification or has other damages such as wear or friction surface (see VALVE GUIDE PROCEDURE below).
Service Limit Exhaust
0.06 mm (0.0024 in.)
Valve Guide Diameter mm (in.) Service Limit
Intake
Exhaust
Valve Stem and Valve Guide Clearance: Measure valve stem and valve guide in three places, using a micrometer and a small bore gauge.
6.060 mm (0.2386 in.)
Intake Valve Face and Seat:
NOTE: Clean valve guide to remove carbon deposits before measuring.
3
2
1
Change valve if valve stem is out of specification or has other damages such as wear of contact surface.
A R610motr127A
R610motr127a2.EPS
A - Valve Seat (1) B - Exhaust Valve Contaminated Area (2) C - Valve Face (contact surface to valve seat) (3) Check valve face and seat for burning or pittings and replace valve or cylinder head if there are signs of damage. R610motr126A
R610motr126a2.EPS
A - Valve Stem Diameter (A)
Ensure to seat valves properly. Apply some lapping compound to valve face and work valve on its seat with a lapping tool (see VALVE GUIDE PROCEDURE below). Measure valve face contact width. NOTE: The location of contact area should be in center of valve seat.
Valve Stem Diameter mm (in.) Minimum (new) Exhaust
5.946 mm (0.2341 in.)
Intake
5.961 mm (0.2347 in.)
Maximum (new) Exhaust
5.960 mm (0.2346 in.)
Intake
5.975 mm (0.2352 in.)
Service Limit
Engine Cylinder and Head - 122
ENGINE CYLINDER AND HEAD Measure valve seat width, using a caliper.
2
Valve Seat Contact Width mm (in.) New Exhaust
1.25 to 1.55 mm (0.049 to 0.061 in.)
Intake
1.10 to 1.30 mm (0.043 to 0.051 in.)
Service Limit Exhaust
2 mm (0.078 in.)
Intake
1.8 mm (0.07 in.) R610motr236A
If valve seat contact width is too wide or has dark spots, replace the cylinder head.
1 R610motr236a2.EPS
A - Thrust Washer Integrated with Integrated Valve Stem Seal (1) B - Sealing Lips of Valve Stem Seal (2)
B
A
To ease installation of cotters, apply oil or grease on them so that they remain in place while releasing the spring. After spring is installed, ensure it is properly locked by tapping on valve stem end with a soft hammer so that valve opens and closes a few times. IMPORTANT: Avoid damage! An improperly locked valve spring will cause engine damage.
Valve Guide Procedure Removal:
V01C1HA
V01c1ha2.EPS
A - Valve Face Contact Width (A) B - Valve Seat Contact Width (B)
Remove: •
cylinder head (see Cylinder Head above)
•
valve spring (see Valve Spring above)
Installation:
•
valve (see Valve above).
For installation, reverse the removal procedure. Pay attention to the following details.
NOTE: Clean valve guide area from contamination before removal.
Install valve stem seal with integrated thrust washer no. 42. Apply engine oil on valve stem and install it.
Using a valve guide remover, remove valve guide no. 43 with a hammer.
IMPORTANT: Avoid damage! Be careful when valve stem is passed through sealing lips of valve stem seal.
Engine Cylinder and Head - 123
ENGINE CYLINDER AND HEAD IMPORTANT: Avoid damage! Push valve guide no. 43 in the cold cylinder head as per following illustration.
1
2
1
A
2
R610motr239A R610motr237A
R610motr239a2.EPS R610motr237a2.EPS
A - Valve Guide Remover (1) B - Valve Guide (2) Inspection: Always replace valve stem seals whenever cylinder head is removed. Installation: For installation, reverse the removal procedure. Pay attention to the following details.
A - Thrust Surface of Cylinder Head (1) B - Valve Guide (2) C - Measurement from Thrust Surface to Valve Guide Top (A) Valve Guide Measurement A Minimum (new)
12.40 mm (0.488 in.)
Maximum (new)
12.80 mm (0.504 in.)
Valve guide to be adjusted in diameter with a hand reamer.
Clean the valve guide bore before reinstalling the valve guide into cylinder head. Use a suitable bolt as per following illustration to install valve guide no. 43. NOTE: Push valve guide in place by hand.
1 B V02B0XA
A
V02b0xa2.eps
Hand Reamer Valve Guide Diameter Minimum (new) R610motr238A
R610motr238a2.EPS
A - Suitable Bolt for Valve Guide Installation (1) B - Bore Ø11.2 ±0.1mm (A) C - Bore Depth 12.6 ±0.2mm
Exhaust Intake Maximum (new)
Engine Cylinder and Head - 124
5.994 mm (0.236 in.)
ENGINE CYLINDER AND HEAD Exhaust
6.018 mm (0.237 in.)
Intake
2
3
A
1 1
A
R400motr89A
R400motr89a2.EPS
A - Valve Seat (1) B - Valve Face (contact surface to valve seat) (2) C - Turn Valve While Pushing Against Cylinder Head (3) D - Valve Seat Angle 45° (A)
R610motr239B
R610motr239b2.EPS
A - Valve Guide (1) B - Valve Guide Diameter (A) NOTE: Use cutting oil and ensure to turn reamer the right way (clockwise) as shown below.
NOTE: Ensure to seat valve properly. Apply layout die to ease checking contact pattern. Repeat procedure until valve seat/valve face fits together.
Cylinder Removal: Lock crankshaft with locking bolt (P/N JDG 529 035 617), refer to CRANKSHAFT AND BALANCER SHAFT. Remove: •
chain tensioner
•
breather
•
decompressor
•
camshaft timing chain
NOTE: Use cutting oil and stop often to clean reamer/ valve guide from metal shavings.
•
cylinder head.
Apply some lapping compound to valve face and work valve on its seat with a lapping tool.
Discard cylinder gasket no. 45.
V02C52A
V02c52a2.eps
Pull cylinder no. 44.
Inspection: Cylinder: Check cylinder for cracks, scoring and wear ridges on the top and bottom of the cylinder. If so, replace cylinder. Cylinder Taper: Measure cylinder bore and if it is out of specifications, replace cylinder and piston ring set no. 46. Measure cylinder bore at 3 recommended positions. See the following illustration.
Engine Cylinder and Head - 125
ENGINE CYLINDER AND HEAD
2
A
B
A 1 B 3 R610motr130A
R610motr130a2.EPS
A - First Measuring Diameter in Line with Cylinder Bottom (1) B - Second Measuring Diameter (2) C - Third Measuring Diameter (3) D - 60 mm (2.362 in.) (A) E - 50 mm (1.968 in.) (B) Cylinder Taper mm (in.) Maximum (new)
0.038 mm (0.001 in.)
Service Limit
0.090 mm (0.004 in.)
R610motr131A
R610motr131a2.EPS
A - Perpendicular to Crankshaft Axis (A) B - Parallel to Crankshaft Axis (B) Cylinder Out Of Round mm (in.) Maximum (new)
0.01 mm (0.0002 in.)
Service Limit
0.02 mm (0.0008 in.)
IMPORTANT: Avoid damage! Always replace gasket no. 45 before installing the cylinder.
Difference between measurements should not exceed the service limit mentioned above.
Installation:
Cylinder Out of Round:
For installation, reverse the removal procedure. Pay attention to the following details.
Measure cylinder diameter in piston axis direction from top of cylinder. Take an other measurement 90° from first one and compare.
Apply engine oil in the bottom area of the cylinder bore and also on the band of the piston ring compressor tool.
NOTE: Take the same measuring points like described in Cylinder Taper above.
Using a piston ring compressor plier slide piston into cylinder.
R610motr132A
R610motr132a2.EPS
Engine Cylinder and Head - 126
ENGINE CYLINDER AND HEAD NOTE: Put timing chain through the chain pit then put the cylinder in place.
Push piston pin no. 48 out of piston.
1
2
R610motr135A
1 R610motr135a2.EPS
A - Piston (1) B - Piston Pin (2) Detach piston no. 49 from connecting rod. R610motr133A
R610motr133a2.EPS
Inspection: Piston:
A - Timing Chain (1) Install cylinder head and the other parts in accordance with the proper installation procedures.
Inspect piston for scoring, cracking or other damages. Replace piston and piston rings if necessary.
Piston
Using a micrometer, measure piston at 18 mm (0.709 in.) perpendicularly (90°) to piston pin.
Removal: Remove: •
cylinder head
•
cylinder.
Place a rag under piston. Remove one piston circlip no. 47 and discard it.
A
R610motr136A
1 R610motr136a2.EPS
A - Measuring Perpendicular (90°) to Piston Pin (1) B - 18mm (0.709 in.) (A) R610motr134A
1 R610motr134a2.EPS
A - Piston Circlip (1) NOTE: The removal of both piston circlips is not necessary to remove piston pin. Engine Cylinder and Head - 127
ENGINE CYLINDER AND HEAD The measured dimension should be as described in the following table. If not, replace piston. Piston Measurement Nominal (New)
99.951 to 99.969 mm (3.935 to 3.936 in.)
Service Limit
99.80 mm (3.929 in.)
Piston/Cylinder Clearance: Adjust and lock a micrometer to the piston dimension.
1 1 F00B0AA
F00b0aa.eps
Typical A - Indicator Set to 0 (zero) (1) Position the dial bore gauge 50 mm (2 in.) above cylinder base, measuring perpendicularly (90°) to piston pin axis. Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. F00B08A
F00b08a.eps
A - Micrometer Set to the Piston Dimension (1) With the micrometer set to the dimension, adjust a cylinder bore gauge to the micrometer dimension and set the indicator to 0 (zero).
Piston/Cylinder Clearance Nominal (New)
0.031 to 0.059 mm (0.001 to 0.002 in.)
Service Limit
0.090 mm (0.004 in.)
NOTE: Make sure used piston is not worn. See Piston Measurement above. If clearance exceeds specified tolerance, replace cylinder.
2
1
NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false. Piston Pin: Using synthetic abrasive woven, clean piston pin from deposits. Inspect piston pin for scoring, cracking or other damages. Measure piston pin. See the following illustration for the proper measurement positions.
F00B09A
F00b09a.eps
A - Use the Micrometer to Set the Cylinder Bore Gauge (1) B - Dial Bore Gauge (2)
Engine Cylinder and Head - 128
ENGINE CYLINDER AND HEAD Installation: For installation, reverse the removal procedure. Pay attention to the following details. Apply engine oil on the piston pin. Insert piston pin into piston and connecting rod. IMPORTANT: Avoid damage! Take care that piston will be installed with the punched arrow on piston top to the exhaust side.
A
R610motr137A
R610motr137a2.EPS
Piston Pin Diameter (A)
1 Piston Pin Minimum (new)
22.996 mm (0.9053 in.)
Maximum (new)
23.000 mm (0.9055 in.)
Service Limit
22.990 mm (0.9051 in.)
Replace piston pin if diameter is out of specifications. Piston Pin/Connecting Rod Bushing Clearance Measure inside diameter of connecting rod. Connecting Rod Small End Diameter Minimum (new)
23.01 mm (0.9059 in.)
Maximum (new)
23.02 mm (0.9063 in.)
Service Limit
23.07 mm (0.908 in.) R610motr139A
1
2
R610motr139a2.EPS
A - Arrow Should Indicate to the Exhaust Side (1) Use a circlip installer to assemble the piston circlip. IMPORTANT: Avoid damage! Secure piston pin with new piston circlips. NOTE: Take care that the hook of the piston circlip is positioned properly. R610motr138A
R610motr138a2.EPS
A - Bushing of the Connecting Rod (1) B - Bore Gauge (2) Replace connecting rod if diameter of connecting rod small end is out of specifications. Refer to CRANKSHAFT AND BALANCER SHAFT for removal procedure of connecting rod.
Engine Cylinder and Head - 129
ENGINE CYLINDER AND HEAD Ring/Piston Groove Clearance mm (in.) Minimum (new) Upper Compression Ring
0.025 mm (0.001 in.)
Lower Compression Ring
0.015 mm (0.0006 in.)
Oil Scraper Ring
0.020 mm (0.0008 in.)
Maximum (new)
R610motr140A
2
1 R610motr140a2.EPS
A - Sleeve with Piston Circlip Inside (1) B - Assembly Jig from Piston Clip Installer (2)
Upper Compression Ring
0.070 mm (0.0028 in.)
Lower Compression Ring
0.060 mm (0.0024 in.)
Oil Scraper Ring
0.055 mm (0.0021 in.)
Service Limit All
0.15 mm (0.006 in.)
1
2
R610motr134B
R610motr134b2.EPS
Correct position of the piston circlip
R610motr141A
R610motr141a2.EPS
Piston Rings
A - Piston (1) B - Feeler Gauge (2)
Removal:
Ring End Gap:
Remove: •
cylinder head
•
cylinder
•
piston pin.
Ring End Gap Minimum (new)
Inspection: Ring/Piston Groove Clearance Using a feeler gauge measure each ring/piston groove clearance. If the clearance is too large, the piston and the piston rings should be replaced.
Upper Compression Ring
0.15 mm (0.006 in.)
Lower Compression Ring
0.15 mm (0.006 in.)
Oil Scraper Ring
0.15 mm (0.006 in.)
Maximum (new)
Engine Cylinder and Head - 130
ENGINE CYLINDER AND HEAD Upper Compression Ring
0.35 mm (0.014 in.)
Lower Compression Ring
0.35 mm (0.014 in.)
Oil Scraper Ring
0.30 mm (0.012 in.)
A A
A
Service Limit All
1.5 mm (0.06 in.)
1 Measure position for ring end gap in the area of 8 to 16 mm (0.315 to 0.630 in.) from top of cylinder.
2
NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. Replace ring if gap exceeds above described specified tolerance.
A31C2OA
A31c2oa.eps
Installation: For installation, reverse the removal procedure. Pay attention to the following details. Install the oil scraper ring first, then the lower compression ring with the word “TO“ facing up, then the upper compression ring with the word “T“ facing up.
A - DO NOT Align Ring Gap with Piston Thrust Side Axis (1) B - DO NOT Align Ring Gap with Piston Pin Bore Axis (2) C - 120° (A)
1 2 3 A31C2NA
A31c2na.eps
A - Upper Compression Ring (1) B - Lower Compression Ring (2) C - Oil Scraper Ring (3)
IMPORTANT: Avoid damage! Ensure that top and second rings are not interchanged. NOTE: Use a ring expander to prevent breakage during installation. The oil ring must be installed by hand. Check that rings rotate smoothly after installation. Space the piston ring end gaps 120° apart and do not align the gaps with the piston pin bore or the thrust side axis.
Engine Cylinder and Head - 131
ENGINE CRANKSHAFT AND BALANCER Crankshaft and Balancer
Crankshaft and Balancer Components
Engine oil MAG 5 Loctite 648 Engine oil 55 N m (40 lbf ft)
3
Engine oil 1
Degreased Engine oil
Degreased PTO 4 2
5
45 N m (33 lbf ft) 6 + 90° rotation
7
Engine oil
R610motr211S
R610motr211sa2.EPS
Engine Crankshaft and Balancer - 132
ENGINE CRANKSHAFT AND BALANCER Crankcase Components
10 N m (89 lbf in) MAG 25 N m (18 lbf ft) Engine oil
Engine oil
25 N m (18 lbf ft) PTO
13 12
10 N m (89 lbf in)
25 N m (18 lbf ft) 8 9
14
17
11 16 Engine oil
Loctite 5910
15
Loctite 243 Engine oil 10 N m (89 lbf in) 10
R610motr212S
R610motr212sa2.EPS
General During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a thread locker.
Engine Crankshaft and Balancer - 133
Multi-purpose grease
ENGINE CRANKSHAFT AND BALANCER R610motr214a2.EPS
c CAUTION: Avoid Injury! Torque wrench
A - Drive Pulley (1)
tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
Remove screw no. 8 and sealing washer no. 9.
1
2
3
Crankshaft Locking Procedure Removal: Unplug ignition coil then remove the spark plug. Remove valve cover (refer to CYLINDER AND HEAD). To place piston at TDC, rotate crankshaft on CVT -Drive on MAG side until piston is at TDC compression position.
R610motr215A
R610motr215a2.EPS
2 1
A - Screw (1) B - Sealing Washer (2) C - Output Shaft on Back Side of Vehicle (3) Use a screwdriver to check if groove in crankshaft is aligned with the hole.
3
1
R610motr213A
R610motr213a2.EPS
A - M8 Screw (1) B - M8 Jam Nut (2) C - Hexagonal Key (3)
R610motr216A
R610motr216a2.EPS
A - Screwdriver (1) Lock crankshaft with crankshaft locking bolt (P/N JDG 529 035 617).
1
R610motr214A
Engine Crankshaft and Balancer - 134
ENGINE CRANKSHAFT AND BALANCER Timing Chain
1
Inspection: Check chain condition for wear and rollers condition. Check timing chain for excessive radial play.
R610motr201A
R610motr217A
1 R610motr201a2.EPS
R610motr217a2.EPS
A - Timing Chain (1)
A - Crankshaft Locking Bolt (1)
If chain is excessively worn or damaged, replace it as a set (camshaft timing gear and timing chain). Removal: Remove: • engine from vehicle (refer to REMOVAL AND INSTALLATION) •
cylinder head cover
•
chain tensioner
• magneto cover and rotor (refer to MAGNETO SYSTEM) • P0004326
Proper Way to Lock Crankshaft
output shaft (refer to GEARBOX).
Installation: The installation is essentially the reverse of the removal procedure but, pay attention to the following details. Ensure to perform proper valve timing. Lock crankshaft and camshaft at TDC (refer to CYLINDER AND HEAD). Install chain then, adjust chain tension (refer to CYLINDER AND HEAD). IMPORTANT: Avoid damage! Improper valve timing will damage engine components.
Chain Tensioner Guide Removal: P0004325
Wrong Way to Lock Crankshaft NOTE: At piston TDC, the printed marks on the camshaft timing gear have to be parallel to cylinder head base.
Remove: •
valve cover (refer to CYLINDER AND HEAD)
•
breather (refer to CYLINDER AND HEAD)
• chain tensioner (refer to CYLINDER AND HEAD) •
camshaft timing gear
Engine Crankshaft and Balancer - 135
ENGINE CRANKSHAFT AND BALANCER (refer to CYLINDER AND HEAD)
• magneto housing cover and rotor (refer to MAGNETO SYSTEM)
• magneto cover and rotor (refer to MAGNETO SYSTEM) •
bearing screw at the bottom of chain tensioner guide.
Pull chain tensioner guide upward to remove it. Inspection: Check chain tensioner guide for wear, cracks or other damages. Replace if necessary.
NOTE: Oil pump removal from crankcase MAG side is not necessary, but recommended to check condition of oil pump (refer to LUBRICATION SYSTEM). •
output shaft (refer to GEARBOX)
•
timing chain (see TIMING CHAIN above)
• cylinder head and cylinder (refer to CYLINDER AND HEAD)
Installation:
•
Clean bearing screw threads then apply Loctite 243 on the screw threads.
Measure axial clearance between the crankshaft no. 1 and crankcase PTO no. 10 with a feeler gauge.
drive pulley (refer to CVT, see Drive Pulley).
Install the guide in crankcase housing then torque bearing screw to 10 N•m (89 lb-in.).
3
R610motr64A
1 R610motr64a2.EPS
A - Feeler Gauge (1) R610motr219A
1
2
Crankshaft Axial Clearance R610motr219a2.EPS
A - Chain Tensioning Guide (1) B - Bearing Screw (2) C - Crankcase MAG Side (3) Reinstall all removed parts in accordance with the proper installation procedures.
Crankcase To reach the balancer shaft and the crankshaft, the crankcase splitting is necessary. The procedures to remove, inspect and install the balancer shaft and the crankshaft are explained further in this section. For all gearbox parts refer to GEARBOX.
Minimum (NEW)
0.2 mm (0.0078 in.)
Maximum (NEW)
0.5 mm (0.0196 in.)
Service Limit
0.6 mm (0.0236 in.)
If measurement is out of specification, inspect contact surfaces of crankshaft and crankcase (MAG/ PTO side) for excessive wear. Remove: •
timing chain
•
intermediate gear
•
retaining ring and drive gear.
Removal: Remove: • engine from vehicle (refer to REMOVAL AND INSTALLATION) Engine Crankshaft and Balancer - 136
ENGINE CRANKSHAFT AND BALANCER 1
R610motr65A
3
2 R610motr65a2.EPS
A - Timing Chain (1) B - Intermediate Gear (2) C - Drive Gear (3)
R610motr158A
R610motr158a2.EPS
Disassembly:
Position for Big Flat Screwdriver
Remove screws retaining crankcase MAG.
R610motr220A
R610motr220a2.EPS
17 Screws
R610motr159A
Split crankcase housings.
R610motr159a2.EPS
NOTE: Hit with a soft hammer to ease lifting crankcase MAG. Lift crankcase housings with two flat screwdrivers.
Position for Big Flat Screwdriver IMPORTANT: Avoid damage! Do not lose the O-ring for oil circulation during lifting of crankcase half.
Engine Crankshaft and Balancer - 137
ENGINE CRANKSHAFT AND BALANCER R610motr221a2.EPS
1
A B C D E
- MAG Plain Bearing without Groove (1) - Oil Bore (2) - Split of the Plain Bearing Halves (3) - Cylinder Base Direction (4) - Plain Bearing Inside Diameter to be Measured in Area of Oil Bore (A)
4 1
3
2
2
P0004328
A - O-Ring (1) B - Crankcase PTO Side No. 10 (2) C - Crankshaft Locking Bolt (3)
1
A
Remove balancer shaft and crankshaft (see BALANCER SHAFT and CRANKSHAFT below). R610motr222A
Inspection: NOTE: To check some parts, it is recommended to remove all components in both crankcase housings. Clean crankcase from contaminations and blow the oil supply lines with compressed air.
c CAUTION: Avoid Injury! Wear safety glasses to
R610motr222a2.EPS
A B C D E
- PTO Plain Bearing without Groove (1) - Oil Bore (2) - Split of the Plain Bearing Halves (3) - Cylinder Base Direction (4) - Plain Bearing Inside Diameter to be Measured in Area of Oil Bore (A)
avoid eye injury.
Check plain bearings no. 11, no. 12, no. 13 and no. 14 for scoring or other damages. Measure plain bearing inside diameter. Replace if the measurement is out of specification.
Plain Bearing Inside Diameter (MAG Side) Service Limit
55.020 mm (2.1661 in.)
Plain Bearing Inside Diameter (PTO Side) Service Limit
46.010 mm (1.8114 in.)
Check oil seal no. 15 if brittle, hard or otherwise damaged. Replace if necessary.
4 3
2
NOTE: The oil seal can be removed easily with a flat screwdriver. Plain Bearing Removal Procedure:
1 A
IMPORTANT: Avoid damage! Always support crankcase housings properly when ball bearings, needle bearings or plain bearings are removed. Crankcase housing damages may occur if this procedure is not performed correctly.
R610motr221A
Engine Crankshaft and Balancer - 138
ENGINE CRANKSHAFT AND BALANCER NOTE: Always use a press for removal or installation of plain bearing halves.
2
1
Remove plain bearings no. 11, no. 12, no. 13 and no. 14 with the proper plain bearing remover. NOTE: Place the proper crankcase support under crankcase before removing plain bearings. Plain Bearing Remover MAG Side
529 035 753
PTO Side
529 035 752
Crankcase Support MAG Side
529 035 755
PTO Side
529 035 754
R610motr223A
R610motr223a2.EPS
A - Crankcase Support MAG (1) B - Crankcase MAG Side (2)
1
2
R610motr224A R610motr163A
2
1 R610motr224a2.EPS
R610motr163a2.EPS
Push Plain Bearing Outside A - Plain Bearing Remover/Installer (1) B - Crankcase Support (2)
A - Crankcase Support PTO (1) B - Crankcase PTO Side (2) NOTE: Mark oil bore position on crankcase to align new plain bearing bore.
To install the plain bearing turn the plain bearing remover/ installer up side down. NOTE: Use crankcase support when removing or pushing plain bearing in place.
Engine Crankshaft and Balancer - 139
ENGINE CRANKSHAFT AND BALANCER 1
3
1
4
2
R610motr221B
R610motr225A
R610motr221b2.EPS
A B C D
- Mark on Crankcase and Oil Bore Position (1) - Split Between Bearing Halves (2) - Perpendicular Axle to Cylinder Base (3) - Crankcase MAG (4)
R610motr225a2.EPS
Push plain bearings inside A - Plain Bearing Remover/Installer (1) Use a suitable installer to install ball bearings nos. 16 and 17. Install new oil seals with the proper installer. Oil Seal Installer
2
4
1
529 035 760
Balancer Shaft Oil Seal
529 035 761
3 3
R610motr222B
R610motr222b2.EPS
A B C D
Crankshaft Oil Seal
2
1
- Mark on Crankcase and Oil Bore Position (1) - Split Between Bearing Halves (2) - Perpendicular Axle to Cylinder Base (3) - Crankcase PTO (4) R610motr168A
IMPORTANT: Avoid damage! Push plain bearings MAG/PTO correctly in place to ensure oil supply to crankshaft (oil bore and split between plain bearing halves).
R610motr168a2.EPS
A - Crankcase Oil Seal (1) B - Oil Seal Installer (2) C - Insertion Jig Handle (3)
Engine Crankshaft and Balancer - 140
ENGINE CRANKSHAFT AND BALANCER 1
2
3 2
1
R610motr169A
R610motr169a2.EPS
A - Balancer Shaft Oil Seal (1) B - Oil Seal Installer (2) C - Insertion Jig Handle (3)
3 P0004332
Assembly: The assembly of crankcase is the reverse of removal procedure. However, pay attention to the following details.
A - Balancer Shaft Counter Weight (1) B - Temporary Mark (2) C - Mark in Line with Shaft (3) 4
Clean oil passages and make sure they are not clogged. Before closing the crankcase, refer to GEARBOX to perform an inspection of gearbox parts and find the proper procedure to clean mating surfaces, apply Loctite 5910 and close crankcase with the proper torquing sequence.
Balancer Shaft Removal: Split crankcase housing (refer to CRANKCASE above). Remove the crankshaft locking bolt. Turn crankshaft until counter weight of the balancer shaft is out of the crankshaft. NOTE: The mark punched on the teeth will line up with the shift fork shaft.
P0004333
Remove balancer shaft no. 4. Inspection: Check balancer shaft and replace if damaged. Check ball bearings on MAG and PTO side for excessive play and smooth operation. Replace if necessary (see CRANKCASE above for proper procedure). If the gear on the balancer shaft is damaged, replace balancer shaft. Check gears on the crankshaft and replace crankshaft if necessary (refer to CRANKSHAFT below).
Engine Crankshaft and Balancer - 141
ENGINE CRANKSHAFT AND BALANCER Installation: For installation, reverse the removal procedure. Pay attention to following detail. Align the dot on crankshaft gear with the balancer shaft gear dot.
1 1
R610motr69A
R610motr69A2.EPS
A - Crankshaft (1) •
Remove shim no. 2.
R610motr67A
R610motr67A2.EPS
A - Punched Marks Located in the Gears (1)
Crankshaft Removal: Remove: •
balancer shaft
•
shim no. 3 1 R610motr70A
1 R610motr70A2.EPS
A - Shim on PTO Side (1) Inspection: Replace crankshaft if the gears are worn or otherwise damaged.
P0008493
A - Shim on MAG Side (1) •
Remove crankshaft no. 1
Engine Crankshaft and Balancer - 142
ENGINE CRANKSHAFT AND BALANCER Measure piston pin. Compare to inside diameter of connecting rod no. 5.
R610motr71A
1
2
2
1
R610motr71A2.EPS
A - Balancer Gear (1) B - Crankshaft Timing Gear (2) Connecting Rod Big End Axial Play: Using a feeler gauge, measure distance between butting face of connecting rod and crankshaft counterweight. If the distance exceeds specified tolerance, replace the crankshaft.
2
1
R610motr73A
R610motr73A2.EPS
A - Bore Gauge (1) B - Connecting Rod (2)
R610motr137A
A R610motr137a2.EPS
A - Piston Pin Diameter in the Area of the Bushing (A) R610motr72A
R610motr72A2.EPS
A - Crankshaft (1) B - Feeler Gauge (2) Connecting Rod Big End mm (in.)
Connecting Rod Small End Diameter Minimum (new)
23.01 mm (0.9059 in.)
Maximum (new)
23.02 mm (0.9063 in.)
Service Limit
23.07 mm (0.908 in.)
Minimum (new)
0.150 mm (0.06 in.)
Maximum (new)
0.302 mm (0.01 in.)
Piston Pin Diameter
Service Limit
0.5 mm (0.02 in.)
Minimum (new)
22.996 mm (0.9053 in.)
Maximum (new)
23.000 mm (0.9055 in.)
Service Limit
22.990 mm (0.904 in.)
Connecting Rod/Piston Pin Clearance:
Engine Crankshaft and Balancer - 143
ENGINE CRANKSHAFT AND BALANCER Piston Pin Bore Clearance Service Limit
0.080 mm (0.0035 in.)
If the connecting rod small end diameter is out of specification, replace connecting rod.
1
Connecting Rod Big End Radial Play:
2
NOTE: Prior to removing connecting rod from the crankshaft, mark big end halves together to ensure a correct reinstallation. Remove connecting rod no. 5 from crankshaft no. 1. IMPORTANT: Avoid damage! Always replace connecting rod screws no. 6 if removing connecting rod. It is recommended to replace bushings no. 7, if the connecting rod is reinstalled. R610motr75A
R610motr75A2.EPS
A - Micrometer (1) B - Crankpin Area for Bushings (2) To measure the connecting rod big end diameter, use the OLD screws no. 6. Install the OLD bushings no. 7 as they were mounted initially. Do the torque procedure as described further. R610motr74A
1 R610motr74A2.EPS
A - Connecting Rod Screw (1) Measure crankpin. Compare to inside diameter of connecting rod big end.
A
R610motr76A
R610motr76A2.EPS
A - Connecting Rod Big End Bushing (A)
Engine Crankshaft and Balancer - 144
ENGINE CRANKSHAFT AND BALANCER Crankshaft Pin Diameter Minimum (new)
45.017 mm (1.7723 in.)
Crankshaft Mag Diameter
Maximum (new)
45.033 mm (1.7729 in.)
Minimum (new)
54.976 mm (2.1644 in.)
Service Limit
44.990 mm (1.771 in.)
Maximum (new)
54.995 mm (2.1651 in.)
Service Limit
54.950 mm (2.1634 in.)
Connecting Rod Big End Diameter Service Limit
45.080 mm (1.774 in.)
Crankshaft Mag Radial Clearance Service Limit
0.07 mm (0.0028 in.)
Connecting Rod Big End Clearance
Crankshaft Radial Play (PTO side):
Service Limit
Measure crankshaft on PTO side. Compare to inside diameter of PTO bushing (see CRANKCASE above).
0.09 mm (0.0035 in.)
Crankshaft Radial Play MAG Side: Measure crankshaft on MAG side. Compare to inside diameter of MAG bushing (refer to see CRANKCASE above).
2 2
1
1
R610motr78A
R610motr78A2.EPS
A - Micrometer (1) B - Crankshaft Area for PTO Bushing (2) R610motr77A
R610motr77A2.EPS
A - Micrometer (1) B - Crankshaft Area for MAG Bushing (2)
Crankshaft PTO Diameter Minimum (new)
45.974 mm (1.8099 in.)
Maximum (new)
45.990 mm (1.8102 in.)
Service Limit
45.940 mm (1.8086 in.)
Crankshaft PTO Radial Clearance Service Limit
Engine Crankshaft and Balancer - 145
0.07 mm (0.0028 in.)
ENGINE CRANKSHAFT AND BALANCER Installation: For installation, reverse the removal procedure. Pay attention to following details. Use NEW bushings no. 7, when connecting rod big end diameter is out of specification. Put bushings correctly in place and clean the split surface on both sides (cracked area) carefully.
3
1
2
R610motr80A
R610motr80A2.EPS
1 R610motr79A
R610motr79A2.EPS
A - Half Bushing of Connecting Rod Big End (1) B - Split Surface of the Connecting Rod (2) C - Nose of Bushing in Line with Connecting Rod Groove (3) Torque NEW connecting rod screws no. 6 as per following procedure: • Install screws with half of recommended torque in the exploded view. Do not apply any thread locker product. • Torque with the recommended values in the exploded view. • Finish tightening the screws with an additional 90° turn using an angle torque wrench.
R610motr82A
R610motr82A2.EPS
IMPORTANT: Avoid damage! Failure to strictly follow this procedure may cause screw to loosen and lead to engine damage. The bushing tapered end must be against the counterweight. Besides, as the “crankpin” screw has been stretched from the previous installation, it is very important to use a new screw at assembly.
A - Insertion of Balancer Shaft (1) IMPORTANT: Avoid damage! Do Not forget shim no. 3 for axial adjustment on crankshaft MAG side.
Engine Crankshaft and Balancer - 146
ENGINE CRANKSHAFT AND BALANCER 1
R610motr84A
1
2 R610motr84A2.EPS
R610motr83A
R610motr83A2.EPS
A - Shim for MAG Side (1) Align the marks of crankshaft and balancer shaft.
A - Crankshaft Locking Bolt (1) B - Engagement Groove for TDC Position of the Piston (2) Refer to GEARBOX for proper procedure to clean mating surfaces, apply Loctite 5910 and proper torquing sequence. NOTE: Always degrease tapers on both sides of the crankshaft before reinstalling rotor or CVT. IMPORTANT: Avoid damage! Make sure the woodruff key on crankshaft MAG is present and correctly in place.
1
R610motr67A
R610motr67A2.EPS
A - Punched Marks Located in the Gears (1) After reinstalling of crankcase MAG, measure axial clearance of crankshaft with a feeler gauge on the PTO side between PTO crankcase and shim no. 2. NOTE: Install crankshaft locking bolt right away after crankcase is screwed, to put crankshaft in TDC position before installing the camshaft and rockers (refer to CYLINDER AND HEAD). NOTE: The following illustration shows an unscrewed crankcase to have a better view of crankshaft locking bolt function.
Engine Crankshaft and Balancer - 147
ENGINE TRANSMISSION - 650 Transmission - 650 Output Shaft and Transmission Components
8 7 5
4
6 9
Engine oil Multi-purpose grease
1
10 N m (89 lbf in) Loctite 243 11 14 23 24
10
Engine oil 25
2 4
Engine oil
12
16
15
3
13 17 18
20
26
Engine oil
19
27
28 Engine 22 oil
31
Engine oil
30 29
Engine oil 32 33
R610motr241S
R610motr241sa2.EPS
Engine Transmission - 650 - 148
21
ENGINE TRANSMISSION - 650 Crankcase Components
10 N m (89 lbf in)
Multi-purpose grease 67 66 65
Engine 10 N m oil (89 lbf in) 10 N m (89 lbf in)
Loctite 243 34
25 N m (18 lbf ft)
37
42
38
10 N m 36 (89 lbf in) 35 Loctite 25 N m 5910 (18 lbf ft)
25 N m (18 lbf ft) 17 N m (150 lbf in) 39 51 57 52 56 53 55 54
Engine oil 43
41 64 44 46 48
45 50
40 Engine oil 47 10 N m 49 (89 lbf in)
Loctite 5910
Multi-purpose grease 58 62
59 4 N m Multi-purpose (35 lbf in) grease Loctite 5331
R610motr242S
R610motr242sa2.EPS
General To remove gearbox, the engine removal is necessary. During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a thread locker. Engine Transmission - 650 - 149
63 60
61 4 N m (35 lbf in) Loctite 243
ENGINE TRANSMISSION - 650
c CAUTION: Avoid Injury! Torque wrench
tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
To remove oil seals no. 7, no. 36, no. 65 and no. 67, the engine removal/disassembly is NOT necessary (see OIL SEALS below). To remove oil seals no. 7 and/or no. 36 disconnect rear and/or front propeller shaft (refer to FRONT DRIVE and/or REAR AXLE).
1
R610motr246A
2
Oil Seals
3
R610motr246a2.EPS
Removal: NOTE: To remove oil seals no. 62 and/or no. 63, it is necessary to remove drive and/or driven pulley.
A - Output Shaft Oil Seal (vehicle front) (1) B - Oil Seal Installer (2) C - Installer Handle (3)
3
Remove oil seals no. 7, no. 36, no. 62, no. 63, no. 65 and no. 67 with a small flat screwdriver.
2
1
IMPORTANT: Avoid damage! Avoid scoring crankshaft MAG end and/or shift shaft and/or main shaft during oil seal removal. Inspection: Check bearings behind each oil seal for contamination and/ or metal shavings. Check oil seal running surface of main shaft, crankshaft MAG and shift shaft for scratches. Replace if necessary (see GEARBOX below). Installation:
R610motr248A
The installation is the reverse of removal procedure. Pay attention to the following details. Use a suitable ring to push oil seals in place. Install oil seals no. 7 and no. 36 with an oil seal installer and installer handle.
R610motr248a2.EPS
A - Output Shaft Oil Seal (vehicle back) (1) B - Oil Seal Installer (2) C - Installer Handle (3) IMPORTANT: Avoid damage! Oil seal must be installed with sealing lip toward engine. NOTE: For oil seals no. 65, no. 67 and/or no. 66 refer to MAGNETO SYSTEM and/or COOLING SYSTEM.
Engine Transmission - 650 - 150
ENGINE TRANSMISSION - 650 Output Shaft NOTE: There are two possibilities to measure the wear between output shaft gear and bevel gear.
Oil Seal Installer Crankshaft oil seal PTO
529 035 760
Crankshaft oil seal MAG
529 035 759
Main shaft oil seal PTO
529 035 761
Output shaft oil seal
529 035 941
Shift shaft oil seal
529 035 758
Water pump oil seal
529 035 766
First possibility: Measure output shaft axial clearance prior to removing output shaft no. 1. This measure will indicate if bevel gear adjustment is necessary.
3 2
1
R610motr243A
2
1
3 R610motr243a2.EPS
R610motr168A
A - Output Shaft (1) B - Metal Plate Mounted on Engine (2) C - Dial Indicator (3)
R610motr168a2.EPS
A - Crankshaft Oil Seal PTO (1) B - Oil Seal Installer (2) C - Installer Handle (3)
Output Shaft Axial Clearance Service Limit
3 2
0.30 mm (0.012 in.)
If the output shaft axial clearance is out of specification, perform the bevel gear adjustment procedure (see BEVEL GEAR ADJUSTMENT below). Removal:
1
Remove: • engine from vehicle (refer to REMOVAL AND INSTALLATION) •
bevel gear access screw no. 37 with gasket ring no. 38.
R610motr169A
R610motr169a2.EPS
A - Main Shaft Oil Seal (1) B - Oil Seal Installer (2) C - Installer Handle (3)
Engine Transmission - 650 - 151
ENGINE TRANSMISSION - 650 C - Bevel Gear Lock Pin (3) NOTE: Bearings no. 3 and no. 5 on output shaft must be properly installed, otherwise the output shaft backlash measurement will be incorrect.
2 1
Output Shaft Backlash
3
Minimum (new)
0.08 mm (0.0031 in.)
Maximum (new)
0.15 mm (0.0059 in.)
Service Limit
0.20 mm (0.0079 in.)
If the output shaft backlash is out of specification, perform the bevel gear adjustment procedure. Remove: •
R610motr144A
bearing cover screws no. 34
R610motr144a2.EPS
A - Bevel Gear Access Screw (1) B - Gasket Ring (2) C - CVT Air Inlet (3) Lock the gearbox with the bevel gear lock pin (P/N JDG 529 035 747).
1
Second possibility:
2
Measure output shaft backlash before removing output shaft no. 1. This measure will indicate if bevel gear adjustment is necessary.
3
Install the head of dial indicator on output shaft gear then turn the output shaft slightly. R610motr146A
2
R610motr146a2.EPS
3
A - Remaining Screw M8 (1) B - Bearing Cover (2) C - Output Shaft Splines (3) •
bearing cover no. 35 including oil seal no. 36
1
1 2
R610motr145A
R610motr145a2.EPS
A - Output Shaft (1) B - Dial Indicator (2)
R610motr244A
R610motr244a2.EPS
Engine Transmission - 650 - 152
ENGINE TRANSMISSION - 650 A - Bearing Cover (1) B - Oil Seal Ring (apply Loctite 5910) (2)
B - Bearing with Writing to the Outside (2) •
shim no. 2
• magneto housing and rotor (for details, refer to MAGNETO SYSTEM) •
output shaft IMPORTANT: Avoid damage! Use a soft hammer to remove output shaft from crankcase MAG side.
•
O-ring no. 4 and bearing no. 5
2
NOTE: Both bearings on output shaft have a transition fit.
1
R610motr150A
R610motr150a2.EPS
A - Shim (1) B - Output Shaft Gear (2) • retaining ring no. 8, oil seal no. 7 and distance ring no. 6.
1
R610motr148A
2 R610motr148a2.EPS
A - O-ring (1) B - Bearing with Writing to the Outside (2) •
O-ring no. 4 and bearing no. 3
R610motr151A
12 3 R610motr151a2.EPS
A - Retaining Ring (1) B - Oil Seal (2) C - Distance Ring (3) Inspection: Check output shaft for cracks and other visible damages.
R610motr149A
1
IMPORTANT: Avoid damage! Always replace output shaft no. 1 and bevel gear shaft no. 25 at the same time.
2 R610motr149a2.EPS
A - O-ring (1)
Check output shaft bearings for excessive play and smooth operation. Replace if necessary.
Engine Transmission - 650 - 153
ENGINE TRANSMISSION - 650 Replace oil seals no. 7 and no. 36 if brittle, hard or damaged.
4
Replace O-ring no. 4 if brittle, hard or damaged. Clean crankcase split surface and especially the bearing areas from metal particles or other contamination. Installation: For installation, reverse the removal procedure. Pay attention to following details Adjust axial play as per following procedure: 1. Use soft hammer to put bearing no. 3 exactly in place against crankcase MAG side.
R610motr154A
3
2
1 R610motr154a2.EPS
A B C D
- Bearing Cover (1) - Ball Bearing (2) - Output Shaft Gear (3) - Feeler Gauge (4)
Remove output shaft again and rebuild it with proper shim. Take measured thickness and choose shim as per the following table.
1
R610motr152A
R610motr152a2.EPS
A - Soft Hammer (1) Push output shaft as per following illustration.
Measured Thickness
Shim Thickness
0.84 to 0.88 mm (0.0331 to 0.0346 in.)
0.75 mm (0.0295 in.)
0.89 to 0.93 mm (0.0350 to 0.0366 in.)
0.80 mm (0.0315 in.)
0.94 to 0.98 mm (0.0370 to 0.0386 in.)
0.85 mm (0.0335 in.)
0.99 to 1.03 mm (0.0390 to 0.0406 in.)
0.90 mm (0.0354 in.)
1.04 to 1.08 mm (0.0409 to 0.0425 in.)
0.95 mm (0.0374 in.)
1.09 to 1.13 mm (0.0429 to 0.0445 in.)
1.00 mm (0.0394 in.)
1.14 to 1.18mm (0.0449 to 0.0465 in.)
1.05 mm (0.0413 in.)
1.19 to 1.23 mm (0.0469 to 0.0484 in.)
1.10 mm (0.0433 in.)
1.24 to 1.28 mm (0.0488 to 0.0504 in.)
1.15 mm (0.0453 in.)
1.29 to 1.33 mm (0.0508 to 0.0524 in.)
1.20 mm (0.0472 in.)
R610motr153A
R610motr153a2.EPS
Way to push the bevel gears together Install bearing cover no. 35 and measure axial gap between bearing and output shaft gear with a feeler gauge.
Engine Transmission - 650 - 154
ENGINE TRANSMISSION - 650 1.34 to 1.38 mm (0.0528 to 0.0543 in.)
1.25 mm (0.0492 in.)
1.39 to 1.43 mm
1.30 mm (0.0512 in.)
(0.0547 to 0.0563 in.)
Finish with ball bearing cover no. 35. Install the retaining ring no.8. NOTE: Place the ends of retaining ring at 90° with the mating surface.
R610motr156A
R610motr156a2.EPS
Measure axial clearance of bevel gear Remove: •
cylinder head and cylinder
•
timing chain
•
drive and intermediate gear of water and oil pump
1
R610motr155A
3
1 R610motr155a2.EPS
A - Retaining Screw (1)
Crankcase Disassembly: Remove: • engine from vehicle (refer to REMOVAL AND INSTALLATION) •
magneto housing cover and rotor
•
output shaft.
R610motr65A
R610motr65a2.EPS
Measure the axial clearance of bevel gear with a feeler gauge then remove bevel gear lock pin.
A - Timing Chain (1) B - Intermediate Gear (2) C - Drive Gear (3) •
screws retaining crankcase housing.
NOTE: Bevel gear axial clearance should be measured before crankcase housings separation. Bevel Gear Axial Clearance Service Limit
2
0.15 mm (0.059 in.)
Engine Transmission - 650 - 155
ENGINE TRANSMISSION - 650 21
3
3
2
1
1
R610motr157A
1 R610motr157a2.EPS
A - 14 Screws M6 x 45 (1) B - 2 Screws M6 x 85 (2) C - 2 Screws M8 x 90 (3)
R610motr159A
R610motr159a2.EPS
Position for big flat screwdriver
Place the crankcase housings on a wood stand, MAG side upwards. Lift crankcase housing no. 39 with 2 screwdrivers.
IMPORTANT: Avoid damage! Do not lose the O-ring no. 50 for oil circulation during lifting of crankcase half. 1
P0004328
A - O-Ring no. 50 (1) Inspection: R610motr158A
R610motr158a2.EPS
Position for big flat screwdriver
NOTE: To check some parts, it is recommended to remove all components in both crankcase housing (refer to CRANKSHAFT/BALANCER SHAFT and see GEARBOX below). Clean crankcase from contaminations and blow the oil supply lines with compressed air.
c CAUTION: Avoid Injury! Use safety goggles to avoid injury to your eyes.
Engine Transmission - 650 - 156
ENGINE TRANSMISSION - 650 Check bearings no. 42, no. 48 and no. 49 as well as needle bearings no. 40 and no. 41 for excessive play and smooth operation. Replace if necessary.
2
Check plain bearings no. 43, no. 44, no. 45 and no. 46 for scoring or other damages. Measure plain bearing inside diameter. Replace if the measurement is out of specification (refer to CRANKSHAFT/BALANCER SHAFT, see CRANKCASE).
1
Bearing Removal Procedure: If necessary heat crankcase housing up to 100°C (212°F) before removing ball bearings, needle bearings or plain bearings.
c CAUTION: Avoid Injury! Clean oil, outside and inside, from housing before heating.
IMPORTANT: Avoid damage! Always support crankcase housings properly when ball bearings, needle bearings or plain bearings are removed. Crankcase housing damages may occur if this procedure is not performed correctly. To remove bevel gear needle bearing no. 40 and main shaft needle bearing no. 41, use a punch.
R610motr162A
R610motr162a2.EPS
A - Main Shaft Needle Bearing Location (1) B - Punch (2) The balancer shaft ball bearing no. 42 on MAG housing is removed with a suitable puller from outside in. Remove plain bearings no. 43, no. 44, no. 45 and no. 46 with the proper plain bearing remover (refer to CRANKSHAFT/BALANCER SHAFT, see PLAIN BEARING REMOVAL PROCEDURE). To remove ball bearings no. 48 and no. 49, use a blind hole bearing puller.
2
R610outi03A
R610outi03a2.EPS
NOTE: The oil seals no. 62 and no. 63 are removed easily with a flat screwdriver. NOTE: To remove oil seals no. 7, no. 36, no. 65 and no. 67, the engine removal/disassembly is NOT necessary (see Oil SealS above). R610motr161A
1 R610motr161a2.EPS
For ball bearing no. 64, remove screw no. 47 then push bearing from outside in with a punch.
A - Bevel Gear Needle Bearing (1) B - Punch (2)
Engine Transmission - 650 - 157
ENGINE TRANSMISSION - 650 Place new bearing in freezer for 10 minutes before installation. Install plain bearings no. 43, no. 44, no. 45 and no. 46 with the proper plain bearing installer (refer to CRANKSHAFT/ BALANCER SHAFT, see CRANKCASE). NOTE: Place crankcase housings on a wood stand, MAG side upwards before installing needle bearings no. 40, no. 41 and no. 51. Needle Bearing Installer Main Shaft Bearing
529 035 762
Bevel Gear Bearing
529 035 763
Starter Drive Bearing
420 876 502
Install needle bearing no. 41 with a needle bearing installer and insertion jig handle.
R610motr164A
R610motr164a2.EPS
2
Use needle bearing remover to remove needle bearing no. 51.
R610motr166A
3
1 R610motr166a2.EPS
R610motr165A
R610motr165a2.EPS
Bearing Installation Procedure: Unless otherwise instructed, never use hammer to install ball bearings, needle bearings or plain bearings. Use press machine only.
A - Main Shaft Needle Bearing (1) B - Needle Bearing Installer (2) C - Insertion Jig Handle (3) Install needle bearing no. 40 using needle bearing installer and insertion jig handle.
If necessary heat crankcase housing up to 100°C (212°F) before installing ball bearings, needle bearings or plain bearings.
c CAUTION: Avoid Injury! Clean oil, outside and inside, from housing before heating.
Engine Transmission - 650 - 158
ENGINE TRANSMISSION - 650 3
4
2
3
R610motr167A
2
R610motr249A
1 R610motr167a2.EPS
A - Bevel Gear Needle Bearing (1) B - Inside Ring of Needle Bearing Mostly Placed on Bevel Gear (2) C - Needle Bearing Installer (3) D - Insertion Jig Handle (4) Install needle bearing no. 51 using needle bearing installer and insertion jig handle. NOTE: With a bearing installer it is possible to push needle bearing no. 51 from both sides of crankcase PTO.
1
R610motr249a2.EPS
A - Starter Drive Needle Bearing Engine Inside (1) B - Needle Bearing Installer (2) C - Installation Towards Engine Inside (3) IMPORTANT: Avoid damage! Ball bearings have to be installed with closed bearing cage to the engine outside. Use a suitable installer for installing ball bearings nos. 48 and 49. Install new oil seals with the proper installer (refer to OIL SEALS above). Assembly: The assembly of crankcase is essentially the reverse of removal procedure. However, pay attention to the following details. Clean oil passages and make sure they are not clogged. Clean all metal components in a solvent. Crankcase mating surfaces are best cleaned using a combination of a chisel gasket remover and a brass brush. Brush a first pass in one direction then make the final brushing perpendicularly (90°) to the first pass cross (hatch).
3
R610motr245A
2
1 R610motr245a2.EPS
IMPORTANT: Avoid damage! Do not wipe with rags. Use a new clean hand towel only.
A - Starter Drive Needle Bearing PTO Side (1) B - Needle Bearing Installer (2) C - Installation Towards Engine Outside (3)
Engine Transmission - 650 - 159
ENGINE TRANSMISSION - 650 IMPORTANT: Avoid damage! When beginning the application of the crankcase sealant, the assembly and the first torquing should be done within 10 minutes. It is suggested to have all you need on hand to save time.
without using the Primer N, which is 4 to 24 hours. Install O-ring no. 50 on crankcase PTO side.
1
NOTE: It is recommended to apply this specific sealant as described here to get a uniform application without lumps. If you do not use the roller method, you may use your finger to uniformly distribute the sealant (unlike the Drei Bond sealing compound, using a finger will not affect the adhesion). Use the silicone-based Loctite 5910 on mating surfaces. NOTE: The sealant curing time is similar to that of Loctite 518 without using Primer N. IMPORTANT: Avoid damage! Do not use Loctite 515 or 518 to seal crankcase. Do not use Loctite Primer N with the Loctite 5910. Using these products or non silicone-based sealant over a previously sealed crankcase with Loctite 5910 will lead to poor adhesion and possibly a leaking crankcase. These products are chemically incompatibles. Even after cleaning, the Loctite 5910 would leave incompatible microscopic particles.
R610motr170A
R610motr170a2.EPS
A - O-ring (1) IMPORTANT: Avoid damage! Place O-ring no. 32 including distance sleeve no. 33. Chamfered bore of distance sleeve has to face the engine.
Use a plexiglas plate and apply some sealant on it. Use a soft rubber roller (50 - 75 mm (2 - 3 in.)) (available in arts products suppliers for print making) and roll the sealant to get a thin uniform coat on the plate (spread as necessary). When ready, apply the sealant on crankcase mating surfaces.
R610motr247A
1
3
2 R610motr247a2.EPS
A - O-ring (1) B - Distance Sleeve (2) C - Chamfered Area of Distance Sleeve (3)
F12R17A
F12r17A2.EPS
Do not apply in excess as it will spread out inside crankcase.
Hand-torqued crankcase screws as per following sequence. Repeat procedure, retightening all screws to 9 N•m (80 lb-in.).
NOTE: Do not use Loctite Primer N with this sealant. The sealant curing time is similar to the Loctite 518 Engine Transmission - 650 - 160
ENGINE TRANSMISSION - 650 16 17
5
18 1
3
7
8
9 10
Gearbox General: During and after gearbox disassembly, inspect the condition of each part closely. In particular, check for:
15 14 4
2
6
11 13 12
R610motr171A
R610motr171a2.EPS
•
gear teeth damage
•
worn or scoured bearing surfaces
•
worn or scoured shift fork
•
worn or scoured shift fork shaft
•
rounded engagement dogs and slots
•
bent shift forks
•
bent shift fork shaft
•
worn shift fork engagement pins
•
worn tracks on shift drum
•
worn shift fork engagement groove
•
worn splines on shafts and gears.
Removal: Remove output shaft. Separate crankcase. Remove: •
balancer shaft
•
parking lever no. 10
•
shift shaft no. 9
R610motr172A
R610motr172a2.EPS
•
shift fork shaft no. 14
Engine Transmission - 650 - 161
ENGINE TRANSMISSION - 650 2
R610motr175A
1 R610motr175a2.EPS
A - Shift Fork (1) B - Shift Drum (2) Insert a flat screwdriver in the slot of index lever no. 11. Turn screwdriver clockwise and remove shift drum.
R610motr173A
R610motr173a2.EPS
•
shift fork no. 15.
R610motr176A
R610motr176a2.EPS
R610motr174A
R610motr174a2.EPS
Disengage shift fork no. 16 from shift drum no. 12.
Remove; •
shift fork no. 16
•
bevel gear shaft no. 25 with low range gear assembly
•
main gear no. 31
•
main shaft with high range gear assembly
• gear selection no. 26, thrust washer no. 27, reverse gear no. 29, needle bearing no. 28 and shim no. 30
Engine Transmission - 650 - 162
ENGINE TRANSMISSION - 650 • distance sleeve no. 17, thrust washer no. 18, intermediate gear no. 19, needle bearing no. 20, thrust washer no. 21 and intermediate gear shaft no. 22.
2
NOTE: It is not necessary to remove index lever no. 11. Check index lever for visible damage and if it moves freely. Replace if necessary.
1
Inspection:
3
Check both shift forks for visible damage, wear or bent shift fork claws. Measure the shift fork claw thickness. R610motr179A
R610motr179a2.EPS
Shift Fork Claw Thickness Minimum (new)
4.800 mm (0.189 in.)
Maximum (new)
4.900 mm (0.193 in.)
Service Limit
4.750 mm (0.187 in.)
A - Track for the Low/Reverse Gear Shift Fork (1) B - Track for the High Gear Shift Fork (2) C - Isolating Washer on the Shift Drum (3) Check shift shaft no. 9 for worn splines and gears. Parking lever no. 10 for cracks or other damages. Index lever with roller no. 11 must move freely. Measure the gap of shift fork engagement groove. NOTE: Both gears no. 26, no. 31 have same gap width and same service limit. Gap of Shift Fork Engagement Groove Minimum (new)
5.00 mm (0.197 in.)
Maximum (new)
5.10 mm (0.201 in.)
Service Limit
5.20 mm (0.205 in.)
A
A 1
R610motr177A
R610motr177a2.EPS
A - Micrometer (1) B - Shift Fork Claw Thickness (A)
1
Check shift drum tracks for scouring or heavy wear, like rounded engagement slots.
2
Replace isolating washer no. 13 if there are signs of wear or visible damages.
R610motr180A
Engine Transmission - 650 - 163
ENGINE TRANSMISSION - 650 R610motr180a2.EPS
A - Main Gear (1) B - Caliper (2) C - Gap for Engagement of Shift Fork (A)
Check all bearings, bearing points, tooth flanks, taper grooves and annular grooves. Annular grooves must have sharp edges. Replace gears only together with the corresponding meshing gears.
Check main shaft for wear.
NOTE: Always replace circlips and use special pliers to install them.
Main Shaft Service Limit MAG Side
17.990 mm (0.708 in.)
PTO Side
24.950 mm (0.982 in.)
1
A - PTO Side (1)
Check all shims for wear. Always replace shim by a new one with the same thickness, when reassembling the gearbox with existing output shaft no. 1 and bevel gear shaft no. 25.
2
2 R610motr181A
R610motr181a2.EPS
1
A - MAG Side (1) B - PTO Side (2)
R610motr183a2.EPS
Check bevel gear shaft.
A - Thrust Washer or Adjusting the Bevel Gear Crankcase on CVT Side (1) B - Area Where Wear Signs Appear (2) C - Thickness of Washer (3)
Bevel Gear Shaft Service Limit PTO Side
3
R610motr183A
24.990 mm (0.984 in.)
1
Bevel Gear Adjustment: Use following course of calculation to adjust bevel gear in place between crankcase PTO and MAG. NOTE: Only necessary if the output shaft backlash and axial clearance of the bevel gear is out of specification.
R610motr182A
R610motr182a2.EPS
Engine Transmission - 650 - 164
ENGINE TRANSMISSION - 650 Measure following items and enter measurement in the following list:
E F
Letter
Measurement 1
Measurement 2
G
A
2 mm (0.0787 in.)
2 mm (0.0787 in.)
H
B
I
C
J
D
B
H
D (E) I (J)
C A
Mating surface Output shaft
Mating surface Crankcase G
F
R610motr191S
R610motr191sa2.EPS
Measure shim on MAG side: NOTE: Clean mating surface of crankcase before measurement. Refer to crankcase assembly procedure. • A = 2 mm (0.0787 in.) nominal thickness of axial needle bearing no. 24.
• B = Distance between butting face and theoretical center of bevel gear taper. K is defined by manufacturer and written on surface of bevel gear. Use following course of calculation to find out value B.
B = (K/100) + 37.8 NOTE: Value K is a number between - 5 and + 5 and equals to the (±) deviation from the nominal value of 37.8 mm (1.488 in.) in hundredth of a millimeter.
Engine Transmission - 650 - 165
ENGINE TRANSMISSION - 650 For example, number K = - 3 equals - 0.03 mm (- 0.0012 in.) to the nominal value of 37.8 mm. B = (- 3/100) + 37.8 = 37.77
R610motr250A
1
2 R610motr250a2.EPS
A - Bevel Gear (1) B - Areas of Written Measurement K (from manufacturer) to Find Out Value B (2) • C = Distance between butting face (MAG side) to mating surface of crankcase MAG.
1
Calculated Thickness (D)
Shim Number (E)
1.25 mm to 1.29 mm (0.0492 to 0.0508 in.)
125
1.30 mm to 1.34 mm (0.0512 to 0.0528 in.)
130
1.35 mm to 1.39 mm (0.0531 to 0.0547 in.)
135
1.40 mm to1.44 mm (0.0551 to 0.0567 in.)
140
1.45 mm to 1.49 mm (0.0571 to 0.0587 in.)
145
1.50 mm to 1.54 mm (0.0591 to 0.0606 in.)
150
1.55 mm to 1.59mm (0.0610 to 0.0626 in.)
155
1.60 mm to 1.64 mm (0.0630 to 0.0646 in.)
160
1.65 mm to 1.69 mm (0.0650 to 0.0665 in.)
165
1.70 mm to 1.74 mm (0.0669 to 0.0685 in.)
170
NOTE: For example, if the measured thickness is 1.53 mm (0.0602 in.), choose the shim 150. The shim number 150 represents a value equal to 1.50 mm (0.0591 in.). Measure shim on PTO side: NOTE: Clean mating surfaces of crankcase before measurement. Refer to crankcase assembly procedure. • F = Distance between mating surface (crankcase PTO) to ball bearing inner race.
R610motr187A
R610motr187a2.EPS
A - Depth Gauge - Measurement C (1) •
D = Theoretical shim thickness.
•
E = Select shim in accordance with D.
Use following course of calculation to get the theoretical thickness D for washer no. 23.
D=B-C-A NOTE: Take theoretical value D and choose shim E (MAG side shim) from the below table. Engine Transmission - 650 - 166
ENGINE TRANSMISSION - 650 2
3
2
R610motr190A
R610motr190a2.EPS
R610motr188A
1 R610motr188a2.EPS
A - Ball Bearing Inner Race (1) B - Mating Surface of Crankcase PTO (2) C - Depth Gauge (3)
I = Theoretical shim thickness.
•
J = Select shim in accordance with I.
Use following course of calculation to get the theoretical thickness I for washer no. 30.
I=F+G-H-A-E
• G = Distance between mating surface of crankcase MAG and butting face.
1
R610motr189A
R610motr189a2.EPS
A - Butting Surface (1) •
•
H = Distance between butting faces of bevel gear shaft.
NOTE: Take theoretical value I and choose shim J (PTO side shim) from the below table. Calculated thickness (I)
Shim number (J)
1.22 mm to 1.26 mm (0.0480 to 0.0496 in.)
120
1.27 mm to 1.31 mm (0.0499 to 0.0516 in.)
125
1.32 mm to 1.36 mm (0.0519 to 0.0535 in.)
130
1.37 mm to 1.41 mm (0.0539 to 0.0555 in.)
135
1.42 mm to 1.46 mm (0.0559 to 0.0575 in.)
140
1.47 mm to 1.51 mm (0.0579 to 0.0594 in.)
145
1.52 mm to 1.56 mm (0.0598 to 0.0614 in.)
150
1.57 mm to 1.61 mm (0.0618 to 0.0634 in.)
155
1.62 mm to 1.66 mm (0.0638 to 0.0654 in.)
160
1.67 mm to 1.71 mm (0.0657 to 0.0673 in.)
165
1.72 mm to 1.76 mm (0.677 to 0.0693 in.)
170
NOTE: For example, if the measured thickness is 1.53 mm (0.0602 in.), choose the shim 150.
Engine Transmission - 650 - 167
ENGINE TRANSMISSION - 650 NOTE: Bevel gear axial clearance of 0.02 to 0.05 mm (0.00079 to 0.00197 in.) is included in the above table. Example: Letter
Measurement 1
A
2 mm (0.0787 in.)
B
37.760 mm (1.487 in.)
C
34.040 mm (1.340 in.)
D
1.72 mm (0.068 in.)
E
170
F
51.800 mm (2.039 in.)
G
39.080 mm (1.539 in.)
H
85.680 mm (3.373 in.)
I
1.500 mm (0.059 in.)
J
145
Installation: For installation, reverse the removal procedure. Pay attention to the following details. IMPORTANT: Avoid damage! Install thrust washer no. 27, no. 18 and no. 21.
2
1
3
Shim on MAG side: R610motr192A
The measure A is 2 mm (0.0787 in.).
R610motr192a2.EPS
Note the measure indicates on bevel gear in the box B. Example: 37.760 mm (1.487 in.). Measure the distance C then indicates its value in the box C. Example: 34.040 mm (1.340 in.).
A - Thrust Washer (1) B - Thrust Washer (2) C - Gear Pinion (right upside position) (3) First install intermediate gear no. 19 with washer no. 18 and spacer no. 17.
B-C-A=D (37.760 - 34.040 - 2 = 1.72 mm). In accordance with the appropriate table, you need a shim number 170.
2
1
Shim on PTO side: Measure the distance F. Indicate this value in the box F. Example: 51.800 mm (2.039 in.). Measure the distance G. Note this value in the box G. Example: 39.080 mm (1.539 in.). Measure the distance between both butting surface of bevel gear shaft. This is the value H. Example: 85.680 mm (3.373 in.).
F+G-H-A-E=I (51.800 + 39.080 - 85.680 - 2 - 1.70 = 1.50 mm). NOTE: The shim number 170 represents a value equal at 1.70 mm (0.0669 in.). If a shim 160 was required, its value would be 1.60 mm (0.0630 in.). In accordance with the appropriate table, you need a shim number 145.
P0008495
A - Washer no. 18 (1) B - Spacer no. 17 (2) Install main shaft assembly with main gear no. 31.
Engine Transmission - 650 - 168
ENGINE TRANSMISSION - 650 2
1
1
R610motr193A
P0008497 R610motr193a2.EPS
A - Intermediate Gear (1) B - Main Shaft (2)
A - Sliding Gear no. 26 (1) Install shift fork no. 16.
IMPORTANT: Avoid damage! Place O-ring no. 32 including distance sleeve no. 33 right away. Chamfered bore of distance sleeve has to face the engine.
Insert a flat screwdriver in the slot of index lever no. 11. Turn screwdriver clockwise and install shift drum on neutral position as per the following illustration.
1 P0008500
A - Neutral Position (1) R610motr247A
1
3
2 R160motr247a2.eps
Main Shaft End PTO Side A - O-Ring (1) B - Distance Sleeve (2) C - Main Shaft End PTO Side (3) Install bevelled gear shaft no. 25 with sliding gear no. 26.
Engine Transmission - 650 - 169
ENGINE TRANSMISSION - 650 Install park lever no. 11.
1
7
NOTE: Run all gears as a final function check before reassembling crankcase MAG.
Shifting Indicator Switch NOTE: The engine removal is not necessary to reach the shifting indicator switches. To reach the shifting indicator switches, remove:
2
R610motr194A
5
3
4
•
CVT cover
•
drive and driven pulley.
NOTE: Use Loctite 5331 on thread of shifting indicator switches. Removal:
6 R610motr194a2.EPS
A B C D E F
- Parking Stop Location (1) - Reverse Stop Location (2) - Neutral Stop Location (3) - High Gear Stop Location (4) - Low Gear Stop Location (5) - Contact to Stop Location for Neutral Position (6) G - Contact to Reverse and Parking Stop Location (7)
NOTE: Clean area from dirt and belt dust before removing parts. Remove: •
screw no. 61
•
air guide no. 60.
Disconnect wiring harness no. 58.
Install shift fork no. 15 then engage both shift fork pins in their corresponding groove on the shift drum. NOTE: Move sliding gears to facilitate engagement of pins inside grooves.
3
Install pin no. 14 with chamfer on top. Insert shift shaft no. 9. Align the edge of the plate with the rib inside the crankcase.
1 R610motr195A
2 R610motr195a2.EPS
A - Brown Wire for Contact to Reverse Gear (1) B - Green/Yellow Wire for Contact to Neutral Gear (2) C - Blue Wire for Contact to Parking Gear (3) Remove screw retaining shifting indicator switch wire. Unscrew the shifting indicator switches no. 59. NOTE: Remove the shifting indicator switches one at a time.
1 P0008501
A - Reference Rib in the Housing Engine Transmission - 650 - 170
ENGINE TRANSMISSION - 650 Test: Check if shifting indicator switches work properly. Check wiring harness and replace if brittle or hard. Using a multimeter, measure the resistance of the shifting indicator switches. Use the following procedure:
If all switches are removed, make sure to put the wires back in the right location. Take care do not damage shifting indicator switches threads during installation.
Starter Drive Pinion
• Reinstall the wire in order to check the harness at the same time.
Removal:
•
Remove:
Install a pin in the connector.
•
drive pulley (refer to CVT)
•
screw no. 54 retaining starter drive pinion cover
•
starter drive pinion cover no. 53
•
thrust washer no. 55 and spring washers no. 56
•
starter drive pinion no. 52
•
thrust washer no. 57.
R610motr196A
R610motr196a2.EPS
• Place one probe of multimeter on the pin and the other on the engine. NOTE: The alligator clip is recommended.
1
Apply the end of switch on the engine.
R610motr198A
2 R610motr198a2.EPS
A - Starter Drive Pinion Cover (1) B - Starter Drive Pinion (2) Inspection:
R610motr197A
R610motr197a2.EPS
If the resistance is infinite (O.L.), replace the shifting indicator switch.
Check if starter drive pinion is free of movement. NOTE: Centrifugal weights prevent the pinion from disengaging while starting the engine.
If the shifting indicator switch and its harness are good, check the vehicle harness and/or indicator lights. Installation: For installation, reverse the removal procedure. Pay attention to the following details.
Engine Transmission - 650 - 171
ENGINE TRANSMISSION - 650
2 1 P0004431
Gear is engaged in CVT drive fixed half (spring loaded) A - Starter Drive Pinion (1) B - Centrifugal Weights (2) Replace needle bearing no. 51 if damaged (see CRANKCASE above). Check starter drive pinion cover for crack and clean it before reinstallation. Installation: For installation, reverse the removal procedure. NOTE: Apply penetrating oil on the spring of starter drive pinion. Secure cover in place using new M6x25 flanged torx bolts no. 54.
Engine Transmission - 650 - 172
ENGINE CVT ASSEMBLY - 500 CVT Assembly - 500
NOTE: This is a lubrication free drive pulley.
Clutch Assembly Components
Degrease 10
17 21
Antiseize lubricant 36
34
15
17
9
19 16 27
37
13 5 N m (44 lbf in) 20 12
Antiseize lubricant 18 29
11 14 5
31 35
25
7
6 100 N m (74 lbf ft)
8
26
32 30
3 24 33
28
23
22 60 N m (44 lbf ft)
2
1 10 N m (89 lbf in)
R610motr251S
R610motr251sa2.EPS
General NOTE: For a better understanding, the following illustrations are taken with engine out of vehicle. To
perform the following instructions, it is not necessary to remove engine. This CVT is lubrication free. Never lubricate any components except drive pulley one-way clutch. During assembly/installation, use the torque values and
Engine CVT Assembly - 500 - 173
ENGINE CVT ASSEMBLY - 500 service products as in the exploded views.
2
Clean threads before applying a thread locker.
c CAUTION: Avoid Injury! Torque wrench
tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
c CAUTION: Avoid Injury! Never touch CVT while engine is running. Never drive vehicle when CVT cover is removed.
IMPORTANT: Avoid damage! Any drive pulley repairs must be performed by a John Deere dealer. Subcomponent installation and assembly tolerances require strict adherence to procedures detailed. IMPORTANT: Avoid damage! Never use any type of impact wrench at drive pulley removal and installation.
1
R610tran02A
R610tran02a2.EPS
A - CVT Cover (1) B - Gasket (2) NOTE: Remove the center top screw last. This screw allows to support the cover during removal. Open driven pulley with the driven pulley expander (P/N JDG 529 035 747). Screw tool in the threaded hole of driven pulley and tighten to open the pulley.
IMPORTANT: Avoid damage! The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch assembly. IMPORTANT: Avoid damage! These pulleys have metric threads. Do not use SAE threads puller. Always tighten puller by hand to ensure that the drive pulley has the same type of threads (metric vs. SAE) prior to fully tightening.
Belt Replacement Removal: Remove: •
LH engine side panel
•
LH foot peg.
R610tran04A
•
screws no. 1 with rubber bushings no. 2
•
CVT cover no. 3 and gasket no. 4.
1 R610tran04a2.EPS
Unscrew clamp retaining CVT cover to CVT exhaust box. Remove:
2
A - Driven Pulley Expander (1) B - Fixed Half of Driven Pulley (2) To remove belt no. 5, slip the belt over the top edge of fixed half, as shown.
Engine CVT Assembly - 500 - 174
ENGINE CVT ASSEMBLY - 500 drive belt has the proper rotation direction. Install it so the arrow printed on belt is pointing towards front of the vehicle. NOTE: Put a small amount of Loctite 5910 in the groove of CVT cover to ease installation of CVT cover with gasket no. 4. Install the center top screw of cover in first. Install the other screws then torque them in a crisscross sequence.
Drive Pulley 3
1
2
R610tran05A
R610tran05a2.EPS
Inspection: Inspect belt for cracks, fraying or abnormal wear. Replace if necessary. Check drive belt width. Replace if it is out of specification (see table below). Drive Belt Width Nominal (new)
32.00 mm (1.260 in.)
Service Limit
30.00 mm (1.181 in.)
R610tran03A
R610tran03a2.EPS
A - Belt (1) B - Drive Pulley (2) C - Driven Pulley (3) Removal of Drive Pulley: Remove belt no. 5. NOTE: To remove drive pulley, three procedures can be followed. First possible procedure: • Remove the spark plug (refer to CYLINDER AND HEAD). • Put piston at TDC and lock crankshaft with crankshaft locking bolt (P/N JDG 529 035 617).
R610tran24A
R610tran24a2.EPS
Installation: For installation, reverse the removal procedure. Pay attention to following details. The maximum drive belt life span is obtained when the
Engine CVT Assembly - 500 - 175
ENGINE CVT ASSEMBLY - 500 1
2
R610tran26A
R610tran26a2.EPS
IMPORTANT: Avoid damage! Prior to removing the drive pulley, mark sliding half and governor cup together to ensure correct reinstallation. There are all 6 levers mounted.
R610motr252A
R610motr252a2.EPS
A - Crankshaft Locking Bolt (1) B - Vehicle Front Side (2) Second possible procedure: Block drive pulley with clutch holding tool.
3
1
R610motr254A
1
2 R610motr254a2.EPS
A - Mark on Drive Pulley Sliding Half (1) B - Mark on Governor Cup (2) Remove drive pulley screw no. 6, spring washer no. 7 and thrust washer no. 8. R610motr253A
2 R610motr253a2.EPS
A - Clutch Holding Tool (1) B - Drive Pulley Sliding Half (2) C - Area to Place Holding Tool Hook (3) Third possible procedure: • Block ring gear with clutch holding tool (P/N JDG 529 035 745).
Engine CVT Assembly - 500 - 176
ENGINE CVT ASSEMBLY - 500 Disassembly of Drive Pulley: Governor Cup:
4 2
3
Carefully lift governor cup no. 11 until slider shoes no. 12 come at their highest position into guides. Sliding Half: Unscrew lock nut no. 13 and remove centrifugal lever pivot bolt no. 14. Remove centrifugal lever no. 15.
1
R610motr255A
R610motr255a2.EPS
A B C D
- Drive Pulley Screw (1) - Spring Washer (2) - Thrust Washer (3) - Drive Pulley (4)
c CAUTION: Avoid Injury! Sliding half of drive pulley is spring loaded.
R610tran10A
1
3
2 R610tran10a2.EPS
Push with your hand the sliding half no. 9 of the drive pulley then remove the screw completely. Slowly release sliding half. Screw clutch puller (P/N JDG 529 035 746) in fixed half no. 10 then remove fixed pulley.
A - Lock Nut (1) B - Centrifugal Lever Pivot Bolt (2) C - Centrifugal Lever (3) Fixed Half:
c CAUTION: Avoid Injury! Always wear safety glasses to remove spring sleeve.
Pull one-way clutch no. 16 slowly until the half of spring sleeves no. 17 are visible.
R610tran08A
1
2 R610tran08a2.EPS
A - Clutch Pulley (1) B - Fixed Half (2)
Engine CVT Assembly - 500 - 177
ENGINE CVT ASSEMBLY - 500
c CAUTION: Avoid Injury! This procedure must be performed in a well-ventilated area.
IMPORTANT: Avoid damage! Avoid contact between cleaner and crankshaft seal because damage may occur.
1
Remove all hardened oil deposits that have baked on crankshaft and pulley tapered surfaces with coarse or medium steel wool and/or sand paper no. 600.
2
IMPORTANT: Avoid damage! Do not use any other type of abrasive. Reclean mounting surfaces with paper towel and cleaning solvent.
R610motr256A
R610motr256a2.EPS
A - One-Way Clutch (1) B - Fixed Half (2)
Wipe off the mounting surfaces with a clean, dry paper towel. IMPORTANT: Avoid damage! Mounting surfaces must be free of any oil, cleaner or towel residue.
Hold both spring sleeve with fingers and release when oneway clutch is disengaged.
2 1
2 1
1 R610tran17A
R610tran17a2.EPS
A - Taper of Fixed Half (1) R610tran33 A
R610tran33a2.EPS
A - Spring (1) B - Spring Sleeve (2)
Only use petrol base cleaner when cleaning bushings no. 18 and no. 19. IMPORTANT: Avoid damage! Do not use acetone to clean bushing.
Cleaning of Drive Pulley: Clean pulley faces and shaft with fine steel wool and dry cloth. Using a paper towel with cleaning solvent, clean crankshaft tapered end and the taper inside the fixed half of the drive pulley, crankshaft threads and threads of drive pulley screw no. 6.
Inspection of Drive Pulley: Drive Pulley: Drive pulley should be inspected annually. Governor Cup: Check governor cup for cracks or other visible damages.
Engine CVT Assembly - 500 - 178
ENGINE CVT ASSEMBLY - 500 Replace if necessary. Roller: Check each roller no. 20 for roundness of external diameter. NOTE: Replace governor cup if the roller does not move freely.
1
Measure the roller diameter. If a roller is out of specification, replace governor cup. Roller Diameter Minimum (new)
13.70 mm (0.539 in.)
Maximum (new)
13.90 mm (0.547 in.)
Service Limit
13.20 mm (0.519 in.)
R610tran13A
R610tran13a2.EPS
A - Contact Surface to the Roller (1)
Centrifugal Lever Pivot Bolt: Measure diameter of centrifugal lever pivot bolt no. 14, replace if it is out of specification.
c CAUTION: Avoid Injury! Whenever replacing centrifugal levers, always replace all lever at the same time. Otherwise, drive pulley misbalancing will occur because of levers difference.
R610tran12A
1
A
R610tran12a2.EPS
A - Centrifugal Lever Pivot Bolt (1) B - Measure Diameter Here (A) Centrifugal Lever Pivot Bolt Diameter Minimum (new)
6.078 mm (0.239 in.)
Maximum (new)
6.100 mm (0.240 in.)
Service LIMIT
6.00 mm (0.236 in.)
Centrifugal Lever: Check bushing diameter in the centrifugal lever no. 15 for wear. Replace centrifugal lever if necessary.
High Altitude Operation: IMPORTANT: Avoid damage! Modifications for altitude changes may be performed on the CTV drive clutch. Vehicle operation at sea level AFTER high level clutch modifications have been made may create performance problems. Not doing so will cause the clutch to engage too early, before the power band of the engine, and could cause the engine to stall. Going from zero to full-throttle quickly might be OK, but if the throttle is eased, the engine would most likely kill. Clutch modifications for high altitude operation should be changed to factory setting for sea level operation. CVT Centrifugal Levers:
Centrifugal Lever Bore Diameter Service Limit
Trail Buck 500 CVT
6.200 mm (0.244 in.) Elevation
Replace centrifugal lever no. 15 with screws no. 14 and lock nuts no. 13 if the contact surfaces show heavy visible wear.
Centrifugal Lever
Engine CVT Assembly - 500 - 179
Sea Level STD
1200 m (4000 ft)
2400 m (8000 ft)
Qty
4 ramps
4 ramps
4
ENGINE CVT ASSEMBLY - 500 Trail Buck 640EX and 650 EXT CVT Elevation Centrifugal Lever
Sea Level STD
1200 m (4000 ft)
2400 m (8000 ft)
Qty
6 ramps
6 ramps
6
For high altitude operation, remove all standard centrifugal levers and replace them with high altitude levers. Levers are sold by package. Each package contains the required quantity of levers to update a machine to high altitude.
c CAUTION: Avoid Injury! Failure to perform
proper installation can cause serious personal injuries to the rider.
A R610tran15A
R610tran15a2.EPS
A - Centrifugal Lever Pivot Bolt Bore Diameter (A)
Slider Shoe: Check slider shoes no. 12 for visible wear and replace if damaged. NOTE: If necessary, use a screwdriver to remove slider shoes.
Centrifugal Lever Pivot Bolt Bore Diameter New Minimum
6.113 mm (0.241 in.)
New Maximum
6.171 mm (0.243 in.)
Service Limit
6.300 mm (0.248 in.)
Measure bushing diameters of sliding half. Use a dial bore gauge to measure bushing diameter. Measuring point must be at least 5 mm (1/4 in.) from bushing edge.
A
R610tran09A
1 R610tran09a2.EPS
A - Slider Shoe (1) Sliding Half: Check sliding half for cracks and sliding contact surface for excessive wear. Replace sliding half if necessary. Measure centrifugal lever pivot bolt bores. Replace sliding half if bores are out of specification or otherwise damaged.
R610tran14A
1 R610tran14a2.EPS
A - Bushing on Fixed Half Side (1) B - Bore Diameter of Bushing (A) Sliding Half Large Bushing New Minimum
Engine CVT Assembly - 500 - 180
55.000 mm (2.165 in.)
ENGINE CVT ASSEMBLY - 500 New Maximum
55.040 mm (2.167 in.)
Service Limit
55.200 mm (2.173 in.)
A
Check for any marks on fixed half plate. Replace if necessary. Check ring gear teeth for excessive wear or other damage. Replace fixed half if necessary.
c CAUTION: Avoid Injury! Fixed half and ring
gear are balanced together. Always replace both parts together otherwise severe injury and/or damages may occur.
Spring: Measure spring free length and squareness. If spring is out of specification, replace by a new one. Spring Free Length Service Limit
Clutch Spring Squareness
1
R610tran11A
75 mm (2.953 in.)
R610tran11a2.EPS
A - Bushing on Governor Cup Side (1) B - Bore Diameter of Bushing (A)
Service Limit
4 mm (0.157 in.)
One-Way Clutch: Check bearings no. 21 for excessive play and smooth operation. Replace one-way clutch if necessary.
Sliding Half Small Bushing New Minimum
30.000 mm (1.181 in.)
New Maximum
30.040 mm (1.183 in.)
Service Limit
30.200 mm (1.189 in.)
IMPORTANT: Avoid damage! Be careful to damage the inside of one-way clutch no. 16 during bearing removal.
Replace sliding half if bushings no. 18 and/or no. 19 is (are) out of specification. Visually inspect coatings. Fixed Half: Check fixed half contact surface to the governor cup for scoring and other damages. If so, replace fixed half.
1 2 R610tran29A
R610tran28A
R610tran29a2.EPS
1 R610tran28a2.EPS
A - Visually Check Here (1)
A - One-Way Clutch (1) B - Bearing (2)
Engine CVT Assembly - 500 - 181
ENGINE CVT ASSEMBLY - 500 torque screw to 100 N•m (74 lb-ft). Bushing Bore Diameter
Run vehicle for 5 minutes around 4000 RPM.
New Minimum
39.990 mm (1.574 in.)
New Maximum
40.085 mm (1.578 in.)
Service Limit
40.100 mm (1.579 in.)
Torque screw to 100 N•m (74 lb-ft).
Driven Pulley Removal of Driven Pulley:
Measure length of spring sleeve no. 17 and check if edges on top of the spring sleeve are excessively worn. If they out of specifications, replace both spring sleeve at the same time. Spring Sleeve Length Service Limit
9 mm (0.276 in.)
Remove: •
belt no. 5 (see BELT REPLACEMENT above)
c CAUTION: Avoid Injury! Driven pulley is spring loaded. Hold driven pulley tight and slowly remove clutch bolt to release spring tension.
1
Assembly of Drive Pulley:
2
3
For assembly, reverse the disassembly procedure. Pay attention to following details. IMPORTANT: Avoid damage! Centrifugal lever no. 15 and rollers no. 20 must move easily after installation. Insert slider shoes into governor cup to properly slide in guides. Installation of Drive Pulley: For installation, reverse the removal procedure. Pay attention to the following details. R610tran07A
IMPORTANT: Avoid damage! Do not apply anti-seize or any lubricant on crankshaft and drive pulley tapers. IMPORTANT: Avoid damage! Never use any type of impact wrench at drive pulley removal and installation. Clean mounting surfaces as described in CLEANING above. Install drive pulley on crankshaft extension. IMPORTANT: Avoid damage! Do not forget to place thrust washer no. 8 prior to install conical washer. Install conical washer no. 7 with its concave side towards drive pulley then install drive pulley screw no. 6.
R610tran07a2.EPS
A - Fixed Half of Driven Pulley (1) B - Sliding Half of Driven Pulley (2) C - Spring (3) Disassembly of Driven Pulley: Fixed Half: Remove retaining ring no. 25 and lift torque gear no. 26. NOTE: The following procedure is not necessary except if ball bearing or shaft must be removed. Refer to INSPECTION before proceeding. Heat ball bearing area up to 100°C (212°F) before removing ball bearing. Use a soft hammer to push shaft no. 27 with bearing no. 28 out of fixed half.
IMPORTANT: Avoid damage! Never substitute conical washer and/or screw with jobber ones. Always use genuine parts for this particular case. Install clutch holding tool (P/N JDG 529 035 745) and Engine CVT Assembly - 500 - 182
ENGINE CVT ASSEMBLY - 500
1
2
1
R610tran19A
R610tran19a2.EPS
A - Main Shaft Support (1) Inspection:
R610tran18A
R610tran18a2.EPS
A - Soft Hammer (1) B - Shaft (2)
Sliding Half: Check bushings no. 29 for cracks, scratch and for free movement when assembled to sliding half.
Remove shaft from ball bearing.
Using a dial bore gauge measure bushing diameter. Measuring point must be at least 5 mm (1/4 in.) from bushing edge.
Cleaning of Driven Pulley: When a dust deposit has to be removed from the cam or the shaft, use dry cloth. Clean pulley faces and shaft with fine steel wool and dry cloth.
This bushing can not be replaced. Replace sliding half if bushings no. 29 are out of specification. Visually inspect coatings.
1
Use cleaner to clean driven pulley. Clean the CVT crankcase area from contamination. Using a paper towel with cleaning solvent to clean main shaft end and the inside of the shaft no. 27.
c CAUTION: Avoid Injury! This procedure must be performed in a well-ventilated area.
IMPORTANT: Avoid damage! To avoid damage, make sure cleaner does not contact the countershaft seal.
R610tran20A
R610tran20a2.EPS
A - Bushings (1) Bushings Bore Diameter New Minimum
Engine CVT Assembly - 500 - 183
30.060 mm (1.183 in.)
ENGINE CVT ASSEMBLY - 500 New Maximum
30.100 mm (1.185 in.)
Service Limit
30.200 mm (1.189 in.)
caliper.
2
Fixed Half: Check ball bearing for free play and smooth operation. Replace if necessary. Check shaft for heavy wear or visible damage. Replace if necessary.
1
If the shaft is removed, using a dial bore gauge, measure bushing diameter. Measuring point must be at least 5 mm (1/4 in.) from bushing edge.
A
This bushing can not be replaced. Replace fixed half if bushing no. 30 is out of specification. Visually inspect coatings. Bushing Bore Diameter
R610tran34A
New Minimum
30.060 mm (1.183 in.)
New Maximum
30.100 mm (1.185 in.)
Service Limit
30.200 mm (1.189 in.)
Check torque gear no. 26 for visible damage and wear limit with a caliper.
R610tran34a2.EPS
A - Contact Surface (1) B - Caliper (2) C - Width to be Measured Due to Wear on Contact Surface (A) Width On Top Surface Service Limit
6.000 mm (0.236 in.)
1
A
2
3
B
A
R610tran21A
R610tran21a2.EPS
A - Measurement Inside (A) B - Measurement Outside (B) R610tran35A
Wear On Teeth Both Sides Service Limit
R610tran35a2.EPS
7.500 mm (0.295 in.)
Cam: Check cam no. 31 for visible damage and wear limit with a
A B C D
- Caliper (1) - Sliding Half (2) - Contact Surface (3) - Wear to be Measured (A)
Engine CVT Assembly - 500 - 184
ENGINE CVT ASSEMBLY - 500 Wear On Contact Surface Service Limit
3
2.000 mm (0.079 in.)
Spring: Measure spring free length and squareness. If spring is out of specification, replace by a new.
1 2
Spring Free Length Service Limit
180 mm (7.087 in.) R610tran37A
R610tran37a2.EPS
Clutch Spring Squareness Service Limit
3.8 mm (0.150 in.)
Assembly of Driven Pulley: For installation, reverse the removal procedure. Pay attention to following details
A - Shaft (1) B - Fixed Half (2) C - Press Machine (3) Install torque gear no. 26 then secure it with retaining ring no. 25.
Heat ball bearing area up to 100°C (212°F) before ball bearing installation. NOTE: Place new ball bearing in a freezer for 10 minutes before installation. Install ball bearing no. 28 with the writing on top and push only on the outer ring.
R610tran31A
1
2 R610tran31a2.EPS
A - Retaining Ring (1) B - Torque Gear (2) R610tran22A
Installation of Driven Pulley:
1 R610tran22a2.EPS
A - Ball Bearing (1)
For installation, reverse the removal procedure. Pay attention to the following details. Install sliding half no. 32 into fixed half no. 33.
IMPORTANT: Avoid damage! Do not use hammer, use press machine only.
Place O-ring no. 36 on main shaft splines and move it with spacer no. 37 in end position. IMPORTANT: Avoid damage! Chamfer on inside diameter of the spacer must face engine side.
Engine CVT Assembly - 500 - 185
ENGINE CVT ASSEMBLY - 500 3
2
1
R610tran23A
R610motr247A
1
3
R610tran23a2.EPS
2 R610motr247a2.EPS
A - O-ring (1) B - Distance Sleeve (2) C - Chamfered Area on Distance Sleeve (3)
A - Cam (1) B - Spring (2) C - Driven Pulley (3)
Install cam retainer no. 34 on main shaft end the right way then install cam no. 31.
P0004408
Correct Cam Alignment
R610motr257A
2
3
1
R610motr257a2.EPS
A - Sharp Edge of Cam Retainer to Engine Side (1) B - Man shaft Spline (2) C - Inscription (3) Place spring no. 35 behind sliding half then align driven pulley with cam.
P0004409
Incorrect Cam Alignment With your hand, push the driven pulley on the shaft to
Engine CVT Assembly - 500 - 186
ENGINE CVT ASSEMBLY - 500 compress the spring. Install the driven pulley screw no. 22, lock tab no. 23 and washer no. 24.
c CAUTION: Avoid Injury! Driven pulley is a spring loaded system.
IMPORTANT: Avoid damage! Always use a new lock tab no. 27 at the time of driven pulley installation. NOTE: Align lock tab with the groove on shaft.
4
3 2 1 R610tran32A
R610tran32a2.EPS
A B C D
- Washer (1) - Lock Tab (2) - Driven Pulley Screw (3) - Groove on Shaft (4)
NOTE: Driven pulley end-play is 0 (zero). Torque driven pulley screw.
Engine CVT Assembly - 500 - 187
ENGINE CVT ASSEMBLY - 500
Engine CVT Assembly - 500 - 188
ELECTRICAL TABLE OF CONTENTS Electrical
Table of Contents
General Information......................................191 Reading Electrical Schematics...................191 Theory of Operation Information ................192 Diagnostic Information................................192 Wire Color Abbreviation Chart....................192 Common Circuit Tests................................193 Conductors for 12 Volt Circuits...................193 Specifications ...............................................194 Electrical Specifications..............................194 Required Tools ...........................................194 Recommended Tools .................................195 Schematics and Harnesses .........................196 Component Location ..................................196 Trail Buck Main Schematic.........................197 Components Overview.................................200 General Operation Information...................200 Charging System........................................200 Starting System ..........................................200 Ignition System...........................................200 Gauges/Accessories ..................................201 General Testing/Troubleshooting Information .................................................201 Fuses Location ...........................................202 Servicing Packard Connectors ...................202 Servicing Deutsch Connectors ...................202 Identification Of Major Connector Pins.......204 Testing Overview ..........................................205 Testing Procedure ......................................205 Battery Overview ..........................................207 Battery ........................................................207 Battery Testing ...........................................207 Battery Removal.........................................208 Battery Cleaning.........................................208 Battery Inspection.......................................208 Battery Storage ..........................................208 Activation Of A New Battery .......................209 Tips For Charging A Used Battery .............210 Charging 2 or More Batteries at a Time .....211 Battery Installation......................................211 Troubleshooting ...........................................212 Starting System Troubleshooting ...............212 Tests and Adjustments ................................213 Starting System Tests ................................213 Electric Starter............................................214
Ignition System ............................................ 217 Ignition System Testing Procedure............ 217 Troubleshooting ......................................... 218 Ignition System Test .................................. 219 Ignition Timing ........................................... 221 Spark Plug ................................................. 221 NGK Spark Plug Symbol Explanation........ 223 12-Volt Auxiliary Power Outlet ................... 223 12-Volt Power Outlet.................................. 224 Headlamp .................................................. 224 Taillight ...................................................... 225 Ignition Switch............................................ 225 Indicator Lights .......................................... 225 Electronic Module ...................................... 226 Speedometer ............................................. 226 Winch......................................................... 226 Winch Control Switch................................. 227 Tests.............................................................. 227 12-Volt Auxiliary Power Outlet ................... 227 12-Volt Power Outlet.................................. 227 Cooling Fan Operation Test....................... 228 Headlamp .................................................. 228 Multi-Function Switch................................. 228 Indicator Lights .......................................... 228 Speedometer ............................................. 229 Winch Control Switch................................. 229
Electrical Table of Contents - 189
ELECTRICAL TABLE OF CONTENTS
Electrical Table of Contents - 190
ELECTRICAL GENERAL INFORMATION General Information
contains a device identifying letter (H) and number (I). The identifying letter is always the same for a specific component, but the identifying numbers are numbered consecutively from upper left to lower right. The terminal designation (J) is placed directly outside the symbol next to the connecting wire path. Switch positions (K) are also placed directly outside the symbol. The solid line (L) shows the position the switch is currently in and dash lines (M) represent other switch positions.
Reading Electrical Schematics The schematic is made up of individual circuits laid out in a sequence of related functions. It is formatted with all power wires (A) across the top and all ground wires (B) across the bottom. Current flow is generally from top to bottom through each circuit and component. All components are shown in the off position. The diagram does not list connector (C) information unless needed to avoid confusion. If the connector is shown, the number next to it is the terminal pin location (D) in the connector.
Each circuit is identified at the bottom of the drawing by a section number (N) and section name (O). The circuit number (P) and wire color (Q) of the wires are shown directly next to the wire path.
Each component is shown by a symbol (E), its name (F), and an identification code (G). The identification code
S1 Key Switch B
Wht
Wht
Red
Red
X1
F2 15 Amp Fuse
S1
X2
X3
M
X3
800 Pink
D
D
6
C
Start
On Off Seat Seat S2 A Seat Switch
414 Yel/ Blk
30
K2 Ignition Relay 87
86
85
Run
210 Red
Off L
K
F3 15 Amp Fuse
K1 Start Relay
F1 Fusible Link
J
X3 H
1 215 Org
X2 721 Pur/ Wht
Red
S
B G1 Battery
W1 Shielded Ground
G
M1 Starting Motor
M
Blk
710 Pur
E
E I
X3 H
F 805 Pnk/Blk W3 X3 Engine X4 Wiring Yel/ Harness T2 T1 Wht Ignition Ignition X5 Yel/Wht Coil Yel/Wht Coil E1 Spark Plug
B
F O
SE1-Power and Starting Circuit
Blk/Yel
C
N
SE2-Ignition and Interlock Circuit MIF
The same component name and identification code are
E2 Spark Plug
Yel/ Wht Wht
P Q
105 Blk
SE3-PTO and Interlock
used consistently on all diagrams in this section. Components can be easily cross-referenced.
Electrical General Information - 191
ELECTRICAL GENERAL INFORMATION Theory of Operation Information
Wire Color Abbreviation Chart
The theory of operation stories divide the electrical system into individual circuits by function. Each circuit is isolated from the main wiring schematic and only shows the components that are used in it. The story contains information on function, operating conditions, and theory of operation. The circuit schematics are drawn with the components in the operating position, with the power, or battery positive, into them across the top and the ground, or battery negative, across the bottom.
BK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
Diagnostic Information The diagnostic procedure is used to test the complete circuit regardless of the problem or complaint. Select a symptom or system from the quick check or troubleshooting chart and follow the test procedures under that heading.
BL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue BR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown GN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green GY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray OR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink PU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red TA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tan VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Violet WH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White YL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow Color
The diagnostic procedure lists: •
Test conditions
•
Test sequence
•
Test location
•
Normal reading
•
Check or test to perform if reading is not normal
AWG Size
Example
BK/YL – 12
Example
RD – 6
When performing the test or check, be sure to set your machine up to the TEST POINT/PROCEDURES listed in the first column and follow the sequence carefully. The middle RESULTS column gives the reading or condition that should be obtained in BOLD print. If the results of the test or check are not normal, perform the test, check, or adjustment listed below the BOLD print. The system diagram that accompanies each test procedure is drawn to resemble machine components. The leader line points to the exact point the test is to be made.
Electrical General Information - 192
ELECTRICAL GENERAL INFORMATION Common Circuit Tests Shorted Circuit: MIF
High resistance or open circuits usually result in slow, dim or no component operation (i.e. poor, corroded, or disconnected connections). Voltage at the component will be low when the component is in operation. To test for high resistance and open circuits: 1. Check all terminals and grounds of the circuit for corrosion. MIF
A shorted circuit may result in the wrong component operating (i.e. improper wire-to-wire contact). To test for a shorted or improperly wired circuit:
2. If terminals are not corroded or loose, the problem is in the component or wiring. Grounded Circuit:
1. Turn component switch on. 2. Start at the controlling switch of the component that should not be operating. 3. Follow the circuit and disconnect wires at connectors until component stops operating. 4. Shorted or improper connections will be the last two wires disconnected. High Resistance or Open Circuit: MIF
Grounded circuits usually result in no component operation or a blown fuse.
Conductors for 12 Volt Circuits Stranded Conductors For 12 Volt Circuits SAE Wire Size (Gauge)
20
18
16
14
12
10
Metric Wire Size (mm)
0.5
0.8
1.0
2.0
3.0
5.0
Typical stranding
7 X 28
16 X 30
19 X 29
19 X 27
19 X 25
19 X 23
Minimum Conductor Area In Circular Mils
1072
1537
2336
3702
5833
9343
Electrical General Information - 193
ELECTRICAL SPECIFICATIONS Specifications Electrical Specifications Magneto/Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 W @ 6000 rpm Ignition System Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.D.I. (Capacitor Discharge Ignition) Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Adjustable Spark Plug Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Spark Plug Make and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NKG DCPR8E Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 - 0.7 mm (0.024 - 0.027 in.) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (159 lb-in.) Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 - 300 ohms Battery Charging Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 ± 0.01 ohms Ignition Coil Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 to 1.15 ohms @ 20° C (68° F) Ignition Coil Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 to 11.7 ohms @ 20° C (68° F) Engine RPM Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7400 Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrolyte Battery Type Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volts Nominal Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A•h Power Starter Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 kW Lights Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 x 30 W Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/27 W, 1157 Pilot Lamp Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEDS, 0.7 V approximately (each) Fuses Location no. 1 (spare 15 A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N.A. Location no. 2 (spare 15 A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N.A. Location no. 3 (accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A (power outlet and auxiliary supply) Location no. 4 (fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 A Location no. 5 (main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 A Location no. 6 (charging system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 A
Required Tools Special or Required Tools Tool Name Jumper Wire
Tool No. 529 035 605
Tool Use Used for self-diagnosis.
Electrical Specifications - 194
ELECTRICAL SPECIFICATIONS Recommended Tools Special or Required Tools Tool Name
Tool No.
Tool Use
Multitester Hand-Held Digital Tachometer
JT05719
Used to check idle speed and starter performance.
D-05351ST
Used to check overall condition of ignition system.
Terminal Remover Spark Tester
Electrical Specifications - 195
ELECTRICAL SCHEMATICS AND HARNESSES Schematics and Harnesses
Component Location
1
4
5
ZONE 1 2
ZONE DESCRIPTION TOP POD BOTTOM POD
3
FRONT
4
MOTOR
5
REAR
3
2
EX: EX: EX:
TERMINAL IDENTIFICATION NAME ZONE-CONNECTOR#-TERMINAL#/A CI 1 CI A PR ME
5
-
5
-
FRAME GROUND ENGINE GROUND PHILLIPS SCREW NUT CONNECTION SPLICE CONNECTION COMPONENT CONNECTION END OF MODULE SECTION OF MODULE SLOTTED SCREW SOLDERED JOINT SHRINK WRAP JOINT CROSSED WIRE WIRE BUS SIMPLE CONDUCTOR WIRE FEMALE TERMINAL MALE TERMINAL STEEL LINK (FRAME) TERMINAL OPTIONAL
Electrical Schematics and Harnesses - 196
PR ME3
-
18
ELECTRICAL SCHEMATICS AND HARNESSES Trail Buck Main Schematic
CC
SP RD/VI1
RD/VI-14
RD/VI-16
1 of 3
RD/VI-14
1-CC KEY SWITCH 1-CC (RUN & RUN/LIGHT SWITCH) YL-14 VI-14
SP RD/VI2
RD/VI-18
OFF RUN LIGHTS RUN GN-14 1-CC RD/GN-14 5-PF1-A
PF
FUSE HOLDER
RD/GN-16 FA PRIMARY FUSE 20A
FB
FF
FAN FUSE 15A
RD/BK-16
WH/GN-16
RD/WH-16
5-PF1-C
5-PF1-D
5-PF1-E
5-PF1-B
RECTIFIER FUSE 30A
SS STARTER RELAY
RD-12
18 AH
WH/RD-18
BK/OR-18
17 START OUT
2
FREE START
BK - 12
1-MG1
RECTIFIER B
BK - 12
SP BK3
BK - 18
SP BK2
SP BK4
Electrical Schematics and Harnesses - 197
YL - 14
2-RD3-2 2-RD3-2 YL - 14
WATTS
C 2-RD1
SP BK1 BK - 12
2-RD3-1 2-RD3-1 YL - 14 YL - 14
RD
RD/VI - 18
5-BN1
BN1
A
1-MG1
COOLING TEMP SWITCH 5-IT
2-RD2
MG
RD/BU - 12
BK - 18
5-ME3-2
MULTIFUNCTION SWITCH 1/3 (START SWITCH) BK - 6
IT
YL/RD - 18
BK - 6
BN2
1
5-IT
BK - 16
STARTER MOTOR
START IN 2
BK-16 BK/WH - 16
SM
5-ME3-17
DYNAMIC BRAKE
12Vdc
5-FT-A
BK - 16
TO SW
BATTERY
FAN MOTOR
5-DC1-1
BK - 16
BAT
FT
DC
DC OUTLET AUXILIARY 1-DC4
BP
BU-16
DC OUTLET 5-DC1-2
RD-6
RD/WH-16 RD/BK-16
RD/BK-16 RD/BK-16
RD-6
1-DC3
5-PF2
5-SS2
5-FT-B
DC
5-SS1
RD-12
SPARE FUSE
SP RD/BK
RD-14
RD-16
NOT USED
BK-14
FE
FD
ACCESSORIES NOT FUSE 15A USED
BK - 12
FC
YL - 14
2-RD3-3 2-RD3-3 YL - 14
ELECTRICAL SCHEMATICS AND HARNESSES
MG
RD/VI-18
RD/VI-18 5-PRD-1
5-PRG-1
MULTIFUNTION SWITCH 3/3 (HI/LO BEAM SWITCH)
RD-18
RD-18
1-MG1
HI
RD/VI - 18
RD/YL - 16
2 of 3
BA STICK COIL
BL-16
GN-16
LO
1-MG1
DI2
BL-16
GN-16
1-MG1
WH-18
SP BU
BU-18
BU - 18
BU-18
7
3-PG-C 3-PD-B
3-PG-B
HI
PG LEFT BEAM
KM-H MPH
BU
HI GROUND
3-PG-A
5-PRD-3
1-C1-16
3-PD-C
LO
DI1
3-PD-A
1-CI-5
1-CI-11
PULSE
KM/MI
PD RIGHT BEAM
PRG TAIL LIGHT
1-CI-6
PRD TAIL LIGHT
PK/GN - 18
BK-18
RD/VI-18
WH/GN-18
LO
WH-18
SPARK PLUG
WH-18
SPK
GN-18
GN-18
SP GN
WH-18
5-PRG-3 4-BA
4-BA
5-PRG-2
5-PRD-2
5-ME-2 PULSE OUT BK/PK - 18
BK - 18
BK - 18
BK - 18
FIRE
TRIGGER WH/GN-18
KM
WH-24
SPEED
1-KM1 RD-24 4-CV-A
BK-20
SENSOR BK-24
BK-18
4-CV-C BK - 18
MAGNETO
BK-18
CA
CV
1-KM2
CPS
4-CA-6
4-CA-4
BK-18
YL-14
4-CV-B
KM/MI SWITCH
TRIGGER COIL
YL-14
5-ME-17
BK - 18
YL-14
GROUND
PULSE IN 5-ME-8
Electrical Schematics and Harnesses - 198
BK - 18
4-CA-5
BK/YL-20
5-ME-6
PK-18
5-ME-1 POWER
ELECTRICAL SCHEMATICS AND HARNESSES 3 of 3
RD/VI - 18
RD/VI - 18
4-FR1
1-FV1
RD-20
FR REAR BRAKE SWITCH
RD/VI - 18
RD/VI-18
RD/VI-18
1-SWW-A
FV FRONT BRAKE SWITCH
SWW WINCH CONTROL IN FREE OUT
4-FR2
(OPTIONAL: EX)
BK-20
GN-20
RD/OR-18
RD/OR-18
1-FV2
RD/VI-18 1-SWW-C
CARBURETOR HEATER (OPTIONAL) (2X15 WATTS)
RD/OR-18
RD/OR-18
40CH2
40CH1
LT BL - 18
CH
1-SWW-B
GN/WH - 18
SP RD/OR
1-CI-8
CI SPEEDOMETER & LED
OIL LED
WATER TEMP LED
POWER
A
PARK LED
REVERSE LED
NEUTRAL LED
RD
RD
GN
RD
YL
F
D
E
C
B
1-CI-2
1-CI-14
1-CI-9
1-CI-20
40CH3
1-CI-21
To SS BK-20
GN-20
WH/BE - 18
VI/GY - 18
YL/PU - 18
YL/GN - 18
BR - 18
IN
RD-6
S-SW2
S-SW1
OUT
SW
(RD)
WINCH CONTACTOR
REAR BRAKE
5-ME-13 OIL
WATER TEMP OUT
5-ME-12 PARK
REVERSE
NEUTRAL
(OPTIONAL: EX)
WATER TEMP SWITCH
OIL PRESSURE SWITCH
4-PM
5-ME-27
YL/GY-18
OR/VI-18
WH/GY-18
4-ABC-2
C NEUTRAL SWITCH
B REVERSE SWITCH
2
A PARK SWITCH
BK - 18
BK-18
RUN P
STOP 4-TE1
3
4
5
WM WINCH MOTOR
4-ABC-1 BU-20
PM
TE 4-TE2
5-ME-28
BK-20
4-ABC-3
A
B 5-ME-29
YL/GN-20
MG MULTIFUNCTION SWITCH 2/3 (STOP SWITCH)
C
5-ME-25
5-ME-26
BR/BU-18
5-ME-32 BK/BU-18
BK/WH - 18 BK/WH - 18
1-MG2
5-ME-23
OIL PRESSURE
WATER TEMP COM
BK/GY- 18
WATER TEMP IN
BK-6
ME MULTI PURPOSE ELECTRONIC MODULE STOP
(YL) (BK)
(BU)
5-ME-14
5-ME-11
BK-6
FRONT BRAKE
5-ME-16
5-ME-22
6
BK - 18
1-MG1
Electrical Schematics and Harnesses - 199
BK-6
5-ME-21
1
ELECTRICAL COMPONENTS OVERVIEW Components Overview
Battery
General Operation Information
The battery supplies the entire vehicle. Therefore, DC current only is used in the entire electrical system.
The electrical system consists of different sub-systems where some are inter-related:
Starting System
•
Charging System
•
Starting System
•
Ignition System
When ignition switch is turned on and start button is pressed, a signal is sent to the starting solenoid. The battery then supply the starter through the starting solenoid to start the engine.
•
Electric Shift System
•
Gauge and Accessories
2
The following gives an outline of each components.
1
7
Charging System 3
All Models It is the source of electrical energy to charge the battery and keep it at a full state of charge. The magneto is coupled to the engine and it transforms magnetic field into electric current through a 3-phase, delta “Y” wound stator on 18 poles. The magneto supplies unregulated AC (alternative current) to the voltage regulator/rectifier.
1 2
4
4
5 V04G1LA
6 V04g1la2.eps
Typical A B C D E F G
- Battery (1) - Ignition Switch (2) - Start Button (3) - Starting Solenoid (4) - Electric Starter (5) - Contact Screw (6) - Brake Switches (7)
Transmission must be on PARK or NEUTRAL (signal from contact screw) to allow engine starting. However, an override mode allows to start the engine with the transmission lever in any position when holding any brake lever while pressing the start button.
3
Ignition System V01G0IA
V01g0ia2.EPS
A B C D
- Magneto Flywheel (1) - Stator (2) - Voltage Regulator/Rectifier (3) - Battery (4)
An CDI (Capacitor Discharge Ignition) system is utilized. The ignition system is made up of the following components:
Voltage Regulator/Rectifier A 3-phase full-wave series-type voltage regulator/ rectifier receives the AC voltage and rectifies (converts) it into DC. The voltage is also regulated to a maximum of 14.5 volts (DC).
Electrical Components Overview - 200
ELECTRICAL COMPONENTS OVERVIEW General Testing/Troubleshooting Information 2
7 3
1
V04G07B
8
6
4
5 V04g07B2.EPS
Typical A B C D E F G H
- Battery (1) - Ignition Switch (2) - Engine Stop Switch (3) - Electronic Module (4) - Magneto Flywheel (5) - Trigger Coil with Stator (6) - Single Spark Ignition Coil (7) - Spark Plug (8)
The following gives general electrical-related problems. For specific system-related problems, refer to proper system section. It is possible that a component seems to operate in static condition but in fact, it is defective. In this case, the best way to solve this problem is to remove the original part and replace it with one which is in good condition. NOTE: When having to solve an electrical problem, the first thing to do is to check the battery condition as well as its cables and connections. Also ensure the ignition switch is turned on. Check related-circuit fuse connection and condition with an ohmmeter — visual inspection could lead to false results. Also visually examine harness and connections. To perform verifications, a good quality multimeter such as Fluke 73 should be used. Pay particular attention to ensure that pins are not out of their connectors or out of shape. The troubleshooting procedures cover problems not resulting from one of these causes. IMPORTANT: Avoid damage! Ensure all terminals are properly crimped on wires and connector housings are properly fastened.
Battery/Ignition Switch The ignition switch allows battery to supply the electronic module for the ignition system. Engine Stop Switch The engine stop switch disables the ignition system. Electronic Module It is basically responsible for interpreting/computing information, distribution of information, ignition system, the engine RPM limiter and the vehicle speed limiter. It reads information through many external sensors to then compute the output actions to the related systems. Magneto Flywheel/Trigger Coil The magneto flywheel features two protrusions that are working with the trigger coil. The trigger coil sends the signals to the electronic module to be processed for the ignition system. Ignition Coil/Spark Plugs The ignition coil receives its signal from the electronic module. The ignition coil steps up the input voltage and the end result is firing of the spark plug.
Gauges/Accessories
Before replacing an electric or electronic part, always check electrical connections. Make sure that they are very tight and they make good contact and that they are corrosionfree. A “defective module” can be repaired simply by unplugging and replugging it. The voltage and current might be too weak to go through dirty wire pins. Check carefully if posts show signs of moisture, corrosion or if they look dull. Clean pins properly and then coat them with silicon-based dielectric grease or other appropriate dielectric lubricant (except if otherwise specified) when reassembling. See connectors information below. It is recommended to always disconnect the battery when replacing any electric or electronic part. IMPORTANT: Avoid damage! Always disconnect BLACK (-) cable first and reconnect last. NOTE: In usual electric circuit, the battery supplies a switch which then supplies the electric consumer. Therefore the switch opens and closes the positive side of the circuit. However, in our electrical system, the battery supplies the electric consumer then the switch completes the circuit to the ground. So the switch opens and closes the negative side of the circuit. Take this into account when troubleshooting the electrical system.
The battery supplies the DC current to all accessories. Electrical Components Overview - 201
ELECTRICAL COMPONENTS OVERVIEW Pay attention to grounding wires. Do not mix grounds. It may affect the MPEM operation. Checking for Shorts Between 2 Wires When checking continuity of a wire in a circuit, wires should be checked for short circuit as follows. Make sure to isolate circuit wires by unplugging connectors. Let’s suppose that the circuit to be checked has a RED and a BLACK wire. Using an ohmmeter, measure the resistance between the RED and the BLACK wire. The resistance should be infinite (0 L). Otherwise, there is a short circuit between both wires. We must therefore identify and correct the fault.
V00G01A
V00g01a3.EPS
A - Spare (1) B - Spare (2) C - Accessories (power outlet and auxiliary supply) (3) D - Fan (4) E - Main (5) F - Charging System (6)
Fuses Location If a fuse is damaged, replace it by one of the same rating. IMPORTANT: Avoid damage! Do not use a higher rated fuse as this can cause severe damage. The fuse holder is located at the rear of the vehicle, on left side, under rear fender.
Servicing Packard Connectors
1
All Models To remove terminal from Packard connector housing, use Snap-on TT600-4 tool.
F01B1JA
F01b1ja.EPS
Servicing Deutsch Connectors All Models V04G1KA
V04g1Ka3.EPS
Waterproof Connector Housing Female and Male Connector Housing
A - Fuse Holder (1) Fuses are identified by a number located beside the fuse.
To remove: •
Using a long nose pliers, pull out the lock.
Electrical Components Overview - 202
ELECTRICAL COMPONENTS OVERVIEW 1
V01G0QA
1 V01g0Qa2.EPS
V01G0OA
1 V01g0oa2.EPS
Female Housing
Female Connector Housing A - Retaining Tab (1) To install:
A - Female Lock (1)
• For insertion of signal contact, make sure the lock is removed. • Insert contact into appropriate circuit cavity and push as far as it will go. • Pull back on the contact wire to be sure the retention fingers are holding the contact. • After all required contacts have been inserted, the lock must be installed. IMPORTANT: Avoid damage! Never apply dielectric grease on contacts in plug connector. The use of dielectric grease will make the seal swollen and move out of the connector. Do not lubricate.
V01G0PA
1 V01g0Pa2.EPS
Male Housing A - Male Lock (1) NOTE: Before extraction, push wire forward to relieve pressure on retaining tab. • Insert a 4.8 mm (0.189 in) wide screwdriver blade inside the front of the contact cavity. • Pry back the retaining tab while gently pulling wire back until contact is removed.
Electrical Components Overview - 203
ELECTRICAL COMPONENTS OVERVIEW Identification Of Major Connector Pins
Connector Pin-Out
DEUTSCH
B
A
A
A C
A B
B
B
B
C B
1
A
B C
D
B
B 1 2
A
A D
A
B
A
B
B
C
A
D
1 2
PACKARD A C
B
A C D
B
B F
V01G0ES
D
C
C B A
C
ED
4 3 4 3
1 2
A
1 2 3
A
3
21
B C
B
3
A
B
B
A
A
C
B
A
2
1
C
A B
A C
1
2
B
B
B
C
85 87 87a 86 30 A
A
A
C
C
A D
A
B
B
A
2
C
A CB
A B
B
D
6 5 4
1 2 3
A
1 2 3 4 5 6
FE
6 5 4
A CB
V01g0es2.EPS
Electrical Components Overview - 204
12 11 10 9 8 7
12 11 10 9 8 7
1 2 3 4 5 6
ELECTRICAL TESTING OVERVIEW Testing Overview
Voltage Test: Proceed as follows:
Testing Procedure
•
NOTE: First, ensure that battery is in good condition prior to performing the following test.
• Connect a multimeter to battery posts. Set multimeter to Vdc scale.
If the battery is regularly discharged, check charging system fuse (30 amp) condition.
•
Start engine.
Bring engine to approximately 5500 RPM.
If multimeter reads over 15 volts, voltage regulator/ rectifier is defective. Replace it. NOTE: Whatever the voltmeter type used (peak voltage or RMS), the voltage must not exceed 15 V. A faulty voltage regulator/rectifier will allow voltage to exceed 15 V as engine speed is increased. NOTE: If it is continually necessary to add distilled water to the battery, this indicates an over voltage situation, requiring replacement of the voltage regulator/rectifier. If, on the other hand, the battery will not stay charged, the problem can be any of the charging circuit components. If these all check good, you would be accurate in assuming the problem to be in the voltage regulator/rectifier.
1 V00G01D
V00g01d3.EPS
A - Charging Fuse (30A) (1) The voltage regulator/rectifier could be the cause of a blown fuse. To check, simply disconnect the voltage regulator/rectifier from the circuit. If the fuse still burns, check for a defective wire. IMPORTANT: Avoid damage! Do not use a higher rated fuse as this can cause severe damage. Voltage Regulator/Rectifier Static Test: Continuity: 1. Due to internal circuitry, there is no static test available. Dynamic Test:
If there is no charging at the battery with the preceding voltage test, the following test can also be performed. Voltage Regulator/Rectifier Output Test Remove the charging system fuse no. 6 (30 amp). Connect the negative probe on engine and the positive probe in the charging system fuse location where the value is 0 Vdc. The obtained value in the other location should be 12 Vdc. NOTE: If the voltage regulator/rectifier is within the specification, the wiring harness between the voltage regulator/rectifier and battery is defective. If the voltage regulator/rectifier is out of specification and the stator test good, the voltage regulator/ rectifier is defective.
Current Test:
Stator
Proceed as follows:
Static Test: Continuity:
•
Start engine.
•
Lay an inductive ammeter on positive cable of battery.
•
Bring engine to approximately 3500 RPM.
1. Disconnect the magneto wiring harness connector. With a good multimeter (preferably a digital one), place the 2 meter test probes onto the stator wire leads AC-1 and AC-2 of the stator. Measure the resistance.
Depending on battery charge, current reading should be approximately 5 amperes. If not, check magneto output prior to concluding that voltage regulator/rectifier is faulty.
Resistance
Electrical Testing Overview - 205
0.3 W ± 0.2
ELECTRICAL TESTING OVERVIEW
V02G01B
YL YL YL WH BL/YL
YL YL YL WH BL/YL
V02G03B
V02g01ba2.EPS
Typical
V02g03ba2.EPS
Typical
1. Place either meter test probe into the remaining stator lead (AC-3) and note the resistance (which should the same as in step no. 1). If the readings are out of specification, the stator will need to be replaced.
Dynamic Test 1. Unplug magneto wiring harness connector. 2. On magneto side, connect test probes of the multimeter to two of the YELLOW wires. 3. Set multimeter to Vac scale. 4. Start engine. The obtained value should be between 4 and 6 Vac. 5. Repeat operation 3 times. 6. If the stator is out of specification, replace it. Trigger Coil Static Test:
V02G02B
Unplug the magneto connector.
YL YL YL WH BL/YL
Measure the resistance between the proper wires. The obtained value should be between 190 and 300 W. V02g02ba2.EPS
Typical
Magneto Connector Wires
White/Yellow and Blue/ Yellow
If the resistance is out of specifications, change the trigger coil.
Static Test: Insulation: With the stator leads disconnected, insert either of the meter test probe into AC-1 and ground the other meter test probe to the engine or the stator iron core and note the reading. There should be no continuity (infinity) between the stator insulated coils and ground. If there is a reading, the stator coils and/or the wiring from the coils is grounded and needs to be replaced/repaired respectively.
Electrical Testing Overview - 206
ELECTRICAL BATTERY OVERVIEW Battery Overview Battery Troubleshooting
1
Symptom: Discharged or Weak Battery CAUSE
REMEDY
Battery posts and/or cable terminal oxidized.
Clean and coat with dielectric grease.
Loose or bad connections.
Check wiring and connector cleanliness, damaged or short circuit.
Faulty battery (sulfated, doesn’t keep a full charge, damaged casing, loose rectifier).
Replace.
Charging system fuse burnt or faulty voltage regulator/rectifier.*
First check charging system generator coil. If it is in good condition replace fuse or rectifier.
Faulty charging system generator coil.*
Replace.
A17E0JA
A17e0ja2.EPS
Typical A - Specific Gravity 1.265 (1) A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte. Most hydrometers give a true reading at 21°C (70°F). In order to obtain correct readings, adjust the initial reading by adding 0.004 points to the hydrometer readings for each 5.5°C (10°F) above 21°C (70°F) and by subtracting 0.004 point for every 5.5°C (10°F) below 21°C (70°F). This chart will be useful to find the correct reading.
To test charging system, refer to CHARGING SYSTEM.
Electrolyte Temperature
Battery Testing
°C
°F
There are 2 types of battery tests: unloaded and loaded. An unloaded test is made on a battery without discharging current. It is the simplest and commonly used. However, be aware that the voltage test can be good while the battery has not enough power to start the engine. A load test gives more accuracy of the battery condition.
38
100
32
90
.008
27
80
.004
21
70
correct reading
Unload Test
16
60
subtract
Check charge condition using either a hydrometer or a multimeter.
10
50
.008
4
40
.012
-1
30
.016
With a multimeter, voltage readings appear instantly to show the state of charge. Always respect polarity. A fully charged battery will have a reading of 12.6 Vdc. A hydrometer more accurately measures the charge of a battery in terms of specific gravity of the electrolyte. A fully charged battery will have a specific gravity between 1.265 to 1.280.
Operation To Perform
add
.012
.004
Example No. 1 Temperature below 21°C (70°F): Hydrometer reading: 1.250 Electrolyte temperature: -1°C (30°F) Subtract 0.016 Sp. Gr. Corrected Sp. Gr. is 1.234
Electrical Battery Overview - 207
to the reading
from the reading
ELECTRICAL BATTERY OVERVIEW Battery Cleaning
Example No. 2 Temperature above 21째C (70째F):
c CAUTION: Avoid Injury! Electrolyte is
Hydrometer reading: 1.235
poisonous and dangerous. It contains sulfuric acid and can cause severe burns. Avoid contact with eyes, skin and clothing. Wear protective eyeglasses and a suitable pair of non-absorbent gloves when removing the battery by hand.
Electrolyte temperature: 38째C (100째F) Add 0.012 Sp. Gr. Corrected Sp. Gr. is 1.247 Load Test This is the best test of battery condition under a starting load. Use a load testing device that has an adjustable load. Apply a load of 3 times the ampere-hour rating of the battery. At 14 seconds into the test, check battery voltage; if battery is in good condition, it will have at least 10.5 Vdc.
Battery Removal
Clean the battery casing, caps, cables and battery posts using a solution of baking soda and water. Remove corrosion (if so) from battery cable terminals and battery posts using a firm wire brush. Rinse with clear water and dry well.
Battery Inspection
Remove seat. Disconnect negative BLACK cable first then positive cable.
c CAUTION: Avoid Injury! Always respect this
order for disassembly; disconnect BLACK negative cable first. Electrolyte or fuel vapors can be present in engine compartment and a spark may ignite them and possibly cause personal injuries.
Visually inspect battery casing for cracks or other possible damage. If casing is damaged, replace battery and thoroughly clean battery rack with water and baking soda.
c CAUTION: Avoid Injury! Should the battery casing be damaged, wear a suitable pair of non-absorbent gloves when removing the battery by hand.
Inspect battery rack mounting. Remove the holding straps.
Inspect battery posts for security of mounting.
Pull out vent tube from frame.
c CAUTION: Avoid Injury! Electrolyte is
poisonous and dangerous. It contains sulfuric acid and can cause severe burns. Avoid contact with eyes, skin and clothing. Wear protective eyeglasses and a suitable pair of non-absorbent gloves when removing the battery by hand.
Remove battery from vehicle being careful not to tilt it so that electrolyte flows out of vent tube. IMPORTANT: Avoid damage! Should any electrolyte spillage occur, immediately wash off with a solution of baking soda and water.
Inspect for cracked or damaged battery caps, replace defective caps.
c CAUTION: Avoid Injury! Battery caps do not have vent holes. Make sure that vent tube is not obstructed.
Battery Storage Disconnect and remove battery from the vehicle (see above). Check electrolyte level in each cell, add distilled water up to upper level line. IMPORTANT: Avoid damage! Do not overfill. The battery must always be stored in fully charged condition. If required, charge until specific gravity of 1.260 is obtained.
Electrical Battery Overview - 208
ELECTRICAL BATTERY OVERVIEW IMPORTANT: Avoid damage! Battery electrolyte temperature must not exceed 50째C (122째F). The casing should not feel hot.
1
Clean battery terminals and cable connections using a wire brush. Apply a light coat of dielectric grease or petroleum jelly on terminals. Clean battery casing and caps using a solution of baking soda and water. Do not allow cleaning solution to enter battery, otherwise it will destroy the electrolyte. Rinse battery with clear water and dry well using a clean cloth. Store battery on a wooden shelf in a cool dry place. Such conditions reduce self-discharging and keep fluid evaporation to a minimum. During the storage period, recheck electrolyte level and specific gravity readings at least every 40 days. As necessary, keep the battery at its upper level line and near full charge as possible (trickle charge).
Activation Of A New Battery
A17E0FA
a17e0fa.eps
A - Battery Electrolyte (1) 2. Remove caps and fill battery to UPPER LEVEL line with electrolyte (specific gravity: 1.265 at 20째C (68째F)). 3. Allow the battery to stand for 30 minutes MINIMUM so that electrolyte soaks through battery cells.
c CAUTION: Avoid Injury! Never charge or boost battery while installed on vehicle.
IMPORTANT: Avoid damage! Prior to charging the battery, always remove it from the vehicle to prevent electrolyte spillage. A new battery is factory fresh dry charged. For storage purposes, it is fitted with a temporary sealing tube. Do not remove the sealing tube or loosen battery caps unless activation is desired. In case of accidental premature removal of caps or sealing tube, battery should be given a full charge. Perform the following operations anytime a new battery is to be installed.
c CAUTION: Avoid Injury! Failure to remove the sealing tube could result in an explosion
1. Remove the sealing tube from the vent elbow. Install vent tube, included in the battery kit, to battery elbow.
A17E0HA
a17e0ha.eps
4. Allow gas bubbles to escape by lightly shaking battery by hand. 5. Readjust the electrolyte level to the UPPER LEVEL line.
c CAUTION: Avoid Injury! Gases given off by a
battery being charged are highly explosive. Always charge in a well ventilated area. Keep battery away from cigarettes or open flames. Always turn battery charger off prior to disconnecting cables. Otherwise a spark will occur and battery might explode.
6. Connect a 2 A battery charger for 10 to 20 hours.
Electrical Battery Overview - 209
ELECTRICAL BATTERY OVERVIEW IMPORTANT: Avoid damage! If charging rate raises higher than 2.4 A reduce it immediately. If cell temperature rises higher than 50°C (122°F) (if the casing feels hot) discontinue charging temporarily or reduce the charging rate. 7. Disconnect battery charger. 8. Test battery state of charge. Use a hydrometer. 9. Let battery settle for 1 hour. 10.Allow gas bubbles to escape by lightly shaking battery. 11.Readjust electrolyte level.
on some factors such as: • Battery temperature: The charging time is increased as the temperature goes down. The current accepted by a cold battery will remain low. As the battery warms up, it will accept a higher rate of charge. • State of charge: Because the electrolyte is nearly pure water in a completely discharged battery, it cannot accept current as well as electrolyte. This is why the battery will not accept current when the charging cycle first begins. As the battery remains on the charger, the current from the charger causes the electrolytic acid content to rise which makes the electrolyte a better conductor and then, the battery will accept a higher charging rate. • Type of charger: Battery chargers vary in the amount of voltage and current that they can supply. Therefore, the time required for the battery to begin accepting measurable current will also vary.
1
Charging a Very Flat or Completely Discharged Battery Unless this procedure is properly followed, a good battery may be needlessly replaced. A17E0LA
a17e0la.eps
A - Baking Soda (1) 12.Reinstall caps and clean any electrolyte spillage using a solution of baking soda and water. IMPORTANT: Avoid damage! Do not allow cleaning solution to enter battery interior since it will destroy the electrolyte. NOTE: It is recommended to verify the battery charge once a month. If necessary, fully charge battery.
Tips For Charging A Used Battery CAUTION: Avoid Injury! Prior to charging the battery, always remove it from vehicle. For best results, battery should be charged when the electrolyte and the plates are at room temperature. A battery that is cold may not accept current for several hours after charging has begun. Do not charge a frozen battery. If the battery charge is very low, the battery may freeze. If it is suspected to be frozen, keep it in a heated area for about 2 hours before charging.
c CAUTION: Avoid Injury! Do not place battery near open flame.
• Measure the voltage at the battery posts with an accurate voltmeter. If it is below 10 volts, the battery will accept current at very low rate, in term of milliamperes, because electrolyte is nearly pure water as explained above. It could be some time before the charging rate increases. Such low current flow may not be detectable on some charger ammeters and the battery will seem not to accept any charge. • Exceptionally for this particular case, set the charger to a high rate. NOTE: Some chargers have a polarity protection feature which prevents charging unless the charger leads are connected to the correct battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly. This will make it appear that the battery will not accept a charge. Follow the charger manufacturer’s instruction on how to bypass or override this circuitry so that the charger will turn on and charge a low-voltage battery. • Since the battery chargers vary in the amount of voltage and current they provide, the time required for the battery to accept measurable charger current might be up to approximately 10 hours or more. • If the charging current is not up to a measurable amount at the end of about 10 hours, the battery should be replaced. • If the charging current is measurable before the end or at the end of about 10 hours, the battery is good and charging should be completed in the normal manner.
The time required to charge a battery will vary depending Electrical Battery Overview - 210
ELECTRICAL BATTERY OVERVIEW • It is recommended that any battery recharged by this procedure be load tested prior to returning it to service.
Charging 2 or More Batteries at a Time Connect all positive battery posts together and use a charger with a capacity (rated) equal to number of batteries to be charged.
-
A17E0PA
1
-
+
+ A17e0pa.EPS
Typical A - Two Batteries Connected In Parallel (1)
Battery Installation Reinstall and fasten the battery, making sure to reinstall the vent tube.
c CAUTION: Avoid Injury! Connect RED (+) cable first then negative cable. Always connect RED (+) cable first.
NOTE: Place the RED (+) cable between holding straps and battery.
Electrical Battery Overview - 211
ELECTRICAL TROUBLESHOOTING Troubleshooting
Starting System Troubleshooting
Symptom
Cause
Remedy
Starter does not turn.
Ignition switch is in the OFF position.
Turn switch in the ON position.
Burnt fuse.
Check main fuse and wiring condition.
Transmission is not set on the Park or Neutral.
Set transmission either in Park or Neutral or use the override mode.
Poor contact of battery terminal(s) or ground cable connections.
Clean and tighten terminal(s).
Weak battery.
Recharge battery.
Poor contact or open circuit of: start/ stop switch or start button and engine stop switch, ignition switch or starting solenoid.
Check and replace defective part.
NEUTRAL or PARK switches are defective.
Check NEUTRAL or PARK switches and wiring condition.
Engine mechanical problem (ensure that other electric components are good).
Communicate with the Service Representative.
Poor contact of battery terminal(s).
Clean and tighten terminal(s).
Poor battery ground cable connection.
Clean and tighten.
Burnt or poor contact of solenoid switch contact disc.
Replace starting solenoid.
Poor contact of brush.
Straighten commutator and brush or replace electric starter.
Burnt commutator.
Turn commutator in a lathe or replace electric starter.
Worn commutator segments.
Undercut mica or replace electric starter.
Shorted armature.
Repair or replace electric starter.
Weak brush spring tension.
Repair or replace electric starter.
Weak magnet.
Repair or replace electric starter.
Worn bushings.
Repair or replace electric starter.
Weak battery.
Recharge or replace battery.
Worn drive pinion gear.
Replace starter drive pinion.
Defective drive.
Replace starter drive pinion.
Poor movement of drive on splines.
Replace starter drive pinion.
Worn drive bushing.
Replace starter drive pinion.
Worn ring gear.
Recharge ring gear.
Starter turns; but does not crank the engine.
Starter turns, but overrunning drive pinion does not mesh with ring gear.
Electrical Troubleshooting - 212
ELECTRICAL TESTS AND ADJUSTMENTS Symptom
Cause
Remedy
Starter motor keeps running.
Shorted starting solenoid switch winding.
Replace starter solenoid.
Melted solenoid contacts.
Replace starter solenoid.
Sticking or defective starter drive pinion.
Replace starter drive pinion.
Tests and Adjustments
Disconnect large cables from solenoid.
Starting System Tests General First ensure the problem is not related to engine mechanical components. Otherwise, test the starting system. Causes of troubles are not necessarily related to starter but may be due to a burnt fuse, faulty battery, start button, ignition switch, engine stop switch, starting solenoid, electrical cables or connections. Check these components before removing starter. Consult also the Starting System Troubleshooting table above for a general view of possible problems.
c CAUTION: Avoid Injury! Short circuiting
electric starter is always a danger, therefore disconnect BLACK (-) cable before carrying out any kind of maintenance on starting system. Do not place tools on battery.
Inspect connections and clean as necessary. Solenoid condition can be checked with an ohmmeter. Install test probes on large connectors of solenoid. Measure resistance when current is applied to small connectors (+ RD/VI, - WH/RD); if it is more than a few ohms, replace solenoid. If solenoid test good, check the electric starter. If starter test good, the NEUTRAL or PARK switches can be suspected. Ignition Switch A quick test to validate it is working. Turn the ignition switch ON. If the lights turn on the ignition switch is good. Otherwise, refer to IGNITION SYSTEM, for testing procedure. If it tests good, continue the next tests. Start/Stop Switch If engine does not turn when pressing the start/ stop button, test the switch as follows. Remove steering cover and unplug the multi-function switch connector.
Fuses Make sure the main fuse (20 amp) is in good condition. If the fuse test good, continue the next tests. Battery To check battery condition, refer to Battery above. If it tests good, continue the next tests. 1
Starting Solenoid NOTE: Solenoid is located on frame, near battery rack. Ensure the solenoid receives electric current as follows. Using a multimeter, place a probe on the YELLOW/RED wire and the other probe on frame. Measure the voltage when pressing the start button with the ignition key turned on. If solenoid does not properly receive voltage, the start button or the engine stop switch can be suspected.
MX31991
A - Unplug Connector (1) Using a multimeter, measure the resistance between the following wires.
If solenoid receives voltage, test the solenoid as follows.
Electrical Tests and Adjustments - 213
ELECTRICAL TESTS AND ADJUSTMENTS POSITION
WIRE
RESISTANCE
Switch released
Red/Violet and Yellow/ Red
Infinite (0.L)
Switch depressed and held
0.6 W max.
Electric Starter Removal: Turn OFF ignition switch. Disconnect BLACK (-) cable connection from battery.
Replace switch if defective. If switch tests good, check wiring going to MPEM. If it tests good, continue the other tests.
IMPORTANT: Avoid damage! Always disconnect Black (-) cable first and reconnect last. Disconnect RED (+) cable connection from battery.
Electrical Cables or Connections
Clean starter area.
Check all connections, cables and wires. Tighten any loose cables. Replace any chafed wires/cables.
Remove RH engine side panel. Refer to BODY/FRAME.
If wiring and connectors are good, check the electric starter. See below.
Disconnect all cables from starter. Remove starter mount screws. Pull starter out.
Electric Starter NOTE: Starter is located at the rear of engine.
Disassembly: Remove bendix retaining circlip and starter bendix.
Remove RH engine side panel to give access to the starter. Refer to BODY/FRAME. Using boosting cables, carefully supply current from the battery directly to the starter. Connect the BLACK (-) cable first. Then connect the remaining jump cable from the battery then to the starter. If starter now turns ensure the cables/connections from battery to solenoid and to starter are in good condition. If starter does not turn, check for mechanical problems in the starter.
F18H0NA
1
2 F18H0Na2.EPS
A - Starter Bendix (1) B - Retaining Circlip (2) Locate index marks on yoke and end covers.
Electrical Tests and Adjustments - 214
ELECTRICAL TESTS AND ADJUSTMENTS
F18H0OA
1 F18H0oa2.EPS
1
F06H1HA
f06h1ha.eps
A - Index Marks (1)
Typical
Loosen through bolts.
A - Thrust Washer (1) Remove the other end cover with brushes and brush holder assembly. Remove armature.
1
F06H1JA
1 f06h1ja.eps
Typical A - Pull Armature Shaft (1)
F18H0PA
F18H0pa2.EPS
A - Through Bolts (1)
Remove brushes from brush holder by loosening retaining screws.
Remove end cover. Remove thrust washer from armature shaft.
Electrical Tests and Adjustments - 215
ELECTRICAL TESTS AND ADJUSTMENTS 1
2
3
testing procedures, except for the one concerning shorted windings in armature. Check commutator for roughness, burnt or scored surface. If necessary, turn commutator on a lathe, just enough to resurface. Check commutator for mica depth. If depth is less than 0.20 mm (0.008 in), undercut mica. Be sure that no burrs are left and no copper dust remains between segments after undercutting operation is completed. Check commutator condition with an indicator. If out of specification, replace the starter.
1 F18H0QA
F18H0qa2.EPS
A - Brushes (1) B - Retaining Screw (2) C - Brush Holder (3) Remove springs. Cleaning: F18H0RA
IMPORTANT: Avoid damage! Yoke assembly and drive unit assembly must not be immersed in cleaning solvent. Discard all O-rings.
F18H0ra2.EPS
A - Commutator Undercut 0.20 mm (0.008 in.) (1) Brush Holder:
Clean brushes and holder with a clean cloth soaked in solvent. Brushes must be dried thoroughly with a clean cloth.
Check brush holder for insulation using an ohmmeter. Place one test probe on insulated brush holder and the other test probe on brush holder plate. If continuity is found, brush holder has to be repaired or replaced.
Blow brush holders clean using compressed air.
Brush
c CAUTION: Avoid Injury! Always wear safety glasses when using compressed air.
Measure brush length. If less than 8.5 mm (0.335 in), replace them. NOTE: New brush length is 12 mm (0.472 in).
Remove dirt, oil or grease from commutator using a clean cloth soaked in suitable solvent. Dry well using a clean, dry cloth. Clean engine ring gear teeth and drive unit (clutch).
1
NOTE: Bushings or bearings must not be cleaned with grease dissolving agents.
2
Immerse all metal components in cleaning solution. Dry using a clean, dry cloth. Inspection: Armature:
A03E05A
NOTE: An ohmmeter may be used for the following
Electrical Tests and Adjustments - 216
A03E05a.EPS
ELECTRICAL IGNITION SYSTEM A - New (1) B - Wear Limit 8.5 mm (0.335 in.) (2)
4. Ignition switch 5. Trigger coil
Assembly:
6. Ignition coil
Reverse the order of disassembly to reassemble starter.
7. Electronic module.
Installation:
Intermittent Ignition Problems
Installation is essentially the reverse of removal procedure. However, pay particular attention to the following.
In dealing with intermittent problems there is no easy diagnosis. For example, problems that occur only at normal engine operating temperature have to be tested under similar conditions.
Make sure that starter and engine mating surfaces are free of debris. Serious trouble may arise if starter is not properly aligned. Apply grease Isoflex on O-rings of starter. Install starter. NOTE: If starter does not mesh properly, try to pull it out and slightly rotate the starter gear; then reinstall starter. One could also temporarily remove both Orings, properly mesh gears then remove starter to reinstall O-rings, being careful not to rotate gear to keep its position, to finally reinstall starter.
In most cases of temperature and/or vibration failure, only parts replacement might solve the problem as most of these failures return to normal when engine is not running. Multiple Problems There is always the possibility of more than one faulty part. If after a component has been replaced, the problem still persists, carefully repeat the complete test procedure to find the other faulty part.
Properly torque starter screws to 10 N•m (89 lb-in.). Connect the RED (+) battery cable to the starter and torque nut to 7 N•m (62 lb-in.). Apply dielectric grease on terminal and nut. First connect RED (+) cable to battery then connect the BLACK (-) cable. Ensure to slide protector over nut to hide metallic parts.
c CAUTION: Avoid Injury! Always connect RED
(+) cable first then BLACK (-) cable last. Whenever connecting the RED (+) cable to the starter motor make sure the battery cables are disconnected to prevent electric shock.
Test starter operation.
Ignition System Ignition System Testing Procedure Ignition Problems When dealing with ignition problems, the following items should be checked in this order. After one item has been checked and it is found not to be the problem, continue with the next item: 1. Main fuse condition. 2. Spark occurrence 3. Battery condition
Electrical Ignition System - 217
ELECTRICAL IGNITION SYSTEM Troubleshooting Check that the transmission lever is in NEUTRAL position and the engine stop switch is in “RUN” position. Check that
the main fuse is not burned and if the battery is fullycharged before diagnosing.
No spark or poor spark Check ignition system connector for poor connections. CORRECT
INCORRECT
Trail Buck Series Quest Series
Traxter Series
Measure battery voltage between BLACK and RED / VIOLET wires at the electric module with the ignition switch in ON position.
Poor connections of circuit connectors.
Measure battery voltage with the ignition switch in ON position.
CORRECT
INCORRECT
Measure ignition coil primary peak voltage. NOTE: This method is applicable only with a multimeter and a peak voltage adaptor.
Faulty ignition switch Faulty engine stop switch Broken wire harness or poor connections of circuit connectors
CORRECT
INCORRECT
Inspect spark plug(s)
Inspect ignition coil
CORRECT
Poor connection of the spark plug cap.
INCORRECT
CORRECT
Faulty ignition coil.
Faulty spark plug(s). Quest Series Trail Buck Series
Faulty electric module Poor connection of ignition connector
V00G03S
INCORRECT
V00G03SA2.EPS
Electrical Ignition System - 218
Traxter Series
Faulty MPEM Poor connection of ignition connector
ELECTRICAL IGNITION SYSTEM Ignition System Test
Ignition switch
Safety Precautions
A quick test to validate it is working. Turn the ignition switch ON. If the headlight turn on, the ignition switch is good.
c CAUTION: Avoid Injury! To prevent powerful
electric shocks while cranking engine, neither touch any electronic ignition components (ignition coil, wire harness, etc.) nor tester lead clips. Also make sure that tester leads do not touch any metallic object.
Fuse Condition Check main fuse (20 A) condition. Replace burnt fuse as necessary.
Test: Remove console and disconnect ignition switch. Measure voltage between RED/GREEN supply wire and the battery ground. If voltage is lower than battery voltage, test the wiring. If voltage is good, test switch. Use a multimeter and measure the resistance between the following wires. POSITION
WIRE
RESISTANCE
OFF
Green and Yellow
Infinite (0.L)
OFF
Green and Violet
Infinite (0.L)
ON (w/lights)
Green and Yellow
0.1 W max.
ON (w/lights)
Green and Violet
0.1 W max.
ON (w/o lights)
Green and Yellow Infinite (0.L)
ON (w/o lights)
Green and Violet
0.1 W max.
Replace switch if defective.
1
If switch is good, continue the other tests. Trigger Coil V00G01B
V00g01B3.EPS
NOTE: The trigger coil is not adjustable. STATIC TEST: Continuity:
A - Main Fuses (1)
Check resistance with a high-sensitivity ohmmeter.
Spark Occurrence Remove spark plug and connect to the ignition coil (stick coil). While holding the spark plug against a metallic part of the engine, start the engine. Look for a spark at the spark plug tip. Replace defective spark plug. Keep in mind that a spark plug might test good this way while not being able to work properly under combustion chamber mixture and pressure. If known good spark plug(s) do(es) not work, continue the other tests. Battery Condition A battery must be present in the vehicle to allow the ignition system to work. Also, at least 8 V is required for proper operation. Check battery voltage.
1. Disconnect the large connector from the electronic module. 2. Connect multimeter probes to the BLACK/ YELLOW wire and to the YELLOW wire. 3. Measure resistance; it should be between 190 - 300 ohms. DYNAMIC TEST: Voltage: 1. Disconnect the large connector from electric module. 2. Connect multimeter probes to the BLACK/ YELLOW wire and to the YELLOW wire, then bring selector switch to and scale to 00.0Vac. 3. Press START button, note result. The obtained value should be between 0.4 and 0.7 Vac. Repeat operation 3 times. 4. If the trigger coil is out of specification, replace it. If it tests good continue the other tests.
Electrical Ignition System - 219
ELECTRICAL IGNITION SYSTEM Ignition Coil NOTE: An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur at high voltage level which is not detectable with an ohmmeter. Replacing the stick coil may be necessary as a test. First, check the ignition coil primary peak voltage. Disconnect the ignition coil connector. V04G0BA
IMPORTANT: Avoid damage! Do not remove the ignition coil before disconnecting the connector, or the wires will be damaged. Do not pry up ignition coil with a screwdriver to avoid damage. Remove spark plug. Insert a pin into WHITE/GREEN wire location in ignition coil connector and connect a multimeter probe to it. Place the other probe on the engine. Shift transmission into PARK or NEUTRAL and turn ignition switch ON. Crank engine a few seconds and check the ignition coil primary peak voltage.
V04g0Ba2.EPS
Secondary Winding The primary winding resistance should be between 0.34 and 0.46 W at 20째C (68째F). The secondary winding resistance should be between 9.2 and 13.8 kW at 20째C (68째F). Electronic Module When every other components above have been tested and are good, the electronic module can be suspected. Ensure wiring and connectors are in good condition prior to replacing the electronic module.
Repeat operation 3 times and note the highest peak voltage. The ignition coil peak voltage should be more than 80 Vdc. If the peak voltage is lower than the specification, check the ignition coil resistance. Ignition Coil Resistance Using a multimeter, check the resistance in both primary and secondary windings.
V04G0AA
V04g0Aa2.EPS
Primary Winding
Electrical Ignition System - 220
ELECTRICAL IGNITION SYSTEM Test: NOTE: On the multimeter, set measuring range from 1 MW - 10 MW. Make sure that positive and negative tester probes are installed on the appropriate wires.
G
V04G0CA
H
Negative (-) Tester Line
I
J V04g0Ca2.EPS
Positive (+) Tester Line
A
A
B
C
D
E
F
G
H
I
J
O
X
X
X
O.L. X
O
X
O
O
O
X
O.L. X
O
O
X
X
X
O.L. X
O
O
O
X
O.L. X
O
X
O
B
O
C
X
O
D
X
O
E
O.L. O.L. O.L. O.L.
F
X
G
O.L. O.L. O.L. O.L. O.L. O.L.
H
O.L. O.L. O.L. O.L. O.L. O.L. O.L.
I
O.L. O.L. O.L. O.L. O.L. O.L. O.L. O.L.
J
O
O
X
X
X
O
X
O
O.L. O.L. O.L. O.L. O.L. X
O
X
O.L. O
X
X
O
O.L. O.L. O.L. O.L. O.L.
O
O.L. O
Symbols:
Heat Range
O: Open circuit, value/pointer change continuously
The proper heat range of the spark plugs is determined by the spark plugs ability to dissipate the heat generated by combustion.
X: No open circuit, value/pointer do not register any change If a fault is detected, the electronic module must be replaced.
Ignition Timing
The longer the heat path between the electrode tip to the plug shell, the hotter the spark plug operating temperature will be and inversely, the shorter the heat path, the colder the operating temperature will be.
It is impossible to check the ignition timing with a timing lamp because there is no access window or mark.
A “cold” type plug has a relatively short insulator nose and transfers heat very rapidly into the cylinder head.
Spark Plug
Such a plug is used in heavy duty or continuous high speed operation to avoid overheating.
Disassembly Disconnect then remove the ignition coil or unplug the spark plug cable. Unscrew the spark plug one turn.
The “hot” type plug has a longer insulator nose and transfers heat more slowly away from its firing end. It runs hotter and burns off combustion deposits which might tend to foul the plug during prolonged idle or low speed operation.
Clean the spark plug and cylinder head with pressurized air. Reinstall ignition coil, unscrew spark plug completely then remove it. Electrical Ignition System - 221
ELECTRICAL IGNITION SYSTEM Spark Plug Analysis
1
2
A00E0AA
1
2
3 A00e0aa.EPS
A00E09A
a00e09a.eps
A - Cold (1) B - Hot (2)
IMPORTANT: Avoid damage! Severe engine damage might occur or major plastic parts might melt if a wrong heat range plug is used. A too “hot” plug will result in overheating, pre-ignition, etc. A too “cold” plug will result in fouling (shorting the spark plug) or may create carbon build up which can heat up redhot and cause pre-ignition or detonation. Fouling Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of compression. Other possible causes are: prolonged idling or low-speed riding, or running on a too rich mixture due to abuse of choke, a clogged air filter, a faulty carburetor adjustment, incorrect fuel, defective ignition system, incorrect ignition timing, incorrect spark plug gap, lubricating oil entering the combustion chamber, or too cold spark plug. The plug face of a fouled spark plug has either a wet black deposit or a black carbon fouling. Such coatings form a conductive connection between the center electrode and ground.
A - Overheated (light grey, white) (1) B - Normal (light brown, brown) (2) C - Fouled (black, wet or dry, dark deposits, grey, melted coating) (3) The plug face reveals the condition of the engine, operating condition, method of driving and fuel mixture. For this reason it is advisable to inspect the spark plug at regular intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber). Spark Plug Installation Prior to installation make sure that contact surfaces of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap to 0.7 mm (0.027 in). 2. Apply anti-seize lubricant over the spark plug threads to prevent possible seizure. 3. Hand screw spark plug into cylinder head, with the ignition coil, and tighten with a torque wrench and a proper socket.
1
2
A00E0BA
a00e0ba.eps
A - Proper Socket (1) B - Improper Socket (2) 4. Torque spark plug. Spark Plug Torque
Electrical Ignition System - 222
18 N•m (159 lb-in.)
ELECTRICAL IGNITION SYSTEM NGK Spark Plug Symbol Explanation
V04G0DS
V04g0Dsa2.EPS
12-Volt Auxiliary Power Outlet The 12-volt auxiliary power outlet is located on the LH rear part of the rear extension frame. The wires are hidden inside harness and are protected by heat shrink tubing.
Removal and Installation: IMPORTANT: Avoid damage! Always to disconnect the battery when replacing any electric or electronic parts. Always disconnect battery exactly in the specified order, BLACK (-) cable first. Do not place tools on battery.
The 12-volt auxiliary power outlet allows the installation of additional accessories. NOTE: This is a direct connection, no key is necessary to get the 12 volts.
Electrical Ignition System - 223
ELECTRICAL IGNITION SYSTEM Test
Adjustment:
Refer to TESTS section.
Adjust beam aiming as follows:
12-Volt Power Outlet
Insert screwdriver into hole and turn adjustment screw to adjust beam height and side orientation as explained below. Adjust both headlamp evenly.
Test: Refer to TESTS section.
•
Turn clockwise to raise beam
•
Turn counterclockwise to lower beam
Removal: Remove the steering cover. Refer to BODY/FRAME. Unplug the connectors of the power outlet. Unscrew the retaining nut. Installation: Reverse the removal procedure.
Headlamp Test:
1
Refer to TESTS section. Bulb Replacement:
MX30905
IMPORTANT: Avoid damage! Never touch glass portion of an halogen bulb with bare fingers, it shortens its operating life. If glass is touched, clean it with isopropyl alcohol which will not leave a greasy film on the bulb. Unplug connector from headlamp.
A - Beam Height Adjustment (1) Select high intensity. Beam aiming is correct when center of high beam is 131 mm (5 in) below the headlight horizontal center line, scribed on a test surface, 5 m (17 ft) away. NOTE: Sit down the driver or place the same weight on the vehicle. Measure headlamp center distance from ground. Scribe a line at this height on test surface (wall or screen). Light beam center should be 131 mm (5 in) below scribed line.
90° 2 1
1
90°
MX30905
A - Connector (1) B - Bulb (2)
2
V01I0VA
V01i0vA2.EPS
Rotate bulb socket counterclockwise then remove headlamp bulb.
Typical A - Headlight Center Lines (1) B - Light Beam Center (2)
Electrical Ignition System - 224
ELECTRICAL IGNITION SYSTEM Ignition Switch Test:
90° A
Refer to IGNITION SYSTEM. Removal:
B
Lift the steering cover and unscrew the ignition switch nut.
1
NOTE: Do not unplug connectors when steering cover is lifted. Unplug the switch connector.
V01I0UA
V01i0uA2.EPS
Typical A - Light Beam Center (1) B - 5 m (17 ft) (A) C - 131 mm (5 in.) (B)
Taillight Bulb Replacement: Turn socket counterclockwise to expose bulb. 1
2 V04G0HA
1 V04g0ha2.EPS
Typical A - Switch Connector (1) Installation: For the installation, reverse the removal procedure.
Indicator Lights Test: MX30906
A - Socket (1) B - Studs (2)
Refer to TESTS section. Removal:
Push bulb in and hold while turning counterclockwise to release.
Remove the steering cover. Refer to BODY/FRAME.
Install the new bulb by first pushing in while turning clockwise.
NOTE: Do not unplug all connectors. Lift up the steering cover and unplug the indicator lights connector only.
Remove the taillight casing by pushing outward on the two studs. The taillight casing can be removed.
Press locking tabs on each side of the indicator lights and push the indicator lights out. Installation: For the installation, reverse the removal procedure.
Electrical Ignition System - 225
ELECTRICAL IGNITION SYSTEM Electronic Module Test: Refer to IGNITION SYSTEM for testing procedures. Removal: The electronic module is located near battery rack. To remove, unscrew both bolts retaining electronic module to frame and unplug the connectors. Installation: For the installation, reverse the removal procedure. NOTE: Do not forget the rubber bushings between electronic module and frame.
MX31991
Disconnect the Connector
Speedometer Test:
Carefully slide a flat blade screwdriver under the bottom edge of the speedometer.
When the key is placed in the RUN position, the speedometer should display the following:
Press down on the dash housing lock tab and rotate the speedometer clockwise. Remove speedometer.
•
backlight
•
slight movement of the speedometer needle
•
all LEDs (approximately 4 seconds)
1 MX31992
Inset Shown with Speedometer Removed MX31993
Normal Display
A - Lock Tab (1) Speedometer Installation:
If any of the above condition is not met, then check the wiring, VSS (Vehicle Speed Sensor) and connector conditions. If normal, change speedometer.
The installation is the reverse of the removal procedure.
Removal:
The speedometer is lighted with LEDs. If one LED burns, replace the speedometer. The LEDs are not available separately.
Remove the steering cover. Refer to BODY/FRAME.
Speedometer Indicator Lights Replacement:
Disconnect the connector to the back of the speedometer.
Electrical Ignition System - 226
ELECTRICAL IGNITION SYSTEM Converting Odometer from Miles to Kilometers:
6. Reinstall instrument trim panel. Odometer will now read in kilometers. To convert back to miles, disconnect black and black/red wires.
Winch EX Models A
Removal:
A
Disconnect, at the battery, the BLACK (-) cable first then RED (+) cable.
c CAUTION: Avoid Injury! Always respect this
63047-1
order for disassembly; disconnect BLACK (-) cable first. Electrolyte or fuel vapors can be present in engine compartment and a spark may ignite them and possibly cause personal injuries.
1. Remove six screws (A) that secure instrument trim panels together. 2. Remove front instrument trim panel.
Disconnect the winch power cables. NOTE: Identify the position of the power cables for the installation. Remove: •
fairlead
•
front skid plate
•
lower bolts retaining the front bumper
•
upper frame bolts.
Loose the top bolts that are attached to the rack. Swing out the whole bumper. 63047-2
3. Locate black wire and black/red wire with bullet connectors that are tied to speedometer wiring harness. 4. Remove tie strap that retains wires to speedometer harness.
Remove the lower winch bolts. Remove winch. Installation: For the installation, reverse the removal procedure.
Winch Control Switch EX Models Test: Refer to TESTS section. Removal: Remove screw retaining winch control switch to handlebar.
63047-4
5. Attach the black wire and black/red wire to each other.
Electrical Ignition System - 227
ELECTRICAL TESTS Tests 12-Volt Auxiliary Power Outlet NOTE: No key required. Using a multimeter, measure the voltage between RED/ BLACK and BLACK wires. The obtained value should be between 12 and 14.5 Vdc. • No voltage: Check accessories fuse and wiring condition. • MX30927
Voltage is good: Check outer accessory.
12-Volt Power Outlet NOTE: No key required.
Screw to Be Removed Remove steering cover, refer to BODY/FRAME.
Remove the steering cover.
Disconnect the winch control switch connector.
Unplug the power outlet connectors.
Installation:
Using a multimeter, measure the voltage between RED/ BLACK and BLACK wires.
For the installation, reverse the removal procedure.
The obtained value should be between 12 and 14.5 Vdc.
1
2
MX31994
A - 12-Volts Power Outlet (1) B - Power Outlet Connectors (2) • No voltage: Check accessories fuse and wiring condition front half. •
Voltage is good: Change power outlet.
Electrical Tests - 228
ELECTRICAL TESTS Cooling Fan Operation Test NOTE: No key required. Unplug the temperature sender connectors. Install a jumper wire end in connectors. Replace the fan if it does not work.
Headlamp Apply parking brake, place transmission lever in NEUTRAL position and start engine. Select low beam position on multi-function switch. Using a multimeter, measure the voltage at the following wires. Model Trail Buck
Wires Green and Black
1
Values 12 to 14.5 Vdc
The obtained value should be between 12 and 14.5 Vdc. Place the headlamp switch selector on high beam position.
MX31991
A - Speedometer Connector (1) Test each LEDs with 12 Vdc power source connected to pin numbers shown in table.
Measure the voltage between the following wires. 2 Model Trail Buck
Wires Blue and Black
9
11
Values 12 to 14.5 Vdc
• No voltage: Check wiring condition and headlamp switch. •
Voltage is good: Change headlamp bulb(s).
Multi-Function Switch Using a multimeter, measure the resistance between the following wires. Position Switch to LO Switch to HI
Wire Red/Yellow and Green Red/Yellow and Blue
14
Resistance 0.6 W max.
20 MX31995
LEDs
Pin Numbers 2 and 11 (ground)
0.5 W max.
14 and 11 (ground)
Replace multi-function switch if defective.
Indicator Lights
9 and 11 (ground)
When the key switch is placed in the ON position all of the indicator lights should light up for approximately 4 seconds. If they do not all light up check the individual LEDs.
20 and 11 (ground)
Remove steering cover. 21 and 11 (ground)
Unplug speedometer connector. Remove speedometer.
LEDs are good: •
Check wiring condition.
Electrical Tests - 229
ELECTRICAL TESTS •
Check connectors.
LEDs are burned: •
Change indicator lights.
Winch Control Switch EX Models Remove steering cover, refer to BODY/FRAME. Disconnect the winch control switch connector. Using a multimeter, measure the resistance between the connector pin A (RED wire), B (BLACK wire) and C (GREEN wire). Position
Connector pin
Resistance
Switch to “IN”
A and C
<5W
Switch to “OUT”
A and B
<5W
If the resistance is above 5 W, change the winch control switch.
Electrical Tests - 230
DRIVE TRAIN TABLE OF CONTENTS Drive Train
Table of Contents
Specifications ...............................................233 Required Tools ...........................................233 Recommended Tools .................................233 Repair.............................................................234 Front Drive Shaft ........................................234 Front Differential.........................................235 Front Propeller Shaft ..................................242 Wheel Hub..................................................242 Knuckle.......................................................243 Wheel Bearing............................................243 Front Drive.....................................................244 Front Drive Components ............................244 Rear Axle .......................................................245 Rear Axle Components ..............................245 General.......................................................246 Rear Differential Oil Level ..........................246 Rear Differential Oil Replacement..............246 Rear Axle Assembly ...................................247 RH Axle .....................................................247 LH Axle.......................................................248 Rear Propeller Shaft...................................248 Rear Hub ....................................................249 Wheel Bearing............................................249 Rear Differential .........................................249 Rear Differential Disassembly ....................251
Drive Train Table of Contents - 231
DRIVE TRAIN TABLE OF CONTENTS
Drive Train Table of Contents - 232
DRIVE TRAIN SPECIFICATIONS Specifications Required Tools Special or Required Tools Tool Name
Tool No.
Pliers (Oetiker 1090) (CV Boot Clamp)
295 000 069
Pliers (Caillau)
295 000 054
Tool Use
Recommended Tools Special or Required Tools Tool Name Valve Spring Compressor
Tool No. JDM70
Tool Use Used to remove and install valve springs.
Shock Absorber Tool Shock Absorber Spring Compressor 41 mm Socket
Drive Train Specifications - 233
DRIVE TRAIN REPAIR Repair Front Drive Shaft Removal: Raise the front of vehicle, support it securely on jack stands and remove front wheel(s).
4
Remove wheel cap no. 13, cotter pin no. 12, castellated nut no. 11, flat washer no. 10 and O-ring no. 14.
1 2
3 1 2 V01H0EA
v01h0ea2.EPS
Typical
V01H0DA
v01h0da2.EPS
Check the O-ring for damage, replace if necessary Remove caliper. IMPORTANT: Avoid damage! Donâ&#x20AC;&#x2122;t let the caliper hang by the hose and donâ&#x20AC;&#x2122;t stretch or twist the hose. Remove cotter pin and castellated nut from upper and lower suspension arms. IMPORTANT: Avoid damage! Discard cotter pins. Always install new cotter pins.
A B C D
- Castellated Nut(1) - Cotter Pin (2) - Lower Suspension Arm (3) - Upper Suspension Arm (4)
Detach tie-rod from knuckle. Separate knuckle no. 8, with hub and brake disk no. 9, from lower and upper suspension arms. Separate knuckle from the drive shaft no. 7. Pull drive shaft out of differential no. 1. NOTE: Pull drive shaft strongly. Inspection: Inspect the condition of boots. If there is any damage or evidence of leaking lubricant, replace them. Refer to Drive Shaft Boot below. Installation: Apply grease to the splines and insert the end of drive shaft in differential and pull joint a little to make sure that the stop ring is locked in differential side gear groove.
Drive Train Repair - 234
DRIVE TRAIN REPAIR
V01H0FA
1 v01h0fa2.EPS
A - Stop Ring (1) Insert the other end of drive shaft in the knuckle and install the knuckle, with hub and brake disk, to the lower and upper suspension arms. Torque the castellated nut to 47 N•m (35 lb-ft) and install a new cotter pin. Reinstall tie-rod. Install a hardened washer on each side of the knuckle arm. Torque tie-rod castellated nut to 73 N•m (54 lb-ft) then install a new cotter pin. Install the O-ring, the flat washer and torque the castellated nut on the drive shaft end to 135 - 155 N•m (100 - 114 lb-ft). Install a new cotter pin and the wheel cap. Reinstall the front wheel(s) and torque nuts to 75 N•m (55 lb-ft).
V01H0XA
2
1 V01h0xa2.EPS
A - Circlip (1) B - Shaft (2) Remove boot from drive shaft. Inspection: Check bearing in plunging joint or CV joint. If bearing is hard to move, change plunging joint or CV joint. Check circlip for damage, change as necessary.
Drive Shaft Boot Removal:
Installation:
Remove:
For installation, reverse the removal procedure. Paying attention to the following details.
• clamps from rubber boot using boot clamp pliers (P/N JDG 295 000 069 and 295 000 054) •
large end of the boot from plunging joint or CV joint.
Move apart circlip and pull out the shaft from bearing. Do not remove circlip.
Insert boot, do not forget the small clamp. Insert shaft and push firmly. Pack bearing area with grease (including with the new boot kit). NOTE: Do not use an other grease.
Front Differential Removal: Raise front of vehicle, support it securely on jack stands and remove front wheels. On LH side, remove: •
wheel cap no. 13
•
cotter pin no. 12
•
castellated nut no. 11
•
flat washer no. 10
•
O-ring no. 14.
Drive Train Repair - 235
DRIVE TRAIN REPAIR On RH side, remove drive shaft. Remove inner fender. Unscrew propeller shaft bolt no. 19. Differential side only. On front side, remove: •
front skid plate
•
differential mounting bracket bolt no. 4
•
front mounting bolt no. 3
•
rear mounting bolt no. 5
•
differential brace no. 6
•
differential mounting bracket no. 2.
3
1 V01H0IA
v01h0ia2.EPS
Remove front differential by the RH side. Separate LH drive shaft from differential. Inspection: Turn front differential gear with a finger; it should turn smoothly. Replace if necessary. With drive shafts installed, check backlash and axial play.
2
Backlash Measurement and Adjustment NOTE: Backlash adjustment is the last procedure to do before the final re-assembly of a differential.
4
Temporarily re-assemble the differential. Install a drive shaft in vise then place the differential on the drive shaft end.
V01H0GA
v01h0ga2.EPS
A B C D
- Front Mounting Bolt M10 x 200 (1) - Differential Mounting Bracket Bolts (2) - Differential Mounting Bracket (3) - Rear Mounting Bolt M10 x 60 (4)
Remove rubber bellows no. 15 on the top from the front differential. Pull differential forward then separate propeller shaft no. 16 from differential.
V04H0JA
V04h0JA2.EPS
NOTE: The drive shaft prevents the gears from moving. Install a backlash measurement tool at the end of the pinion
Drive Train Repair - 236
DRIVE TRAIN REPAIR gear.
90°
V04H0MA
V04h0mA2.EPS
V04H0KA
The reading on the dial indicator gives the backlash.
1 V04h0kA2.EPS
A - Backlash Measurement Tool (1) From center of bolt, measure 25.4 mm (1 in) and scribe a mark on the tab.
To be acceptable, the backlash must be between 0.102 and 0.356 mm (0.004 and 0.014 in). If the backlash is not within specifications, disassemble the differential and reposition the shims of the ring gear carrier accordingly in order to move it either closer to or further away from the pinion. The backlash is adjusted by moving shims from one end of the ring gear carrier to the other as required.
1
IMPORTANT: Avoid damage! Never eliminate any shims, simply move them from one end to the other to be able to move the ring gear carrier either closer to or further away from the pinion in order to get the correct backlash.
2 A
Moving ring gear carrier closer to the pinion will decrease backlash. Moving it further away from the pinion will increase backlash. Re-assemble the differential and check the backlash again. Repeat the procedure until the backlash is within specifications.
V04H0LA
V04h0lA2.EPS
A - Tab of Backlash Measurement Tool (1) B - Mark on Tab (2) C - 25.4 mm (1 in.) (A)
After obtaining the proper backlash, do the final reassembly. Disassembly:
NOTE: This measure is equal to the radius of pinion gear and is used where no specification is available.
Ring Gear Carrier/Ring Gear Removal:
Position the dial indicator tip against the tab at a 90-degree angle and right on the previously scribed mark.
•
Gently move the pinion shaft back and forth.
To change ring gear carrier no. 21 or ring gear no. 22: Unscrew the drain plug no. 23 and empty differential.
• Unscrew the TORX screws no. 24, then separate half housings. • Extract ring gear carrier with ring gear out of half housing. •
Unscrew Allen socket screws no. 25 then separate ring
Drive Train Repair - 237
DRIVE TRAIN REPAIR gear from ring gear carrier. To assembly, reverse the removal procedure. Pay attention to the following details. NOTE: NOTE: If ring gear carrier, pinion gear, ring gear, housing or bearing is (are) changed, recenter the ring gear carrier in the housing before final assembly. See PINION GEAR AND RING GEAR CARRIER RECENTERING below. Verify condition of half housing seal no. 26. Change seal if necessary. Check all bearings and all oil seals. Change them if necessary.
V04H06A
Pinion Gear Removal:
V04h06a2.EPS
Remove oil seal no. 27. Unscrew the pinion nut no. 28. Use a differential spanner socket.
Subtract measure “B” from measure “A”. Note this result “C”. A-B=C
Remove the bearing no. 29 at the same time as the pinion gear no. 30.
Remove ring gear carrier then install pinion gear into housing.
NOTE: The pinion gear and bearing can be easily removed using the following suggested tool:
Measure distance between mounting surface and the pinion shim surface. This is measure “D”.
•
pipe 3-1/2” dia. x 5” (1)
•
threaded rod M10 x 1.25, 7” in length (1)
•
nut M10 x 1.25 (3)
•
flat bar (1)
To install, reverse the removal procedure. Paying attention to the following details. Check O-ring no. 31 for damage. If so, change it. Install the shim no. 32 then the ball bearing. NOTE: If ring gear carrier, pinion gear, ring gear, housing or bearing is (are) changed, recenter the ring gear carrier in the housing before final assembly. See below. Install the nut and a new oil seal. Pinion Gear and Ring Gear Carrier Recentering:
V04H07A
V04h07a2.EPS
Remove pinion gear then measure the distance between mount surface and bearing surface. This is measure “E”.
NOTE: All measurements require great care and absolute cleanliness to obtain accurate results. First; center pinion gear. Install pinion gear into housing. Measure distance between mount surface and the top of pinion gear. This is measure “A”. Remove pinion and install ring gear carrier with ring gear installed. Measure distance between mount surface and the top of ring gear. This is measure “B”. Drive Train Repair - 238
DRIVE TRAIN REPAIR V01h1Da2.EPS
Measure the other half housing between housing edge and the inner ring of bearing. This is measure “H”.
V04H08A
V04h08a2.EPS
Subtract measure “E” from measure “D”. Note this result “F”.
V01H1EA
D-E=F
V01h1Ea2.EPS
The difference between result “F” and result “C” is the pinion shims thickness.
Measure the edge of half housing. This is measure “J”.
F - C = Pinion shims thickness Determine the appropriate pinion shim using the following pinion gear shims kit (P/N JDG 703 500 049). Thickness 0.25 mm (0.010 in) 0.38 mm (0.015 in) 0.51 mm (0.020 in) 0.56 mm (0.022 in)
Notches 0 1 2 4
Install pinion, shims, bearing and pinion nut. Apply Loctite 243 to nut and torque to 98 N•m (72 lb-ft). Check if pinion gear teeth and ring gear teeth are equal. After pinion installation, center ring gear carrier. Take the half housing with pinion gear. Measure distance between housing edge and the inner ring of bearing. This is measure “G”.
V01H1FA
V01h1Fa2.EPS
Subtract the measure “J” from measure “H” then add this result to “G”. Note this result “K”. G + (H - J) = K (housing inside length) Measure ring gear carrier length. This is measure “L”.
V01H1DA
Drive Train Repair - 239
DRIVE TRAIN REPAIR
V01H1GA
V01H1IA
V01h1Ga2.EPS
Measure the distance between the end of ring gear carrier and the bearing shoulder. Note this measure “M”.
V01h1Ia2.EPS
Add measure “M” from measure “N”. Subtract this result from measure “L”. Note this result “P”. The result “P” is the length of ring gear carrier between bearings. L - (M + N) = P Subtract result “P” from “K”. At this measure subtract the clearance 0.127 mm (0.005 in). The result is the shim thickness. K - P = X - 0.127 mm (0.005 in) = shim thickness
V01H1HA
V01h1Ha2.EPS
Take the same distance to the other end. This is measure “N”.
Thickness 0.25 mm (0.010 in) 0.38 mm (0.015 in) 0.51 mm (0.020 in) 0.64 mm (0.025 in) 0.56 mm (0.022 in)
Notches 0 1 2 3 4
Determine the appropriate shim using the following ring gear carrier shims kit. Distribute total shim thickness between both end of ring gear carrier to obtain specified backlash between ring gear and pinion gear.
Drive Train Repair - 240
DRIVE TRAIN REPAIR
E
B
J H
A
D
G
V01H1JS
V01h1Js2.EPS
Front Differential Oil Level:
Assembly and Installation:
Clean filler plug prior to check oil level.
The differential assembly is essentially the reverse of the disassembly procedure. Pay attention to the following detail.
With vehicle on a level surface, check oil level by removing filler plug. Oil level must reach the lower edge.
Install the differential on the vehicle before filling oil. Refer to "Specifications" section for recommended oil.
Add oil if necessary. Refer to "Specifications" section for capacity and recommended oil.
Drive Train Repair - 241
DRIVE TRAIN REPAIR Front Differential Oil Change:
Inspection:
Place vehicle on a level surface. Set transmission in park position.
Check propeller shaft for wear or damage, replace if necessary.
Lift LH side of vehicle.
Installation:
Clean drain plug area.
Installation is the reverse of removal procedure.
Place a drain pan under differential drain plug area. Remove drain plug.
NOTE: Secure propeller shaft with a new self-locking screw no. 19. Use Loctite 271 on M8 screw no. 18.
Unscrew filler plug.
Wheel Hub Removal: Raise front of vehicle, support it securely on jack stands and remove front wheel(s). Remove wheel cap, cotter pin, castellated nut, flat washer and O-ring. NOTE: Check O-ring for damage, replace if necessary. Use hub puller to extract the wheel hub.
V01H0WA
1
2 V01h0wa2.EPS
A - Drain Plug (1) B - Filler Plug (2) Clean drain plug area then reinstall plug. Lower vehicle. Use a funnel and refill front differential at the proper level with the recommended oil. Refer to "Specifications" section. Reinstall filler plug.
V04H0FA
V04h0fA2.EPS
Front Propeller Shaft
Inspection:
Removal:
Check O-ring for damage, replace if necessary.
Remove: â&#x20AC;˘
engine skid plate
â&#x20AC;˘
RH inner fender.
Check wheel hub taper for scratches or other damages. Replace hub if necessary.
Remove propeller shaft bolts and flat washers. One on engine side no. 17 and 18, one on differential side no. 19 and 20. Discard bolts. Remove rubber bellows no. 15 on the top from the front differential. Pull differential forward then separate propeller shaft no. 16 from differential and engine.
Check wear sleeve no. 33 for friction surface damage. Replace wear sleeve if damaged. Installation: The installation is the reverse of removal procedure but paying attention to the following details. Use a press machine to insert wheel hub into knuckle. Check if bearing turns smoothly. Always install new cotter pins.
Drive Train Repair - 242
DRIVE TRAIN REPAIR Knuckle
Installation:
NOTE: It is possible to remove the knuckle with the wheel hub assembly. To do so, remove the castellated nut retaining drive shaft and continue the following procedure without removing hub.
Place new bearing in a freezer for 10 minutes before installation.
Removal:
Press bearing into knuckle.
Remove hub.
When the knuckle is cold, apply synthetic grease on bearing then install the new seals.
Remove cotter pin and castellated nut from upper and lower A-arms. Detach upper and lower A-arms from knuckle.
Place the knuckle in oven to 100°C (212°F) for a half hour maximum to ease bearing installation.
Install the other parts in the reverse order of removal procedure.
Remove cotter pin and castellated nut from tie-rod and separate tie-rod from knuckle. Separate knuckle from drive shaft. Inspection: Inspect knuckle for damage. If any damage is detected, change the knuckle. Installation: For installation, reverse the removal procedure. Pay attention to the following details. Reinstall front wheel(s) and torque nuts to 75 N•m (55 lb-ft) in a criss-cross sequence. NOTE: Do not interchange left and right tires. Install them according to rotation mark on their sidewall.
Wheel Bearing Inspection: Raise front of vehicle. NOTE: First check suspension ball joints play. Perform all repairs before checking the wheel bearing condition. Be careful not to mistake suspension ball joint play for wheel bearing play. Take tire by the top and the bottom. Check lateral play. If there is any play, change wheel bearing. Removal: Separate wheel hub from knuckle. Remove: •
knuckle
•
seals and circlip.
Place knuckle on a workshop press. Remove and discard bearing.
Drive Train Repair - 243
DRIVE TRAIN FRONT DRIVE Front Drive Front Drive Components Loctite 271
35 N m (26 lbf ft) 17
18 13
Quest Series 42 N m (31 lbf ft) 19 20
12 14 33
11
10
35 36
8
Synthetic grease
23 N m (17 lbf ft) 4
16
7
135-155 N m 34 (100-114 lbf ft)
18
15
Loctite 271 34
17 35 N m 19 (26 lbf ft) 42 N m (31 lbf ft)
20
5 62 N m (46 lbf ft)
1
Traxter Series
6 62 N m (46 lbf ft) 2
3
36 N m (27 lbf ft) 25
24 33 N m (24 lbf ft) 26
13 N m (115 lbf in) 23
21 22 95 N m (70 lbf ft) 28
32
27 30
31
29
Loctite 243
V04H0NS
V04h0nsa2.EPS
Drive Train Front Drive - 244
DRIVE TRAIN REAR AXLE Rear Axle Rear Axle Components 13
18 19
11 135-155 N m 12 (100-114 lbf ft)
17 5
20 10
50 N m (37 lbf ft) 9
16
Quest
8 4
14 34 N m (25 lbf ft)
48 N m (35 lbf ft)
Traxter Loctite 243
15
26 28
42 N m (31 lbf ft)
29
25 30
22 20-25 N m (15-18 lbf ft)
27
25 N m (18 lbf ft)
6 75 N m (55 lbf ft)
95 N m (70 lbf ft)
21 24
23 33 N m (24 lbf ft)
25 N m (18 lbf ft) 1 2 10 20
7
3
18 12 135-155 N m 11 (100-114 lbf ft)
19
13
V04H0OS
V04H0OSA2.EPS
Typical
Drive Train Rear Axle - 245
DRIVE TRAIN REAR AXLE General The rear axle assembly has two axles, a differential, a hitch and a differential protector. Each axle assembly consists of an axle, a housing and two bearings. During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying thread locker.
Model
Capacity
Recommended oil
All models
200 mL (6.8 U.S. oz)
80W90 (API GL5)
Rear Differential Oil Replacement Ensure vehicle is on a level surface. Clean drain plug area. Place a drain pan under rear differential drain plug area.
IMPORTANT: Avoid damage! Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
Unscrew filler plug. Remove drain plug.
Rear Differential Oil Level Park machine on a level surface. Clean filler plug prior to check oil level. Check oil level by removing filler plug. Oil level must be between 25 and 32 mm (1.0 and 1.25 in.) below lower edge of filler hole. It is possible to verify the oil level by inserting a wire with a 90° bend through the filler hole.
V04H02B
1
2 V04h02b2.EPS
A - Drain Plug (1) B - Filler Plug (2) Clean drain plug area then reinstall drain plug. IMPORTANT: Avoid damage! Do not overfill differential. Overfilling may result in oil leaking from the differential vent bellows. When filling the differential it is easier to measure the correct quantity of oil before adding it than to measure the oil level to reach the proper level.
V04H02A
Oil level must be between 25 and 32 mm (1.0 and 1.25 in.) below lower edge of filler hole.
1 V04h02a2.EPS
A - Filter Plug (1) IMPORTANT: Avoid damage! Do not overfill differential. Overfilling may result in oil leaking from the differential vent bellows.
Use a funnel and refill rear differential at the proper level with recommended oil. See “Rear Differential Oil Level” above. Reinstall filler plug.
Add or drain oil if necessary.
Drive Train Rear Axle - 246
DRIVE TRAIN REAR AXLE Rear Axle Assembly Removal: Lift rear of the vehicle until rear shock absorbers are fully extended. Install jack stands under frame to support vehicle. Remove rear wheels. Remove lower shock absorber bolts. Remove rear brake caliper and detach brake hose from bracket on rear axle. IMPORTANT: Avoid damage! Don’t let caliper hang by the hose and don’t stretch or twist brake hose.
1
V04H04A
V04h04a2.EPS
LH Side
Unscrew bolts no. 6 and no. 9 retaining rear axle assembly to swing arm. See the following illustrations.
A - Remove these bolts (1) Detach rear axle assembly from swing arm.
1
Installation: Installation is essentially the reverse of removal procedure. Paying attention to the following details. Apply grease on the end of propeller shaft. Install all bolts before torquing. On the LH side, torque the hexagonal bolts no. 9 in a crisscross sequence. See the following illustration.
4
3
2 1 V04H03A
2
3 V04h03a2.EPS
RH Side A B C D
- Remove these bolts (1) - Swing Arm (2) - Differential Protector (3) - Rear Differential (4)
V04H04B
1
4 V04h04b2.EPS
Torque to 48 N•m (35 lb-ft)
RH Axle RH Axle Housing Removal: Lift rear of the vehicle. Install jack stands under swing arm. Remove: •
wheel and wheel cap
•
cotter pin no. 13
Drive Train Rear Axle - 247
DRIVE TRAIN REAR AXLE NOTE: Discard the cotter pin. At installation, use a new cotter pin.
Unfasten TORX head screws no. 8 retaining LH axle housing no. 4 from rear differential.
•
castellated nut no.11
Remove axle housing then pull out axle no. 5.
•
flat washer no. 12
Inspection:
•
caliper
Check axle housing for wear or other damage, replace if necessary.
IMPORTANT: Avoid damage! Don’t let caliper hang by the hose and don’t stretch or twist brake hose. •
rear differential protector no. 1
•
lower bolt retaining RH shock from axle housing.
Unfasten TORX head screws no. 6 and no. 7 retaining RH axle housing no. 2 from rear differential.
Check axle for wear, cracks, bend, spots of rust, or other damage. Change the axle if any problem is detected. Check all axle housing ball bearings for excessive play and smooth operation. Replace if necessary. Installation:
Remove axle housing then pull out axle no. 3.
For installation, reverse the removal procedure. paying attention to the following details.
Inspection:
Apply grease on splines.
Check axle housing for wear or other damage, replace if necessary.
Torque castellated nut no. 11 to 135-155 N•m (100-114 lbft).
Check axle for wear, cracks, bend, spots of rust, or other damage. Change the axle if any problem is detected.
NOTE: NOTE: Always install a new cotter pin when the axle is reinstalled.
Check all axle housing ball bearings no. 10 for excessive play and smooth operation. Replace if necessary.
Rear Propeller Shaft
Installation:
Removal:
For installation, reverse the removal procedure. paying attention to the following details.
Remove swing arm with rear axle assembly. Refer to REAR SUSPENSION.
Apply grease on splines.
Remove the propeller shaft bolt no. 14 and flat washer.
Torque castellated nut no.11 to 135-155 N•m (100-114 lbft).
Separate rear propeller shaft no. 16 from engine.
NOTE: Always install a new cotter pin when the axle is reinstalled.
LH Axle Lift rear of the vehicle. Install a jack stand under swing arm and another under rear differential. Remove: wheel and wheel cap
•
cotter pin no. 13
Check yoke U-joint no. 17 for wear, backlash or axial play, replace if necessary. Inspect engine seal for damage or leak. Replace if necessary.
LH Axle Housing Removal:
•
Inspection:
Installation: Installation is essentially the reverse of removal procedure. Pay attention to the following details. Apply grease to splines of transmission output shaft. Apply grease to splines before inserting the end of the propeller shaft into differential.
NOTE: Discard the cotter pin. At installation, use a new cotter pin.
Grease U-joint from rear propeller shaft. Use a grease gun with SHELL, Alvania EP-2 grease only.
•
castellated nut no.11
Rear Propeller Shaft U-Joint:
•
flat washer no. 12
•
rear differential protector no. 1
Follow the same procedure as for the front propeller shaft U-joint.
•
lower bolt retaining LH shock from axle housing.
Refer to FRONT DRIVE subsection.
Drive Train Rear Axle - 248
DRIVE TRAIN REAR AXLE Rear Hub
c CAUTION: Avoid Injury! Remove all grease or
Removal:
oil on and in housing before heat.
NOTE: Replace bearings when rear hub is removed.
Install bearing in housing.
Lift rear of the vehicle until rear shock absorbers are fully extended. Install jack stands under frame to support vehicle.
When housing is cold, apply synthetic grease on bearings then install circlip and new seal.
Remove:
Install the other parts in the reverse order of removal procedure.
•
rear wheel(s)
•
caliper (RH side only)
Note that oil seals no. 19 must be installed with their metal shield facing differential.
IMPORTANT: Avoid damage! Don’t let caliper hang by the hose and don’t stretch or twist hose. •
Removal:
cotter pin no. 13
NOTE: Discard the cotter pin. At installation, use a new cotter pin. •
castellated nut no.11
•
flat washer no. 12.
Rear Differential Remove the rear axle from swing arm. Remove the rear differential protector no. 1. Unscrew all TORX screws no. 6 and no. 8 retaining axle housings no. 2 and no. 4 to differential.
Using a hub puller, pull out hub (with brake disc on RH side). Installation: Installation is essentially the reverse of the removal procedure.
Backlash Procedure: NOTE: Backlash adjustment is the last procedure to do before the final re-assembly of a differential. Temporarily, re-assemble the differential. Install a drive shaft in vise then place the differential on the drive shaft end.
Wheel Bearing Inspection: Raise rear of vehicle. Take tire by the top and the bottom. Check lateral play. If there is any play, change wheel bearing. Removal: Separate wheel hub no. 18 from housing no. 2 or no. 4. Remove: •
housing no. 2 or no. 4
•
rear axle no. 3 or no. 5
•
seal no. 19 and circlip no. 20.
V04H0JA
V04h0JA2.EPS
Use a tube, around 60 cm x 65 mm (24 in x 2.5 in), to push the bearings out of housing. Use a workshop press.
NOTE: The drive shaft prevents the gears from moving.
Installation:
Install a backlash measurement tool at the end of the pinion gear.
Place new bearing in a freezer for 10 minutes before installation. Place the housing in an oven. Heat it to 100°C (212°F) for a half hour maximum to ease bearing installation.
Drive Train Rear Axle - 249
DRIVE TRAIN REAR AXLE
90°
V04H0MA
V04H0KA
V04h0mA2.EPS
1 V04h0kA2.EPS
The reading on the dial indicator gives the backlash. To be acceptable, the backlash must be between 0.102 and 0.356 mm (0.004 and 0.014 in).
A - Backlash Measurement Tool (1) From center of bolt, measure 25.4 mm (1 in) and scribe a mark on the tab.
1 2 A
If the backlash is not within specifications, disassemble the differential and reposition the shims of the ring gear accordingly in order to move it either closer to or further away from the pinion. The backlash is adjusted by moving shims from one side of the ring gear to the other as required. IMPORTANT: Avoid damage! Never eliminate any shims, simply move them from one end to the other to be able to move the ring gear either closer to or further away from the pinion in order to get the correct backlash. Moving ring gear closer to the pinion will decrease backlash. Moving it further away from the pinion will increase backlash.
V04H0LA
V04h0lA2.EPS
A - Tab of Backlash Measurement Tool (1) B - Mark on Tab (2) C - 25.4 mm (1 in.) (A)
Re-assemble the differential and check the backlash again. Repeat the procedure until the backlash is within specifications. After obtaining the proper backlash, do the final reassembly.
NOTE: NOTE: This measure is equal to the radius of pinion gear and is used where no specification is available. Position the dial indicator tip against the tab at a 90-degree angle and right on the previously scribed mark. Gently move the pinion shaft back and forth.
Drive Train Rear Axle - 250
DRIVE TRAIN REAR AXLE Rear Differential Disassembly
First; center pinion gear. Install pinion gear into housing.
Ring Gear Removal:
Measure distance between mount surface and the top of pinion gear. This is measure “A”.
To change ring gear no. 21: •
Unscrew the drain plug no. 22 and empty differential.
• Unscrew the TORX screws no. 23, then separate half housings. •
Remove pinion and install ring gear. Measure distance between mount surface and the top of ring gear. This is measure “B”.
Extract ring gear out of half housing.
To assembly, reverse the removal procedure. Paying attention to the following details. NOTE: NOTE: If pinion gear, ring gear, housing or bearing is (are) changed, recenter the ring gear in the housing before final assembly. See PINION GEAR AND RING GEAR RECENTERING below. Verify condition of half housing seal no. 24. Change seal if necessary. Check all bearings and all oil seals. Change them if necessary. Pinion Gear Removal:
V04H06A
Unscrew bolt no. 15 retaining the coupling sleeve to differential.
V04h06a2.EPS
Remove oil seal no. 25.
Subtract measure “B” from measure “A”. Note this result “C”.
Unscrew the pinion nut no. 26.
A-B=C
Remove the bearing no. 27 at the same time as the pinion gear no. 28.
Remove ring gear then install pinion gear into housing.
NOTE: The pinion gear and bearing can be easily removed using the following suggested tool: •
pipe 3-1/2” dia. x 5” (1)
•
Threaded rod M10 x 1.25, 7” in length (1)
•
nut M10 x 1.25 (3)
•
flat bar (1).
Measure distance between mounting surface and the pinion shim surface. This is measure “D”.
To install, reverse the removal procedure. Paying attention to the following details. Check O-ring no. 29 for damage. If so, change it. Install the shim no. 30 then the ball bearing. NOTE: If pinion gear, ring gear, housing or bearing is (are) changed, recenter the ring gear in the housing before final assembly. See below.
V04H07A
V04h07a2.EPS
Remove pinion gear then measure the distance between mount surface and bearing surface. This is measure “E”.
Install the nut and a new oil seal. Torque a new bolt no. 15 to 42 N•m (31 lb-ft). Pinion Gear and Ring Gear Recentering: NOTE: All measurements require great care and absolute cleanliness to obtain accurate results.
Drive Train Rear Axle - 251
DRIVE TRAIN REAR AXLE
V04H08A
V04H09A
V04h08a2.EPS
Subtract measure “E” from measure “D”. Note this result “F”.
V04h09a2.EPS
Measure the other half housing between housing edge and the inner ring of bearing. This is measure “H”.
D-E=F The difference between result “F” and result “C” is the pinion shims thickness. F - C = Pinion shims thickness Determine the appropriate pinion shim among the following pinion gear shim kit. Thickness 0.25 mm (0.010 in.) 0.38 mm (0.015 in.) 0.51 mm (0.020 in.) 0.56 mm (0.022 in.)
Notches 0 1 2 4
Install pinion, shims, bearing and pinion nut. Apply Loctite 243 to nut and torque to 98 N•m (72 lb-ft). Check if pinion gear teeth and ring gear teeth are equal.
V04H0AA
V04h0Aa2.EPS
Measure the edge of half housing. This is measure “J”.
After pinion installation, center ring gear. Take the half housing with pinion gear. Measure distance between housing edge and the inner ring of bearing. This is measure “G”.
V04H0BA
V04h0Ba2.EPS
Subtract the measure “J” from measure “H” then add this result to “G”. Note this result “K”. G + (H - J) = K (housing inside length)
Drive Train Rear Axle - 252
DRIVE TRAIN REAR AXLE Measure ring gear length. This is measure “L”.
V04H05A
V04h05a2.EPS V04H0CA
V04h0Ca2.EPS
Measure the distance between the end of ring gear and the bearing shoulder. Note this measure “M”.
Add measure “M” from measure “N”. Subtract this result from measure “L”. Note this result “P”. The result “P” is the length of ring gear between bearings. L - (M + N) = P Subtract result “P” from result “K”. At this measure subtract the clearance 0.127 mm (0.005 in.). This is the shim thickness. K - P = X - 0.127mm (0.005 in.) = shim thickness Determine the appropriate shim among the following ring gear shim kit. Thickness 0.25 mm (0.010 in.) 0.38 mm (0.015 in.) 0.51 mm (0.020 in.) 0.64 mm (0.025 in.) 0.56 mm (0.022 in.)
V04H0DA
V04h0Da2.EPS
Take the same distance to the other end. This is measure “N”.
Notches 0 1 2 3 4
Distribute total shim thickness between both end of ring gear to obtain specified backlash between ring gear and pinion gear.
Drive Train Rear Axle - 253
DRIVE TRAIN REAR AXLE
E
B
J H
A
G
V01H1JS
V01h1Js2.EPS
Assembly and Installation: The rear differential assembly is essentially the reverse of the disassembly procedure. Paying attention to the following detail. Install the rear differential on the vehicle before filling oil. Use specified oil, refer to "Specifications" section.
Drive Train Rear Axle - 254
D
STEERING TABLE OF CONTENTS Steering
Table of Contents
Specifications ...............................................257 Steering Control Specifications ..................257 Recommended Tools .................................257 Component Location....................................258 Steering System .........................................258 Repair.............................................................259 General.......................................................259 Handlebar Grip ...........................................259 Handlebar ..................................................259 Steering Column.........................................259 Tie-Rod.......................................................260 Steering Column Bearing ...........................260 Multi-Function Switch .................................261 Throttle Handle Housing.............................261 LH Brake Handle ........................................262 RH Master Cylinder ....................................262
Steering Table of Contents - 255
STEERING TABLE OF CONTENTS
Steering Table of Contents - 256
STEERING SPECIFICATIONS Specifications Steering Control Specifications Turning Radius 2-Wheel Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2130 mm (84 in.) Turning Radius 4-Wheel Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 mm (83 in.) Total Toe (vehicle on ground) Each Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ± 4 mm (0.315 ± 0.157 in.) Camber Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0° Tie-Rod Maximum Length Unengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 5 mm (0.787 ± 0.197 in.)
Recommended Tools Special or Required Tools Tool Name
Tool No.
Shock Absorber Tool Shock Absorber Spring Compressor
Steering Specifications - 257
Tool Use
STEERING COMPONENT LOCATION Component Location
Steering System 3
1
5 N m (44 lbf in) 26
7 0.4 N m (3.5 lbf in) 5 6 Loctite 406 8
24 N m (18 lbf ft)
17
16 65-80 N m (43-59 lbf ft) 22
13
20
18 19 20 21 22
18 19 20 21 22 34 N m (25 lbf ft) 25
Loctite 243 19 N m (168 lbf in)
11 19 65-80 N m (43-59 lbf ft)
2
14
15
12
24
18
4
16
23
20
6
13 22 34 N m (25 lbf ft)
9
10 65-80 N m (43-59 lbf ft)
20
20 18
V01I1YS
V01I1YSA2.EPS
Steering Component Location - 258
65-80 N m 19 (43-59 lbf ft)
STEERING REPAIR Repair
• throttle handle housing no. 3 and multi-function switch no. 4 (see below in this subsection)
General
• steering clamp mounting bolts no. 5 and steering clamp no. 6
During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying thread locker. IMPORTANT: Avoid damage! Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
cut grip using a knife for removal.
Inspect the handlebar for damage, cracks or bending, replace if any problems is detected. Installation: For the installation, reverse the removal procedure. Torque front steering clamps nuts first, then rear nuts.
Steering Column
•
Remove: •
Inspection:
Remove:
Removal: grip screw and end piece
handlebar no. 7.
Removal:
Handlebar Grip
•
•
front fender and steering cover (Refer to BODY/FRAME)
• steering clamp mounting bolts no. 5, steering clamp no. 6, handlebar no. 7 and steering cover support no. 8 • cotter pin no. 9, castellated nut no. 10 and flat washer no. 11 from bottom end of steering column no. 12.
Installation: Remove all rubber residues of the old grip and glue from handlebar. Clean the handlebar with parts cleaner or alcohol to remove any greasy matter on it.
Unfasten tie-rods no. 13 from steering column. Refer to TIE-ROD. Remove half housing bolts no. 14, stopper plates no. 15, half housings no. 16 and housing bushings no. 17. Pull steering column.
Install handlebar grip using compressed air. Install Smoothflow™ tapered tip on Loctite 406 glue bottle.
Inspection:
Lift grip edge using a metal tool and inject Loctite 406 (about 4 spots per end).
Inspect steering column for damage, cracks or bending, replace if any problems is detected.
NOTE: Loctite 406 dries quickly. Do not apply loctite 406 before installing grip.
Installation:
Apply pressure on the grip for approximately 30 seconds to set the glue.
Install a new cotter pin. Separate both halves of cotter pin. Fold them against a different nut flat.
For the installation, reverse the removal procedure.
Install end piece and grip screw. Torque grip screw to 0.4 N•m (3.5 lb-in.).
Handlebar Removal: Remove: •
steering cover (Refer to BODY/FRAME)
•
handlebar grips no. 1 as described above
• brake handle no. 2 and master cylinder. (see below in this subsection)
Steering Repair - 259
STEERING REPAIR Tie-Rod
Steering Column Bearing
Removal:
Removal:
Place the vehicle on jack stands and remove front wheel(s).
Place vehicle on jack stands and remove front wheels.
Remove cotter pins no. 18, castellated nuts no. 19, hardened washers no. 20 and flat washer no. 21.
Remove front fender. Refer to BODY/FRAME.
Inspection: Inspect ball joint ends for wear or looseness, if excessive, replace.
Separate tie-rods no. 13 from steering column no. 12. Refer to TIE-ROD. Remove cotter pin no. 9, castellated nut no. 10 and flat washer no. 11 from bottom end of steering column no. 12. Pull up steering column.
Installation:
Remove carriage bolts no. 23 and bearing flanges no. 24.
For the installation, reverse the removal procedure. Pay attention to the following details. At the time of reinstallation or of the new tie-rod(s) installation, screw threaded end of tie-rod into ball joint. The maximum length for tie-rod groove to ball joint end must be the value A in the following chart:
Remove bearing no. 25. Installation: For installation, reverse the removal procedure. Pay attention to the following details. Assemble bearing to bearing flanges. Flange collars of bearing flange must be facing outward.
B
V01I0YA
A
NOTE: Install both bearing flanges on top of frame support.
A
Install carriage bolts no. 23, apply Loctite 243 on threads. V01i0ya2.EPS
Model All
mm in.
A 20 ± 5 25/32 ± 3/16
B 311 ± 1 12-1/4 ± 1/32
Torque the ball joint lock nut no. 22 to 34 N•m (25 lb-ft). Torque ball joint nuts no. 19 to 65 - 80 N•m (48 - 59 lb-ft). Install new cotter pins. Separate both halves of cotter pin. Fold them against a different nut flat. Toe Adjustment: Place vehicle on level surface. Check that handlebar is straight. Use a long rule and check if the rear and front wheels are aligned.
V01I0NA
1
2 v01i0na2.EPS
Adjust alignment with tie-rod.
Both bearing flanges and bearing on top of frame
Adjust total toe-out to 8 mm ± 4 mm (0.315 in ± 0.157 in.).
A - Flange Collar (1) B - Bearing (2) Install a new cotter pin. Separate both halves of cotter pin. Fold them against a different nut flat.
Steering Repair - 260
STEERING REPAIR Multi-Function Switch
Throttle Handle Housing
Test:
Removal:
Refer to INSTRUMENTS AND ACCESSORIES for Hi-Lo Beam button.
Remove screws no. 26.
1
Refer to STARTING SYSTEM for engine stop switch and start button. Removal: Remove the two screws.
V01I0ZA
1
V01i0za2.EPS
A - Screws (1) Separate throttle handle housing no. 3 from handlebar no. 7. V04i04a2.EPS
A - Screws (1)
Remove throttle cable housing from throttle handle housing.
Separate multi-function switch no. 4 from handlebar no. 7.
3
Remove steering cover. Refer to BODY/FRAME.
2
4
1
Unplug multi-function switch connector. The connector is located under steering cover.
1
V01I10B
V01i10B2.EPS
MX31991
Under Steering Cover A - Multi-Function Switch Connector (1) Installation: For installation, reverse the removal procedure.
A B C D
- Throttle Handle Housing (1) - Throttle Cable Housing (2) - Throttle Cable Barrel (3) - Lever Slot (4)
Slide cable in lever slot and remove the cable barrel from the lever. Installation:
Steering Repair - 261
STEERING REPAIR For installation, reverse the removal procedure.
RH Master Cylinder
Refer to CARBURETOR AND FUEL PUMP for adjustment and lubrication procedure.
Removal: Remove screws.
LH Brake Handle Removal: Remove screws.
1 1
V01I11A
V01i11a2.EPS
A - Screws (1) V04I05A
Separate master cylinder from handlebar no. 7.
1 V04i05a2.EPS
Typical
If necessary, unplug connectors under steering cover and cut locking tie. Hose Removal:
A - Screws (1) Separate brake handle no. 2 from handlebar no. 7.
Refer to HYDRAULIC BRAKES for specific instructions.
If necessary, cut locking tie.
Installation:
Cable Removal:
For installation, reverse the removal procedure.
Refer to HYDRAULIC BRAKES for specific instructions. Installation: For installation, reverse the removal procedure.
Steering Repair - 262
SUSPENSION TABLE OF CONTENTS Suspension
Table of Contents
Specifications ...............................................265 Suspension Specifications .........................265 Recommended Tools .................................265 Component Location....................................266 Swing Arm ..................................................266 Repair.............................................................267 General.......................................................267 Rear Shock.................................................267 Swing Arm ..................................................268
Suspension Table of Contents - 263
SUSPENSION TABLE OF CONTENTS
Suspension Table of Contents - 264
SUSPENSION SPECIFICATIONS Specifications Suspension Specifications Front Suspension type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent Suspension - Double A-Arm Suspension Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 mm (7 in.) Shock Absorber Qty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Shock Absorber Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Spring Free Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 mm (11 in.) Spring Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Orange/Black/Black Front Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N.A. Rear Suspension type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rigid Swing Arm Suspension Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190.5 mm (7.5 in.) Shock Absorber Qty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Shock Absorber Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Spring Free Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 mm (6.3 in.) Spring Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red/Black Front Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Settings
Recommended Tools Special or Required Tools Tool Name
Tool No.
Shock Absorber Tool Shock Absorber Spring Compressor
Suspension Specifications - 265
Tool Use
SUSPENSION COMPONENT LOCATION Component Location
8
Swing Arm
3
7 6 48 N m (35 lbf ft)
2
6 4 147 N m (108 lbf ft) 14
1
4
1 5
11
5
10
6 48 N m (35 lbf ft) 1
Synthetic grease 6 48 N m (35 lbf ft)
9
10 11 Synthetic grease
147 N m (108 lbf ft) 12 13 11 N m (97 lbf in)
V01J0YS
V01J0Ysa2.EPS
Suspension Component Location - 266
SUSPENSION REPAIR Repair General During assembly/installation, use the torque values and service products as in the exploded views. IMPORTANT: Avoid damage! Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed. Clean threads before applying a thread locker.
Rear Shock
V01J0TA
V01j0ta2.EPS
Removal: Lift rear of vehicle until rear shock absorbers no. 1 are fully extended. Install jack stands or blocks under the frame to support the vehicle. Remove upper no. 4 and lower no. 5 bolts and nuts no. 6 retaining shock absorbers each side.
1
Disassembly: Use shock spring remover and put it in a vise. Mount shock in it and turn shock so that spring coils no. 3 match spring compressor. Close and lock bar. Adjust handle horizontal by changing position of clevis pin. Push down on handle until it locks. Remove spring stopper and cap then release handle.
1 1 2
2
V04J03A
2
3 V04j03a2.EPS
Typical A - Upper Bolts (1) B - Lower Bolts (2)
A01B4LA
A01b4la.eps
Typical A - Clevis Pin (1) Suspension Repair - 267
SUSPENSION REPAIR B - Bar (2) C - Handle Horizontal (3)
• Seizing or binding condition except at extreme end of either stroke.
At installation, cap opening no. 8 must be 180° from spring stopper opening no. 7.
•
Oil leakage.
• A gurgling noise, after completing one full compression and extension stroke. Renew if any faults are present. Installation: Assembly and installation are essentially the reverse of disassembly and removal procedures.
Swing Arm
1 2
Removal: All Models: Lift rear of vehicle until rear shock absorbers no. 1 are fully extended. Install jack stands or blocks under the frame to support the vehicle.
A03F12A
a03f12a.eps
Typical
Remove both side panels. On the EXT model, remove the both rear fenders too. Refer to BODY/FRAME. Remove lower nuts no. 6 and bolts no. 5 retaining shock to rear axle.
A - Cap Opening (1) B - Spring Stopper Opening (2)
4
Inspection:
1
Secure the shock body end no. 2 in a vise with its rod upward.
1
A14F0BA
a14f0ba.eps
Typical V04J04A
A - Clamp Here (1)
2
3
2 V04j04a2.EPS
IMPORTANT: Avoid damage! Do not clamp directly on shock body. Examine each shock for leaks. Extend and compress the piston several times over its entire stroke. Check that it moves smoothly and with uniform resistance with its rod upward. Pay attention to the following conditions that will denote a defective shock: • A skip or a hang back when reversing stroke at mid travel.
Typical A B C D
- Rear Brake Caliper (1) - Remove Bolts (2) - Brake Hose (3) - Swing Arm (4)
Temporarily, remove the RH rear wheel then unfasten rear brake caliper. Detach brake hose from brackets on rear axle tube and on swing arm.
Suspension Repair - 268
SUSPENSION REPAIR IMPORTANT: Avoid damage! Do not let caliper hang by the hose and do not stretch or twist brake hose. Reinstall rear wheel. Remove screws retaining master cylinder.
V04J06A
1 V04j06a2.EPS
1
V04J05A
Typical
2 V04j05a2.EPS
A - Pivot Bolt RH (1) Pull back rear drive train assembly to detach swing arm assembly from the frame and disengage the propeller shaft.
Typical A - Remove Bolts (1) B - Master Cylinder (2) Loosen jam nut no. 12. Unscrew and remove LH pivot bolt no. 13.
NOTE: Be careful not to damage rubber bellows (if so equipped). Separate the swing arm from rear axle. Refer to REAR AXLE. Inspection: Check condition of swing arm. Inspect for distortion or damage. Check oil seals no. 11 for wear or damage. Replace swing arm if necessary. Check condition of bearings no. 10. Make sure they turn smoothly. Replace if necessary. Ensure outer race of bearing fits tightly inside swing arm pivot.
V01J08A
2
3
Installation:
1 V01j08A2.EPS
Typical A - Swing Arm (1) B - Pivot Bolt LH (2) C - Jam Nut (3) Unscrew and remove RH pivot bolt no. 14.
Installation is essentially the reverse of removal procedure. However, pay attention to the following details. Join the rear axle and the swing arm together. See the REAR AXLE section for the proper procedure. Pack cone bearing cavities with synthetic grease. Apply grease to spring and splines before insert the end of the propeller shaft into swing arm.
Suspension Repair - 269
SUSPENSION REPAIR Push rear axle assembly toward the engine to engage propeller shaft splines and position the swing arm in the frame. NOTE: Insert rear propeller shaft into the right hole of the swing arm. Make sure to route the brake line over the swing arm. Line up cone bearing and install RH pivot bolt.
1
2
V01J0AA
V01j0AA2.EPS
A - RH Pivot Bolt (1) B - Pivot Bearing (2) Install LH pivot bolt. Move the swing arm up and down several times and tighten LH pivot bolt. Torque LH pivot bolt to 11 N•m (97 lb-in). Torque RH pivot bolt to 147 N•m (108 lb-ft). IMPORTANT: Avoid damage! The LH pivot bolt must have more than 2 threads out of jam nut. Install jam nut and torque to 147 N•m (108 lb-ft) while holding pivot bolt. Reinstall master cylinder. Check brake pedal adjustment. Refer to HYDRAULIC BRAKES for complete adjustment procedure. Fasten rear brake caliper. Route brake hose and secure to the brackets. Reinstall shock absorbers.
Suspension Repair - 270
HYDRAULIC BRAKES TABLE OF CONTENTS Hydraulic Brakes
Table of Contents
Specifications ...............................................273 Brakes Specifications .................................273 Recommended Tools .................................273 Component Location....................................274 Front Brakes...............................................274 Rear Brake .................................................275 Repair.............................................................276 General.......................................................276 Hydraulic Brakes System ...........................276 Parking Brake.............................................276 Brake Fluid .................................................276 Master Cylinder ..........................................278 Caliper ........................................................280 Brake Pads.................................................281 Brake Disc ..................................................282 Brake Lever ................................................283 Brake Pedal................................................283 Brake Cable................................................284 Brake Hoses...............................................285 Brake Light Switch......................................286
Hydraulic Brakes Table of Contents - 271
HYDRAULIC BRAKES TABLE OF CONTENTS
Hydraulic Brakes Table of Contents - 272
HYDRAULIC BRAKES SPECIFICATIONS Specifications Brakes Specifications Front Brake Qty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 discs Front Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Rear Brake Qty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 disc Rear Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Cable/Hydraulic Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Brake and Brake Lever Lock on LH Brake Lever Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floating Lining Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semi Metallic Minimum Pad Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.04 in.) Minimum Brake Disc Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 mm (0.18 in.) Maximum Brake Disk Warpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.01 in.)
Recommended Tools Special or Required Tools Tool Name Vacuum/Pressure Pump
Tool No.
Tool Use Used to replace brake fluid.
Shock Absorber Tool Shock Absorber Spring Compressor
Hydraulic Brakes Specifications - 273
HYDRAULIC BRAKES COMPONENT LOCATION Component Location 6 N m (53 lbf in)
Front Brakes 1 N m (9 lbf in)
1
2 3 4
8
24 N m 9 (18 lbf ft) 7 10
6
5
5 N m (44 lbf in)
11
5 N m (44 lbf in) 14
13 6 N m (53 lbf in) 17 25 N m 21 19 18 (18 lbf ft) 8
Loctite 243 17 N m (150 lbf in)
24 N m 16 (18 lbf ft)
20
15 12
19
22
34 N m (25 lbf ft)
23
V01K1OS
V01K1OSA2.EPS
Hydraulic Brakes Component Location - 274
HYDRAULIC BRAKES COMPONENT LOCATION Rear Brake 4 9 N m (80 lbf ft)
5 N m (44 lbf ft) 26
TRAXTER/XL/XT 25 N m (18 lbf ft) Loctite 243 15
25 6 N m (53 lbf in) 17
24
8
12
24
Pipe sealant
9
27 46
8
36
24 N m (18 lbf ft)
TRAXTER MAX series 22
Cable lubricant
Pipe sealant
18
Loctite 243
20 19 17 N m (150 lbf in)
24 N m (18 lbf ft) 16
35
34 N m (25 lbf ft)
23
25 N m (18 lbf ft) 28 29
32
37 39
40
31 42
38
39 41
Synthetic grease
TRAXTER MAX series
36
Synthetic grease
46
45 44
16
37
V01K1PS
V01K1Psa2.EPS
Hydraulic Brakes Component Location - 275
34
Other models
Synthetic grease
43
33
30
38
HYDRAULIC BRAKES REPAIR Repair
Brake Fluid
General
Recommended Fluid
During assembly/installation, use torque values and service products as in the exploded views.
Always use brake fluid meeting the specification DOT 4 only. IMPORTANT: Avoid damage! Use only DOT 4 brake fluid from a sealed container.
Clean threads before applying a thread locker.
Hydraulic Brakes System The brake system consists of two separate circuits. Each system has its own master cylinder and reservoir.
IMPORTANT: Avoid damage! Never use other type of oil, do not mix different types of brake fluid. Fluid Level
Both front and rear brakes are disc type. IMPORTANT: Avoid damage! Periodically check the brake hoses for damage or leaks. Repair any damage before operating the vehicle.
With vehicle on a level surface, check brake fluid in reservoir for proper level. It should be above MIN. mark. Add fluid as required. Do not overfill. Clean filler cap before removing.
Parking Brake The parking brake operates the rear brake only. It is activated by a locking mechanism on LH brake lever.
NOTE: A low level may indicate leaks or worn brake pads. Front Brake Fluid Reservoir Turn steering in the straight-ahead position to ensure reservoir is level. Check the brake fluid level, the reservoir is full when the fluid reaches the top of window. Visually inspect lever boot condition. Check for cracks, tears, etc. Replace if damaged.
2 1 MX30872
A - LH Brake Lever (1) B - Locking Mechanism (2)
V04K04A
V04k04a3.EPS
Rear Brake Fluid Reservoir Remove seat to gain access to reservoir.
Hydraulic Brakes Repair - 276
HYDRAULIC BRAKES REPAIR With vacuum pump: • Install a vacuum pump to bleed valve. See the manufacturer’s operating instructions. • Pump vacuum pump and loosen bleed valve. Close bleed valve and refill reservoir when the fluid level is low. NOTE: Check fluid level often to prevent air from being pumped into the system. • Repeat the procedure until no more air bubbles appear in bleed hose. NOTE: For the front brake system, switch to LH and RH caliper. Turn handlebar to full RH side when bleeding right caliper and turn to the LH side for the left caliper. This helps the bleeder to reach air into the caliper. • Close bleed valve and operate brake lever no. 4 or brake pedal no. 38. If it still feels spongy, bleed system again. • Repeat the procedures until air bubbles don’t appear in tube and lever or pedal is stiff.
V04C06A
V04c06a3.EPS
Brake Fluid Replacement:
•
Fill reservoir to the upper level with DOT 4 brake fluid.
•
Install diaphragm and cover on reservoir.
•
Without vacuum pump:
• If vacuum pump is not available, use the following procedure. •
c CAUTION: Avoid Injury! A contaminated brake disc or pas reduces stopping power. Discard contaminated pads and clean a contaminated disc with high quality brake degreasing agent.
IMPORTANT: Avoid damage! Avoid spilling brake fluid on plastic, rubber or painted parts. Protect these parts with a rag when servicing brake system. Brake Fluid Draining: Remove reservoir cover. On caliper, connect bleed hose to bleed valve no. 17. Loosen bleed valve and pump brake lever no. 4 or brake pedal no. 38 until no more fluid flows out of bleed valve.
Install a tube to bleed valve.
• Open bleeder. Fill reservoir and pump brake lever or brake pedal until fluid freely flows out of the tube. •
Close bleed valve.
• Pump up system pressure with brake lever or brake pedal until lever or pedal resistance is felt. • Squeeze brake lever or depress brake pedal, open bleed valve and then close it. NOTE: Do not release brake lever or brake pedal until bleed valve has been closed. For the front brake system, switch to LH and RH caliper. Turn handlebar to full RH side when bleeding right caliper and turn to the LH side for the left caliper. This helps to reach air into the caliper. NOTE: Release brake lever or brake pedal slowly. NOTE: Repeat the procedures until air bubbles do not appear in tube and lever or pedal is stiff.
Brake Fluid Filling and Bleeding: Close bleed valve. Fill reservoir with DOT 4 brake fluid. IMPORTANT: Avoid damage! Do not mix different types of brake fluid. Use only DOT 4 brake fluid. Bleed system as per the following procedure.
Hydraulic Brakes Repair - 277
HYDRAULIC BRAKES REPAIR Master Cylinder
2
1
Removal: Front Brakes: Remove reservoir cover no. 1 with diaphragm no. 2 and drain brake fluid from master cylinder no. 3. IMPORTANT: Avoid damage! Avoid spilling brake fluid on plastic, rubber or painted parts. Protect these parts with a rag when servicing brake system. Remove Banjo bolt no. 9 and sealing washers no. 8 retaining brake hose no. 10 to master cylinder. Remove screws from master cylinder holder and remove master cylinder from handlebar.
2
V04K08A
3 V04k08a2.EPS
Typical A - Brake Fluid Reservoir (1) B - Reservoir Cover (2) C - Flexible Hose (3) Raise rear of vehicle and support it securely. V01K12A
3
1
4
Remove RH wheel and RH side panel to allow access to rear brake master cylinder no. 28.
V01k12A2.EPS
Unplug rear brake switch.
Typical A B C D
- Oil Level Mark (1) - Banjo Bolt (2) - Sealing Washers (3) - Remove Screws (4)
Rear Brake: Remove seat to have access to master cylinder reservoir no. 28. Unscrew reservoir cover.
V04K09A
V04k09a2.EPS
Drain brake fluid from rear master cylinder.
Hydraulic Brakes Repair - 278
HYDRAULIC BRAKES REPAIR NOTE: At this time, check hoses and fittings for damages or leaks.
Inspection and Lubrication:
Disconnect flexible hose no. 15 from reservoir and plug the end to avoid brake fluid spillage.
Clean reservoir, master pistons and master cylinders thoroughly with clean brake fluid.
Remove Banjo bolt no. 9 and sealing washers no. 8 retaining brake hose no. 25 to master cylinder no. 28.
Check:
Discard sealing washers. Unhook push rod yoke no. 33 from brake pedal no. 38. Remove bolts no. 29 retaining master cylinder to frame.
Discard any remaining fluid inside reservoir.
•
boots for crack
•
springs for damage
•
piston cups for wear, deterioration or damage
• master cylinders and pistons for scoring, scratches or other damage. Change part(s) if necessary. Check locking pin no. 34 for excessive wear, replace if necessary.
2
1
NOTE: If master cylinder is damaged or leaking, replace as an assembly. Assembly: Front Master Cylinder: Coat master piston and piston cups with clean brake fluid. Install:
3
•
spring onto master piston
•
master piston into master cylinder
•
snap ring into groove in the master cylinder
•
boot into master cylinder and the groove in piston.
Apply silicone grease to the brake lever contacting surface of the piston.
V04K0AA
V04k0aa2.EPS
Typical
Install brake lever and locking mechanism. NOTE: Apply silicone grease on lever pivot bolt.
A - Master Cylinder (1) B - Rear Brake Hose (2) C - Rush Rod (3)
Rear Master Cylinder: For the rear master cylinder use the same procedure as the front master cylinder, however pay attention to the following:
Disassembly: Front Master Cylinder:
If push rod yoke no. 33 is reinstalled, adjust push rod length, see the following illustration.
Remove brake lever no. 4. Remove piston boot no. 5, snap ring no. 6, master piston and spring. Rear Master Cylinder: Remove boot no. 31 from master cylinder. Remove snap ring no. 30 and push rod no. 32 using snap ring pliers. Remove master piston and spring.
Hydraulic Brakes Repair - 279
HYDRAULIC BRAKES REPAIR normally before driving. Rear Brake: Install master cylinder to frame. Install rear brake hose to master cylinder using new sealing washers. Connect flexible hose from reservoir and secure with new locking tie. Fill up reservoir with clean brake fluid. IMPORTANT: Avoid damage! Do not mix different types of brake fluid. Use only DOT 4 brake fluid.
A
Bleed rear brake system. Check for leaks and make sure the brakes operate normally before driving. Connect brake light switch.
V04K0BA
V04k0ba2.EPS
Caliper
A - 99 Âą 1 mm (3-7/8 Âą 1/32 in.) (1) Installation:
Removal:
For the installation, reverse the removal procedure, paying attention to the following details.
Loosen wheel nuts.
Front Brakes:
Remove wheel(s).
Place the brake lever assembly no. 4 on the handlebar.
Remove Banjo bolt no. 9 with sealing washers no. 8 and detach brake hose from caliper.
Position cylinder holding bracket with the UP mark upward. Install bolts and tighten loosely. With the handlebar in straight ahead position, position cylinder reservoir parallel to the ground. Tighten upper bolt in first.
Raise vehicle and support it securely.
Catch spilled fluid with a rag. Attach the brake hose in a position to prevent the fluid from flowing out. Unscrew bolts no. 21 retaining caliper to knuckle and remove caliper.
3
2 1
2
V01K13A
V01k13A2.EPS
Connect brake hose to master cylinder with Banjo bolt and new sealing washers.
V04K0CA
V04k0ca2.EPS
Bleed front brake system. Check for leaks and make sure the brakes operate
A - Remove Banjo Bolt and Washers (1) B - Unscrew Bolts (2)
Hydraulic Brakes Repair - 280
HYDRAULIC BRAKES REPAIR C - Brake Hose (3)
Check for leaks and make sure the brakes operate normally before driving.
Disassembly: Remove brake pads no. 12, see the following section. Remove: •
slide pins no. 19
•
pad spring no. 15.
Brake Pads Removal: Raise vehicle and support it securely. Remove wheels.
Place rag over piston.
Loosen pad pins no. 20.
Place caliper body with piston down and apply small squirts of air pressure to the fluid inlet to remove piston. IMPORTANT: Avoid damage! Do not use high pressure air or bring nozzle too close to inlet. Remove piston seal. IMPORTANT: Avoid damage! Be careful not damage piston sliding surface. Clean piston grooves, caliper cylinder and piston with clean brake fluid. Clean slide pins with brake cleaner and a rag. Inspection: If boots no. 18 are deteriorated or hard, replace with new ones. Check caliper cylinder for scratches, rust or other damages. If so, replace caliper. Check piston for scratches, rust or other damages. If so, replace piston. Assembly: Coat piston seal with clean brake fluid and install it into piston grooves in caliper. Coat piston with clean brake fluid and install into cylinder with the closing toward caliper body. Apply silicone grease into sliding bores and install slide pins. NOTE: Make sure that rubber boots are correctly installed in slide pins grooves. Install pad spring, caliper bracket and pads. Installation:
V02K0AA
2
3
1 V02k0AA2.EPS
A - Pad Pins (1) B - Caliper (2) C - Pads (3) Remove caliper from knuckle. Unscrew pad pins then remove pads. IMPORTANT: Avoid damage! Do not let the caliper hang by the hose and do not stretch or twist the hose. Push piston all the way in to allow installation of new pads. NOTE: It’s very important to clean remaining O.D. of piston out from caliper with brake fluid before pushing in the piston. Make sure the piston is free of any contaminant and is shiny.
For the installation, reverse the removal procedure, paying attention to the following details. Use new sealing washers when installing Banjo bolt retaining brake hose to caliper. Install caliper to knuckle. If hose was disconnected, bleed the brakes. Hydraulic Brakes Repair - 281
HYDRAULIC BRAKES REPAIR B - Piston (2)
Inspection: IMPORTANT: Avoid damage! Soiled brake pads must be replaced by new ones. Measure lining brake pad thickness.
Install new brake pads. Install new pad pins by pushing in the pads against pad spring to align pad slots in the pads and caliper body. Install brake caliper so the disc is positioned between pads.
Brake pads must be replaced when lining is 1 mm (1/32 in) thick or less, or check the hollow places on both sides on the pad lining. There are four hollow places on one set of brake pads. When the pad wear reaches one of the hollow places, the pad must be changed even if the pad wear does not reach another hollow place.
1
NOTE: Be careful not to damage pads and that pads are correctly inserted in their location. After the job is completed, firmly depress the brake lever a few times to bring the pads in contact with the disc. Check for leaks and make sure the brakes operate normally before driving. The pads must rest flat on the disk.
Brake Disc Inspection: Brake discs no. 23 can be inspected without removing from the vehicle.
V02K0FA
V02k0Fa2.EPS
A - Hollow Place (1) Brake Pad Minimum Thickness. . . . . . . 1 mm (1/32 in.)
c CAUTION: Avoid Injury! Avoid getting oil or grease on brake pads. Contaminated brake pads can affect stopping capacities.
IMPORTANT: Avoid damage! Brake pads must always be replaced in pairs.
Raise vehicle and support it securely. Remove wheels and visually inspect disc surfaces for scratches or grooves. Make sure to check both sides of disc. Measure thickness of the disc. Replace disc if not within specifications. IMPORTANT: Avoid damage! Brake discs should never be machined. Turn the disc by hand and check warpage Disc Minimum Thickness . . . . . . . . . 4.5 mm (0.187 in.) Disc Warpage (max.) . . . . . . . . . . . . . . 0.2 mm (0.01 in.) Removal:
Installation: Push caliper pistons inward before installing brake pads. Make sure that pad spring no. 15 is in position.
IMPORTANT: Avoid damage! Replace the bearing when the brake disc is changed. Remove caliper as described previously. After removing the caliper, suspend it out of the way. IMPORTANT: Avoid damage! Do not let the caliper hang by the hose and do not stretch or twist the hose. NOTE: Wheel hub has to be removed from vehicle to replace brake disc. Remove cotter pin and unscrew castellated nut. Remove O-ring.
V02K0BA
1
2 V02k0bA2.EPS
A - Pad Spring (1) Hydraulic Brakes Repair - 282
HYDRAULIC BRAKES REPAIR
1 3 4 2
1
V01H0BA
V01h0ba2.EPS
V01K0BA
Typical
V01k0ba2.EPS
A - Remove O-ring (1)
Torque to 34 N•m (25 lb-ft)
Using hub puller, pull out wheel hub with disc.
1
Brake Lever 2
Removal and Installation: Use the same procedure as the front master cylinder.
Brake Pedal Removal: Remove RH foot rest with foot peg. Unhook the return spring no. 37. Unhook the brake cable no. 46 and push rod from brake pedal.
1
V01K0AA
2
3
V01k0aa2.EPS
Typical A - Knuckle (1) B - Wheel Hub (2) Remove screws no. 22 retaining brake disc to wheel hub. NOTE: Heat up disc around screws to facilitate removal. Installation: Install brake disc on wheel hub and tighten screws no. 22 to 34 N•m (25 lb-ft) in a criss-cross sequence.
V04K0BB
4 V04k0bb2.EPS
Hydraulic Brakes Repair - 283
HYDRAULIC BRAKES REPAIR Brake Cable
Typical A B C D
- Master Cylinder (1) - Return Spring (2) - Brake Cable (3) - Brake Pedal (4)
Lubrication: The brake cable must be lubricated with cable lubricant only.
Remove circlip no. 43, washer no. 44 and O-ring no. 45 then remove pedal no. 38 from pivot. Remove the O-ring no. 16 on the pivot.
IMPORTANT: Avoid damage! Using another lubricant could cause sticking or stiffness of brake lever/ cable.
Inspection:
Remove brake lever lock (screw, nut and spring).
Check brake pedal for cracks or distortion.
Remove cable from hand lever. To ease this operation, apply a force on the brake pedal to loosen the cable.
Check O-rings for damage, change if necessary. Installation and Adjustment:
Put cable luber on the cable. Insert the needle of lubricant can on cable luber hole.
For installation, reverse the removal procedure. Pay attention to the following details. Apply synthetic grease on O-rings. Adjust the master cylinder push rod at the following dimension.
c CAUTION: Avoid Injury! Always wear eye
protection and gloves when you lubricate a cable.
NOTE: Place a rag around cable luber to prevent lubricant splash. Spray a small quantity of cable lubricant then press the brake pedal to move the brake cable. Repeat this procedure until the silicone lubricant flows out the other end of the cable. Readjust cable, see below. Removal: NOTE: Before removing brake cable from vehicle, note cable routing for reinstallation. Brake Pedal:
A
Remove adjusting nut no. 36 and disconnect brake cable no. 46 from brake pedal.
V04K0BA
V04k0ba2.EPS
Typical A - 99 Âą 1 mm (3-7/8 Âą 0.039 in.) Install master cylinder push rod to the brake pedal. Install return spring no. 37. Adjust brake cable, see BRAKE CABLE for procedure.
Hydraulic Brakes Repair - 284
HYDRAULIC BRAKES REPAIR
V04K0FA
1
2
V04K0FB
1
2
V04k0fa2.EPS
V04k0fb2.EPS
Typical
Typical
A - Adjusting Nut (1) B - Brake Cable (2)
A - Adjustment Nut (1) B - Stopper (2)
NOTE: It may be necessary to hold the rod with locking pliers to prevent it from turning.
Brake Hoses
Release cable housing from frame bracket.
Removal:
Brake Handle:
NOTE: Before removing any hoses, drain brake system.
Unscrew the bolt retaining the parking lever lock from brake lever no. 4 and remove the parking lever lock no. 35. If necessary, press brake pedal to release the tension on brake lever. Rotate cable end bushing so that cable aligns with the brake lever recess, then lift cable end. Inspection: Inspect cable ends for wear or deterioration. Replace if necessary. Check cable for free movement into the cable sheath. Lubricate or replace if necessary. Installation and Adjustment:
Front Flexible Brake Hose: Remove: â&#x20AC;˘
console
â&#x20AC;˘
front luggage rack and front fender assembly.
Refer to BODY/FRAME for complete procedure. Disconnect master cylinder hose no. 10 from master cylinder no. 3 and discard sealing washers no. 8. Cut all locking ties and remove clips no. 11 retaining hose. Remove T-fitting from frame. Pull out grommets no. 13 from their hooks.
Installation is the reverse of the removal procedure. NOTE: Adjust brake pedal prior to adjusting brake cable. If brake pedal is not correctly adjusted, the parking device will not function properly.
Disconnect hose no. 10 from caliper and discard sealing washers no. 8.
Lean brake pedal until it stops. Turn the adjustment nut until stopper comes in contact with the brake pedal lever.
Hydraulic Brakes Repair - 285
HYDRAULIC BRAKES REPAIR 2
1
V04K0GA V04K0IA
V04K0iA2.EPS
A - Front Brake Caliper (1) B - Flexible Brake Hose (2)
2
1 V04k0ga2.eps
A - Rear Brake Caliper (1) B - Flexible Brake Hose (2)
Remove hose from vehicle.
Pull out grommets no. 13 from their hooks and remove hose from vehicle.
Disconnect rear brake switch connectors then remove brake switch.
Inspection:
Remove Banjo bolt no. 9 retaining flexible hose no. 25 on top of rear master cylinder no. 28.
Periodically inspect flexible brake hoses for cracks, leaks, blisters and any other damage. If any sign of deterioration is found, replace the defective part with a new one. Installation: Flexible Hoses: To install a hose, attach it to the caliper first. Always use new washers on both sides of the fitting.
1
Make sure brake hoses are properly secured and that they do not come in contact with moving parts. Bleed brake system.
Brake Light Switch Removal: Front Brake Light Switch: The front brakes switch no. 7 is located on the master cylinder and cannot be adjusted. Check that switch is securely installed. V04K0AB
V04k0ab2.EPS
Typical A - Disconnect Brake Hose (1) Remove Banjo bolt no. 9 and sealing washers no. 10 retaining hose to rear caliper.
Hydraulic Brakes Repair - 286
HYDRAULIC BRAKES REPAIR
V01K0XA
1 V01k0xa2.EPS
A - Front Brake Light Switch (1) Rear Brake Light Switch: The rear brake switch no. 24 is located on the top of rear master cylinder. The rear brake light switch cannot be adjusted. Disconnect switch connectors. Unscrew rear brake light switch from Banjo bolt and remove switch. Catch spilled fluid with a rag. Inspection and Installation: Check switch for dirt or corrosion. Make sure it is operating properly. Turn ignition switch ON then depress brake pedal and check for brake light to turn on. For installation, reverse the removal procedure. NOTE: Apply pipe sealant on threads of rear brake light switch.
Hydraulic Brakes Repair - 287
HYDRAULIC BRAKES REPAIR
Hydraulic Brakes Repair - 288
BODY / FRAME TABLE OF CONTENTS Body / Frame
Table of Contents
Repair.............................................................291 Body Parts..................................................291 Seat ............................................................294 General.......................................................295 Seat ............................................................295 Steering Cover ...........................................295 Console ......................................................296 Front Skid Plate/Bumper/ Luggage Rack ...296 Front Fender/Mudguard/ Facia...................297 Inner Fender...............................................298 Engine Side Panel......................................299 Foot Rest....................................................300 Rear Luggage Rack/Rear Bumper .............300 Rear Fender/Rear Fender Cover ...............301 Rear Mudguard/Facia.................................302 Engine Skid Plate .......................................302 Arm Protector .............................................302 Latch Lever/Latch Base/Spring ..................302 Seat Adjustment .........................................303 Seat Cover Replacement ...........................303 Storage Cover Latch ..................................304 Seat Cleaning.............................................304 Decals Replacement ..................................304 Hitch/Trailer Ball .........................................304 Plastic Maintenance ...................................304 Plastic Repair .............................................305 Body and Frame............................................306 Body ...........................................................306 General.......................................................307 Footrest Support.........................................307 Removable Brace.......................................307 Rear Frame Extension ..............................307 Frame .........................................................308
Body / Frame Table of Contents - 289
BODY / FRAME TABLE OF CONTENTS
Body / Frame Table of Contents - 290
BODY / FRAME REPAIR Repair
Trail Buck Series
Body Parts 7
3 Nm (27 lb-in.) 9
3 Nm (27 lb-in.)
8 25
10
34
3 Nm (27 lb-in.) 30
3 Nm (27 lb-in.) 28
26
34 27 29
26 24
32 12 8 Nm (71 lb-in.)
55 54
33
53 15 Nm (132 lb-in.)
15 Nm (132 lb-in.) 13 15 Nm (132 lb-in.) 15
15 Nm (132 lb-in.) 12
14
VO4I1PSA2a.tif
Body / Frame Repair - 291
BODY / FRAME REPAIR Trail Buck Series
1 Nm (9 lb-in.) 46 48
44 43
3 Nm (27 lb-in.)
45
47 37 50 51
35
49 3 Nm 25 (27 lb-in.) 36
35 3 Nm (27 lb-in.) 23
36 24 3 Nm (27 lb-in.) 5 Nm (44 lb-in.)
VO4I1NSa2a.tif
Body / Frame Repair - 292
BODY / FRAME REPAIR Trail Buck Series
15 Nm (132 lb-in.) 42
21
41
39
20 15 Nm (132 lb-in.)
19 18 40 38 16 17 25 Nm (18 lb-ft)
EX Model
41
EX Model
6
4 6
VO4L09SA2a.tif
Body / Frame Repair - 293
BODY / FRAME REPAIR Seat
Trail Buck Series
64
56
4 N m (35 lbf in)
60 4 N m (35 lbf in) 59 4
2 3 4 N m (35 lbf in)
61
63
8 N m 62 (71 lbf in)
V04L0AS
VO4LOASA2.eps
Body / Frame Repair - 294
30 N m (22 lbf ft)
1 57
58
BODY / FRAME REPAIR General
2
1
During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker.
c CAUTION: Avoid Injury! Torque wrench
tightening specifications must strictly be adhered to.Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
Seat
V04L02A
Vo4L02A3.eps
Removal:
A - Insert this tab in hook (1) B - Hook (2)
Seat: To remove seat, pull latch no. 1 upward while gently lifting rear of seat. Continue lifting movement until you can release the front retaining device, then, completely remove seat.
c CAUTION: Avoid Injury! Periodically verify the
seat lock pin no. 4 and seat hook. Tighten them if necessary. Make sure seat is securely latched before riding.
Steering Cover Removal: Storage Cover: The storage cover is retained by two rubber latches no. 6. Unlatch cover, lift then remove cover. Steering Cover: Remove three screws on each side of instrument panel. Remove top of panel
V00A11A
2
1 V00A11A3.eps
A - Seat (1) B - Seat Latch (2) Installation: Insert front tab no. 2 of seat into frame hook no. 3. When seat rests in its position, firmly push seat down to latch.
MX30925
Body / Frame Repair - 295
BODY / FRAME REPAIR Remove screws securing front of panel to handlebar tabs.
4 2
5 1
1
MX31991
Disconnect all electrical connectors.
2
Inspection: Storage Cover: Check rubber latches no. 6 from storage cover for cracks or other damages. Change if necessary.
3
5 V04L0FA
Steering Cover and Shifter Guide Cover:
V04L0FA2.eps
Check for damages. Replace if necessary.
Console Removal Remove screws no. 7 retaining console hooks no. 8.
A B C D E
- Plastic Screws (1) - Steering Cover (2) - Fuel Tank Cap (3) - 12-volt Power Outlet (4) - Console (5)
Remove console no. 10. Installation: The installation is the reverse of removal procedure.
Front Skid Plate/Bumper/ Luggage Rack Removal
1
Front Skid Plate: All Trail Buck Models except EX To remove front skid plate no. 11, unscrew bolts no. 12 and screws no. 13.
V04L0CA
2 V04L0CA2.eps
A - Console Hooks (1) B - Console (2) Remove plastic screws no. 9 near steering cover.
Body / Frame Repair - 296
BODY / FRAME REPAIR Front Luggage Rack: Remove bolts no. 18, no. 19 and no. 20. NOTE: Remove headlight to reach nut. Refer to INSTRUMENTS AND ACCESSORIES.
MX30926a
Trail Buck EX Model: Remove: •
hitch hook no. 14
•
fairlead no. 15
•
screws no. 13.
Withdraw front skid plate. Front Bumper: NOTE: The attachments of front bumper no. 16 are located at the same place for all models even if the bumper shape is different. Remove front skid plate.
V04L0IA
V04L0IA2.eps
Remove plastic anchors and bolts securing front panel. Detach the headlight harness. Pull front luggage rack no. 21 upward. Installation:
Installation is in the reverse order of removal.
Front Fender/Mudguard/ Facia Removal: Front Fender: Unscrew steering cover bolts then lift it. Remove front luggage rack. NOTE: To remove front fender no. 22 with luggage rack, do not remove screws no. 20. Remove screws no. 23 and no. 24 on each side. MX31573a
Body / Frame Repair - 297
BODY / FRAME REPAIR Inner Fender Removal: Inner Fender: Remove front wheel to access inner fender no. 32. Remove screws no. 33.
1 V01L13A
V01I13A.eps
Remove RH and LH engine side panels no. 25 and no. 26. Remove fuel cap. Lift front fender no. 22. Front Mudguard: Remove screws no. 24 and no. 25. Remove screw no. 26 near the front facia then separate front mudguard no. 27 from headlight facia.
V04L0LA
2 Vo4L0LA2.eps
A - Clip (1) B - Screws (2) Installation: Install in first, the upper clip; secondly, the lower front screw and then the lower rear screw. NOTE: Install both screws before torquing.
MX30917
Installation: Installation is the reverse order of removal.
Body / Frame Repair - 298
BODY / FRAME REPAIR Engine Side Panel Removal Remove latches no. 34 behind inner fender. LH Side: Remove engine side panel pin from grommet in rear fender.
MX30939
Front Fender Side
MX30749
Remove LH engine side panel no. 26. RH Side: Place transmission lever in NEUTRAL position then remove the transmission lever handle.
MX30940
Rear Fender Side 1
Lower the engine side panel no. 25 so that lower tabs come out of foot rest slots.
2
MX30941
A - Transmission Lever Handle (1) B - Bolt Retaining Handle (2) Come off side panel tabs from front fender and rear fender.
Body / Frame Repair - 299
BODY / FRAME REPAIR V01L1DA.eps
2
Installation: Installation is the reverse order of removal.
Rear Luggage Rack/Rear Bumper Removal: Under rear fender no. 37, remove bolts no. 38. One on each side.
V04L0TA
1 V04L0TA2.eps
A - RH Engine Side Panel Tabs (1) B - Foot Rest Slots (2) Remove RH engine side panel. Installation: For installation, reverse the removal procedure.
Foot Rest V01L1FA
Removal:
V01L1FA.eps
Remove seat.
Typical
Remove engine side panel(s). Remove footpeg(s) no. 35.
Remove bolts no. 39 retaining rear luggage rack no. 40 to rear bumper no. 41.
Remove screws no. 23 retaining foot rest no. 36 to front and rear fender.
Withdraw rear luggage rack.
On front and rear mudguards, remove the three first screws no. 25 and screws no. 24 retaining foot rest to mudguards.
Rear Bumper: Remove bolts no. 39 retaining rear luggage rack to rear bumper no. 41. Remove bolts no. 42 under rear facia no. 43. Pull the rear bumper. Installation: Installation is the reverse order of removal. NOTE: Install all bolts before torque.
V01L1DA
Body / Frame Repair - 300
BODY / FRAME REPAIR Rear Fender/Rear Fender Cover
Rear Fender Cover: Remove rear luggage rack.
Removal:
Remove screws no. 44 under rear facia.
Rear Fender: Remove seat, RH and LH engine side panels and rear luggage rack. Remove screws no. 44 under rear facia, screws no. 45 near tail light and screws no. 46 on the top.
V01L1HB
V01l1hb.eps
Lift the rear of the rear fender and remove the ten latches no. 47. V01L1HA
V01l1ha.eps
Remove screws no. 23 and no. 24.
V01L1LA
V01l1la.eps
Typical Remove rear fender cover no. 48.
V04L0MA
V04L0ma2.EPS
Disconnect brake light.
Installation: Installation is the reverse order of removal.
Body / Frame Repair - 301
BODY / FRAME REPAIR Rear Mudguard/Facia
Engine Skid Plate
Removal:
Inspection:
Rear Mudguard:
This skid plate no. 52 protects the engine. Check for damage, crack or looseness.
Remove darts no. 49 and screws no. 25 retaining mudguard no. 50 and rear fender. Remove screws retaining mudguard and foot rest.
Change if skid plate is damaged or cracked. Torque all bolts at a regular interval. Removal: Engine Skid Plate: Under vehicle, remove bolts no. 53 and cups no. 54. Installation: Installation is the reverse order of removal. NOTE: Install all bolts before torque. Do not forget the rubber pads no. 55.
Arm Protector Removal: Remove the bolts.
V04L0MA
V04L0ma2.EPS
Remove screw no. 51 near rear facia. Rear Facia: Remove rear luggage rack. Unfasten screws no. 44 and no. 46 retaining rear facia no. 43 to rear fender.
V04L0OA
V04L0oa2.EPS
Installation: Installation is the reverse order of removal.
Latch Lever/Latch Base/Spring Removal: Latch Lever: MX30922
Remove push nut no. 56 and rivet no. 57.
Installation:
Separate latch lever no. 1 from spring no. 58.
Installation is the reverse order of removal.
Latch Base: Remove bolts no. 59 and separate latch base no. 60 from spring.
Body / Frame Repair - 302
BODY / FRAME REPAIR B - Frame Hook (2) C - Adjusting Nuts (3) D - 28 ± 1 mm (1.1 ± 0.039 in.) (A)
Spring: Remove latch base. Separate spring from latch base and latch lever.
Install seat.
Installation: Installation is the reverse order of removal.
Check seat adjustment. If necessary, screw or unscrew the adjusting nuts no. 63 to the best adjustment.
Seat Adjustment
Seat Cover Replacement
Rear Attachment:
Remove the old seat cover no. 64. Check the foam and replace if necessary.
For latch stud no. 4 adjustment, unscrew the latch stud nut no. 61 and screw or unscrew the latch stud to the best height. See the following illustration.
1
Install staples with an electric stapler such as Arrow stapler no. ETN-50 or with a manual stapler such as Arrow stapler no. T-50. NOTE: For an easier installation, it’s highly recommended to use an electric stapler. Ensure that the seat rest firmly against a hard surface such as a piece of wood. This is done to get the staples completely pushed in place.
2
A
V03L0CA
V03L0ca2.EPS
A - Lock Pin (1) B - Adjustment Nut (2) (apply Loctite 271) C - 36.5 ± 2 mm (7/16 ± 3/64 in.) (A) Torque the latch stud nut. Front Attachment: For frame hook no. 3 adjustment, unscrew the nuts no. 62 and screw or unscrew the adjusting nut no. 63. Temporarily, adjust frame hook at 24 mm ± 1 mm (0.945 in ± 0.039 in). See the following illustration.
1 F01L3YA
2 F01l3ya.eps
A
2 1 3
Typical A - Piece of Wood (1) B - ETN-50 (electric) or T-50 (manual) After cover installation cut all around the excess of material.
V04L0UA
V04L0Ua2.EPS
A - Seat Tab (1) Body / Frame Repair - 303
BODY / FRAME REPAIR Storage Cover Latch Inspection: Inspect for crack or damage. Change if a any crack or damage are detected.
Remove half of the decal back protective film and align decal with marks. Start sticking it from center and remove the other half of the film to stick it completely. Carefully squeegee decal beginning at center and working outward using, firm, short, overlapping strokes. DECALS HAVING A PROTECTIVE FILM ON BOTH SIDES
Removal: Under front fender, pull the storage cover latch. Installation:
These decals usually contain graphics and are used on plastic.
Under front fender, insert the storage cover latch in the slot. Pull the latch by the top.
INSTALLATION ON PLASTIC
Seat Cleaning
Using a pencil and the decal as a template, mark the area where decal will be located.
Clean surface with isopropyl alcohol.
It is recommended to clean the seat with a solution of warm soapy water, using a soft clean cloth. IMPORTANT: Avoid damage! Avoid use of harsh detergents such as strong soaps, degreasing solvents, abrasive cleaners, paint thinners, etc. that may cause damage to the seat cover.
Decals Replacement
IMPORTANT: Avoid damage! Do not use soapy water to locate decal on plastic parts. Remove back protective film from decal and carefully align decal with marks. When well aligned squeegee decal beginning at center and working outward using firm, short, overlapping strokes.
Hitch/Trailer Ball
Removal:
Inspection:
Using a heat gun warm up one end of decal for a few seconds until decal can roll off when rubbing with your finger.
The hitch/trailer ball is optional. If the vehicle is equipped with this option, often check the solidity of the installation.
Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off.
Plastic Maintenance
If decal tears while pulling off, it has to be heated for a few seconds longer. If decal tends to stretch while pulling off, stop heating and wait a few seconds to let it cool, then peel it off.
Maintenance:
Installation:
Clean the vehicle thoroughly, removing all dirt and grease accumulation. To clean use a soft clean cloth and either soapy water or isopropyl alcohol.
There are 2 types of decals used on UATV. One has a protective film on back side and the other has a protective film on both sides. They are used on 2 types of materials; plastic and metal.
To remove grease, oil or glue use isopropyl alcohol.
DECALS HAVING A PROTECTIVE FILM ON BACK SIDE ONLY
The following products must not be used to clean or wax any of the plastic components used on the vehicles:
These decals usually contain written information (ex.: warning) and are used on metal. Clean surface with a good solvent such as ACRYLICLEAN DX 330 from PPG or equivalent (refer to manufacturer instructions). Using a pencil and the decal as a template, mark the area where decal will be located.
IMPORTANT: Avoid damage! Do not apply isopropyl alcohol or acetone directly on decals.
•
gasoline
•
brake fluid
•
kerosene
•
diesel fuel
•
lighter fluid
Body / Frame Repair - 304
BODY / FRAME REPAIR •
varsol
•
naphtha
•
acetone
•
strong detergents
•
abrasive cleaners
• waxes containing an abrasive or a cleaning agent in their formula.
Plastic Repair No plastic part on the vehicle is repairable. Change all defective parts.
Body / Frame Repair - 305
BODY / FRAME BODY AND FRAME Body and Frame Body Trail Buck Series
3
48 N m 9 (35 lbf ft)
5
9 48 N m (35 lbf ft) 8 24 N m (17 lbf ft)
24 N m (17 lbf ft) 6
8 24 N m (17 lbf ft) 4
V04L05T
V04l05TA2.EPS
Body / Frame Body and Frame - 306
2
1
BODY / FRAME BODY AND FRAME General
•
battery (refer to STARTING SYSTEM)
For installation, use the torque values and Loctite products from exploded views. Clean threads before using Loctite product when installing screws.
•
radiator with fan (refer to COOLING SYSTEM)
IMPORTANT: Avoid damage! Before performing electrical welding anywhere on the vehicle, first disconnect the battery negative cable, then unplug the electronic module connector and the voltage regulator. This will protect the electronic module and battery against damage caused by flowing current when welding.
• muffler and heat shield (refer to REMOVAL AND INSTALLATION) •
voltage regulator (refer to CHARGING SYSTEM)
•
electronic module
•
fuse holder
•
taillight
•
winch solenoid (EX model).
Remove mounting flanged bolts no. 9 then withdraw the rear frame extension no. 3.
Footrest Support Removal: Remove: • engine side panel and foot rest (Refer to BODY/ FRAME.) •
mounting flanged bolts no. 6.
Withdraw the foot rest no. 1. Inspection: Check for cracks or bent tube. Change or repair if necessary.
1
Installation: Installation is essentially the reverse of removal procedure.
Removable Brace Removal: Remove footrest. Refer to BODY/FRAME. Unscrew bolts no. 8. Remove the removable brace no. 2. V01L2JA
Inspection:
V01l2ja2.EPS
Check for crack or bent tube. Change if necessary.
A - Remove the mounting flanged bolts (1)
Installation:
Inspection:
For the installation, reverse the removal procedure.
Check for crack, bent tube or other damage. Repair or change if necessary.
Rear Frame Extension
Installation:
Removal:
Installation is the reverse of removal procedure.
Remove: •
rear luggage rack/rear bumper (refer to BODY/FRAME)
•
rear fender (refer to BODY/FRAME)
Body / Frame Body and Frame - 307
BODY / FRAME BODY AND FRAME Frame Cleaning: Clean frame no. 5 and rear frame extension with appropriate cleaners and rinse with high pressure hose. Touch up all metal spots where paint has been scratched off. Spray all bare metal parts of vehicle with metal protector. Welding: Steel Frame: •
electric welding
•
amperage: 70 - 110 A
•
voltage: 20 - 24 V
•
rod: E-7014 (3/32 in). IMPORTANT: Avoid damage! Before performing electrical welding anywhere on the vehicle, first disconnect the battery negative cable, then unplug the electronic module connector and the voltage regulator. This will protect the electronic module and battery against damage caused by flowing current when welding.
NOTE: Install the ground as close as possible from the reparation area. IMPORTANT: Avoid damage! If welding is to be done near plastic material, it is recommended to either remove the part from the area or to protect it with aluminum foil to prevent damage.
Body / Frame Body and Frame - 308