Crossfire 1000GTR Manual

FOREWORD
Brief introduction to maintenance handbook of
HS1000UTV/HS900UTV/HS800UTV-5
The handbook is edited by Technical Center of Chongqing Huansong Science And
Technology Industrial Co.,Ltd, and is supplied to dealers and technicians as document of
technique.Mainly, the handbook gives methods to check, maintain and repair utility terrain
vehicles （UTV）, and supplies some relevant technique and performance data. Some
techniques and method inside may be used to check, maintain and repair other models of
UTV, although it is mainly for HS1000UTV/HS900UTV/HS800UTV-5.
Please read the handbook through and fully understand it; otherwise, any improper
repairing and amounting would bring you problems, and accident may occur in your use.
Proper use and maintenance can guarantee UTV being driven safely, reduce its
malfunction, and help the vehicle remain its best performance.
The standards, performances and specifications mentioned in interpretation are
based on the sample in design, and they are subject to changes according to the
product’s improvement without prior notice.
First version ,October, 2014
Published by Chongqing Huansong Science And Technology Industrial Co.,Ltd
Chongqing Huansong Science And Technology Industrial Co.,Ltd holds the copy right.
No publishing and reprinting without permission.

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CONTENT
CHAPTER 1
GENERAL INFORMATION
GENERAL INFORMATION……………………………………………………………………1
WATNINGS, CAUTIONS AND NOTES……………………………………………………1
DESCRIPTION……………………………………………………………………………………2
IDENTIFICATION CODE……………………………………………………………………… 3
Frame No. ………………………………………………………………………………… 3
Engine No. ………………………………………………………………………………… 3
SAFETY ………………………………………………………………………………………… 4
Handing gasoline safely…………………………………………………………………… 4
Cleaning parts……………………………………………………………………………… 5
Warning labels……………………………………………………………………………… 5
SERIAL NUMBERS…………………………………………………………………………… 6
FASTENERS…………………………………………………………………………………… 6
Torque specifications ……………………………………………………………………… 6
Self-locking fasteners……………………………………………………………………… 6
Washers…………………………………………………………………………………… 6
Cotter pins…………………………………………………………………………………… 7
Snap rings and E-clips …………………………………………………………………… 7
SHOP SUPPLIES……………………………………………………………………………… 8
Lubricants and Fluids……………………………………………………………………… 8
Engine oils…………………………………………………………………………………… 8
Greases……………………………………………………………………………………… 8
Brake fluid…………………………………………………………………………………… 9
Coolant……………………………………………………………………………………… 9
Cleaners, Degreasers and solvents …………………………………………………… 9
Gasket sealant…………………………………………………………………………… 9
Gasket remover ………………………………………………………………………… 10
Thread locking compound……………………………………………………………… 10
BASIC TOOLS ………………………………………………………………………………… 10
Screwdrivers……………………………………………………………………………… 11

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CONTENT
CHAPTER 1
GENERAL INFORMATION
GENERAL INFORMATION……………………………………………………………………1
WATNINGS,CAUTIONS AND NOTES……………………………………………………1
DESCRIPTION……………………………………………………………………………………2
IDENTIFICATION CODE……………………………………………………………………… 3
Frame No. ………………………………………………………………………………… 3
Engine No. ………………………………………………………………………………… 3
SAFETY ………………………………………………………………………………………… 4
Handing gasoline safely…………………………………………………………………… 4
Cleaning parts……………………………………………………………………………… 5
Warning labels……………………………………………………………………………… 5
SERIAL NUMBERS…………………………………………………………………………… 6
FASTENERS…………………………………………………………………………………… 6
Torque specifications ……………………………………………………………………… 6
Self-locking fasteners……………………………………………………………………… 6
Washers…………………………………………………………………………………… 6
Cotter pins…………………………………………………………………………………… 7
Snap rings and E-clips …………………………………………………………………… 7
SHOP SUPPLIES……………………………………………………………………………… 8
Lubricants and Fluids……………………………………………………………………… 8
Engine oils…………………………………………………………………………………… 8
Greases……………………………………………………………………………………… 8
Brake fluid…………………………………………………………………………………… 9
Coolant……………………………………………………………………………………… 9
Cleaners,Degreasers and solvents …………………………………………………… 9
Gasket sealant…………………………………………………………………………… 9
Gasket remover ………………………………………………………………………… 10
Thread locking compound……………………………………………………………… 10
BASIC TOOLS ………………………………………………………………………………… 10
Screwdrivers……………………………………………………………………………… 11

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Wrenches ………………………………………………………………………………… 11
Adjustable wrenches …………………………………………………………………… 12
Socket wrenches, ratchets and handles ……………………………………………… 12
Impact drivers …………………………………………………………………………… 13
Allen wrenches…………………………………………………………………………… 13
Torque wrenches………………………………………………………………………… 13
Torque adapters ………………………………………………………………………… 14
Pliers……………………………………………………………………………………… 15
Snap ring pliers…………………………………………………………………………… 15
Hammers ………………………………………………………………………………… 16
Ignition grounding tool…………………………………………………………………… 16
PRECISION MEASURING TOOLS ………………………………………………………… 16
Feeler gauge ……………………………………………………………………………… 16
Calipers…………………………………………………………………………………… 17
Micrometers……………………………………………………………………………… 18
Adjustment ……………………………………………………………………………… 18
Care ……………………………………………………………………………………… 19
Metric micrometer………………………………………………………………………… 19
Standard inch micrometer……………………………………………………………… 20
Telescoping and small bore gauges…………………………………………………… 21
Dial Indicator……………………………………………………………………………… 21
Compression gauge……………………………………………………………………… 22
Multimeter………………………………………………………………………………… 22
Cltp-on ammeter………………………………………………………………………… 22
Magneto puller………………………………………………………………………………23
ELECTRICAL SYSTEM FUNDAMENTALS……………………………………………… 23
Voltage …………………………………………………………………………………… 23
Resistance………………………………………………………………………………… 23
Amperage………………………………………………………………………………… 23
BASIC SERVICE METHODS……………………………………………………………… 24
Removing frozen fasteners……………………………………………………………… 25
Removing broken fasteners …………………………………………………………… 25
Repairing damaged threads …………………………………………………………… 26
Stud Removal/Installation ……………………………………………………………… 26
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Removing hoses ………………………………………………………………………… 26
Bearings…………………………………………………………………………………… 27
Removal…………………………………………………………………………………… 27
Installation………………………………………………………………………………… 28
Interference fit …………………………………………………………………………… 28
Seal replacement………………………………………………………………………… 30
STORAGE……………………………………………………………………………………… 30
Storage area selection…………………………………………………………………… 30
Preparing the motorcycle for storage …………………………………………………… 30
Returning the UTV to service…………………………………………………… 31
TROVBLESHOOTING……………………………………………………………………… 31
ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 32
STARTING THE ENGINE ………………………………………………………………… 32
Engine is cold …………………………………………………………………………… 33
Engine is warm…………………………………………………………………………… 33
Flooded engine……………………………………………………………………………33
ENGINE WILL NOT START ……………………………………………………………… 34
Identifying the problem ………………………………………………………………… 34
Spark test………………………………………………………………………………… 35
The starter cannot work repeatedly or can only work slowly………………… 36
POOR ENGINE PERFORMANCE………………………………………………………… 36
The engine starts slowly or difficultly…………………………………………… 36
Engine backfires, cuts out or misfires during acceleration…………………………… 36
The engine is not idling or cannot idle stably…………………………………………… 37
Poor fuel mileage………………………………………………………………………… 37
Engine will not idle or idles roughly …………………………………………………… 37
Low engine power ………………………………………………………………………… 37
Poor idle or low speed performance…………………………………………………… 39
Poor high speed performance ………………………………………………………… 39
FUEL SYSTEM……………………………………………………………………………… 39
Rich mixture……………………………………………………………………………… 40
Lean mixture……………………………………………………………………………… 40
ENGINE………………………………………………………………………………………… 40
Engine smoke……………………………………………………………………………… 40

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Removing hoses ………………………………………………………………………… 26
Bearings…………………………………………………………………………………… 27
Removal…………………………………………………………………………………… 27
Installation………………………………………………………………………………… 28
Interference fit …………………………………………………………………………… 28
Seal replacement………………………………………………………………………… 30
STORAGE……………………………………………………………………………………… 30
Storage area selection…………………………………………………………………… 30
Preparing the motorcycle for storage …………………………………………………… 30
Returning the UTV to service…………………………………………………… 31
TROVBLESHOOTING……………………………………………………………………… 31
ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 32
STARTING THE ENGINE ………………………………………………………………… 32
Engine is cold …………………………………………………………………………… 33
Engine is warm…………………………………………………………………………… 33
Flooded engine……………………………………………………………………………33
ENGINE WILL NOT START ……………………………………………………………… 34
Identifying the problem ………………………………………………………………… 34
Spark test………………………………………………………………………………… 35
The starter cannot work repeatedly or can only work slowly………………… 36
POOR ENGINE PERFORMANCE………………………………………………………… 36
The engine starts slowly or difficultly…………………………………………… 36
Engine backfires, cuts out or misfires during acceleration…………………………… 36
The engine is not idling or cannot idle stably…………………………………………… 37
Poor fuel mileage………………………………………………………………………… 37
Engine will not idle or idles roughly …………………………………………………… 37
Low engine power ………………………………………………………………………… 37
Poor idle or low speed performance…………………………………………………… 39
Poor high speed performance ………………………………………………………… 39
FUEL SYSTEM……………………………………………………………………………… 39
Rich mixture……………………………………………………………………………… 40
Lean mixture……………………………………………………………………………… 40
ENGINE………………………………………………………………………………………… 40
Engine smoke……………………………………………………………………………… 40

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Black smoke ……………………………………………………………………………… 40
Blue smoke………………………………………………………………………………… 40
White smoke or steam…………………………………………………………………… 41
Low engine compression ………………………………………………………………… 41
High engine compression ……………………………………………………………… 41
Engine overheating (cooling system) ………………………………………………… 41
Engine overheating (engine)…………………………………………………………… 42
The ignition advance angle is too large………………………………………………… 42
Detonation………………………………………………………………………………… 42
Power loss ……………………………………………………………………………… 42
engine noises……………………………………………………………………………… 43
ENGLNE LUBRICATION…………………………………………………………………… 44
HIGH OIL CONSUMPTION OR EXCESSIVE……………………………………………… 44
Exhaust smoke…………………………………………………………………………… 44
Low oil pressure ………………………………………………………………………… 44
High oil pressure ………………………………………………………………………… 44
No oil pressure…………………………………………………………………………… 44
Oil level too low…………………………………………………………………………… 44
Oil contamination………………………………………………………………………… 45
CYLINDER LEAK DOWN TEST…………………………………………………………… 45
ELECTRICAL TESTING…………………………………………………………………… 47
Preliminary checks and precautions …………………………………………………… 47
Intermittent problems…………………………………………………………………… 48
Electrical component replacement ……………………………………………………… 49
Test equipment …………………………………………………………………………… 49
Ammeter …………………………………………………………………………………… 49
Self-powered test light …………………………………………………………………… 49
Ohmmeter ………………………………………………………………………………… 49
Jumper wire……………………………………………………………………………… 50
TEST PROCEDURES………………………………………………………………………… 51
Voltage test……………………………………………………………………………… 51
Voltage drop test………………………………………………………………………… 51
Peak voltage test………………………………………………………………………… 52
Continuity test……………………………………………………………………………… 52
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Testing for a short with a self-powered test light or ohmmeter……………………… 52
Testing for a short with a test light or voltmeter………………………………………… 53
BRAKE SYSTEM……………………………………………………………………………… 53
Soft or spongy brake lever or pedal…………………………………………………… 53
Brake drag………………………………………………………………………………… 54
Hard brake lever or pedal operation…………………………………………………… 55
Brake Grabs……………………………………………………………………………… 55
Brake squeal or chatter ………………………………………………………………… 55
Leaking brake caliper …………………………………………………………………… 55
Leaking master cylinder………………………………………………………………… 55
CHAPTER 2
SPECIFICATIONS
HOW TO USE CONVERSION TABLE OF UNIT…………………………………………… 57
How to use conversion table…………………………………………………………… 57
Definition of unit ………………………………………………………………………… 57
GEBERAR SPECIFICATIONS ……………………………………………………………… 58
ENGINE SPECIFICATIONS ………………………………………………………………… 61
CHASSIS SPECIFICATIONS………………………………………………………………… 67
ELECTRICAL SPECIFICATIONS…………………………………………………………… 69
TIGHTENING TORQUES …………………………………………………………………… 71
Engine tightening torques………………………………………………………………… 71
Chassis tightening torques ……………………………………………………………… 74
GENERAL TIGHTENING TORQUE SPECIFICATIONS ………………………………… 76
LUBRICATION PIONTS AND LUBRICANT TYPES……………………………………… 77
Engine……………………………………………………………………………………… 77
Chassis……………………………………………………………………………………… 78
HYDROGRAPHIC CHART…………………………………………………………………… 79
LUBRICATION OIL WAY…………………………………………………………………… 80

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Testing for a short with a self-powered test light or ohmmeter……………………… 52
Testing for a short with a test light or voltmeter………………………………………… 53
BRAKE SYSTEM……………………………………………………………………………… 53
Soft or spongy brake lever or pedal…………………………………………………… 53
Brake drag………………………………………………………………………………… 54
Hard brake lever or pedal operation…………………………………………………… 55
Brake Grabs……………………………………………………………………………… 55
Brake squeal or chatter ………………………………………………………………… 55
Leaking brake caliper …………………………………………………………………… 55
Leaking master cylinder………………………………………………………………… 55
CHAPTER 2
SPECIFICATIONS
HOW TO USE CONVERSION TABLE OF UNIT…………………………………………… 57
How to use conversion table…………………………………………………………… 57
Definition of unit ………………………………………………………………………… 57
GEBERAR SPECIFICATIONS ……………………………………………………………… 58
ENGINE SPECIFICATIONS ………………………………………………………………… 61
CHASSIS SPECIFICATIONS………………………………………………………………… 67
ELECTRICAL SPECIFICATIONS…………………………………………………………… 69
TIGHTENING TORQUES …………………………………………………………………… 71
Engine tightening torques………………………………………………………………… 71
Chassis tightening torques ……………………………………………………………… 74
GENERAL TIGHTENING TORQUE SPECIFICATIONS ………………………………… 76
LUBRICATION PIONTS AND LUBRICANT TYPES……………………………………… 77
Engine……………………………………………………………………………………… 77
Chassis……………………………………………………………………………………… 78
HYDROGRAPHIC CHART…………………………………………………………………… 79
LUBRICATION OIL WAY…………………………………………………………………… 80

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CHAPTER 3
MAINTENCE AND ADJUSTMENT OF THE UTV
MAINTENANCE SCHEDULE……………………………………………………………… 82
ENGINE
Adjusting the valve clearance…………………………………………………………… 84
Checking the spark plug ………………………………………………………………… 87
Checking the ignition timing……………………………………………………………… 88
Measuring the compression pressure………………………………………………… 89
Checking the engine oil level …………………………………………………………… 90
Changing the engine oil ………………………………………………………………… 91
CHASSIS
Cleaning the air filter………………………………………………………………… 93
Checking the coolant level …………………………………………………………… 94
Changing the coolant…………………………………………………………………… 95
Checking the coolant temperature warning light …………………………………… 98
Checking the v-belt……………………………………………………………………… 99
Cleaning the spark arrester …………………………………………………………… 100
Adjusting the brake pedal……………………………………………………………… 101
Checking the brake fluid level ………………………………………………………… 102
Checking the front brake pads………………………………………………………… 103
Checking the rear brake pads………………………………………………………… 103
Checking the brake hoses and brake pipes ………………………………………… 104
Bleeding the hydraulic brake system ………………………………………………… 104
Adjusting the select lever shift rod …………………………………………………… 106
Adjusting the brake light switch …………………………………………………… 106
Checking the final gear oil level…………………………………………………… 107
Changing the final gear oil…………………………………………………… 107
Checking the differential gear oil…………………………………………………… 108
Checking the constant velocity joint dust boots……………………………………… 109
Checking the steering system………………………………………………………… 110
Adjusting the toe-in …………………………………………………………………… 111
Adjusting the front and rear shock absorbers………………………………………… 112
Checking the tires ……………………………………………………………………… 114
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Checking the wheels…………………………………………………………………… 115
Checking and lubricating the cables ………………………………………………… 116
ELECTRICAL
Checking and charging the battery…………………………………………………… 117
Checking the fuses …………………………………………………………………… 123
Changing the headlight bulb………………………………………………………… 125
Changing the tail/brake light bulb …………………………………………………… 126
CHAPTER 4
ENGINE
ENGINE NOTE……………………………………………………………………………… 128
ENGINE REMOVAL………………………………………………………………………… 129
CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 131
ROCKER ARMS VALES AND CAMSHAFT……………………………………………… 136
VALVES AND VALVE SPRINGS…………………………………………………………… 139
CYLINDER AND PISTON………………………………………………………………… 144
ENGINE LEFT CRANKCASE COVER AND A.C. MAGNETO…………………………148
STARTER MOTOR AND WATER PUMP…………………………………………………152
PRIMARY AND SECONDARY SHEAVES…………………………………………………155
CRANKCASE COVER AND OIL PUMP……………………………………………………159
CRAKCASE AND MIDDLE DRIVEN SHAFT………………………………………………163
GEARCASE SHIFT LEVER AND OIL PUMP……………………………………………171
GEARCASE TRANSMISSION………………………………………………………………175
CHAPTER 5
CHASSIS
MALFUNCTION INSPECTION…………………………………………………………… 181
PANEL AND CARGO BED
Front panel………………………………………………………………………………… 184

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Checking the wheels…………………………………………………………………… 115
Checking and lubricating the cables ………………………………………………… 116
ELECTRICAL
Checking and charging the battery…………………………………………………… 117
Checking the fuses …………………………………………………………………… 123
Changing the headlight bulb………………………………………………………… 125
Changing the tail/brake light bulb …………………………………………………… 126
CHAPTER 4
ENGINE
ENGINE NOTE……………………………………………………………………………… 128
ENGINE REMOVAL………………………………………………………………………… 129
CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 131
ROCKER ARMS VALES AND CAMSHAFT……………………………………………… 136
VALVES AND VALVE SPRINGS…………………………………………………………… 139
CYLINDER AND PISTON………………………………………………………………… 144
ENGINE LEFT CRANKCASE COVER AND A.C. MAGNETO…………………………148
STARTER MOTOR AND WATER PUMP…………………………………………………152
PRIMARY AND SECONDARY SHEAVES…………………………………………………155
CRANKCASE COVER AND OIL PUMP……………………………………………………159
CRAKCASE AND MIDDLE DRIVEN SHAFT………………………………………………163
GEARCASE SHIFT LEVER AND OIL PUMP……………………………………………171
GEARCASE TRANSMISSION………………………………………………………………175
CHAPTER 5
CHASSIS
MALFUNCTION INSPECTION…………………………………………………………… 181
PANEL AND CARGO BED
Front panel………………………………………………………………………………… 184

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Side cover………………………………………………………………………………… 188
Side cover parts…………………………………………………………………………… 189
Cargo bed………………………………………………………………………………… 191
Head shed frame………………………………………………………………………… 193
DIRECTION SYSTEM
Steering wheel part……………………………………………………………………… 196
Steering mechanism part……………………………………………………………… 199
BRAKE SYSTEM…………………………………………………………………………… 204
Disk brake components………………………………………………………… 205
FOOTREST PART ………………………………………………………………… 223
WHEEL AND TYRE PARTS ……………………………………………………………… 226
Front wheels……………………………………………………………………………… 226
Rear wheels……………………………………………………………………………… 227
TRANSMISSION SYSTEM……………………………………………………………… 231
C.V axle, front axle……………………………………………………………………… 231
Front bridge……………………………………………………………………… 232
C.V axle, rear axle……………………………………………………………………… 237
Rear bridge reducer………………………………………………………… 238
SHIFT OPERATING SYSTEM …………………………………………………………… 245
SUSPENSION……………………………………………………………………………… 248
Front swing arm……………………………………………………………………… 248
Front suspension……………………………………………………………………… 249
Rear suspension……………………………………………………………………… 254
COOLING SYSTEM………………………………………………………………………… 259
Water and oil radiator…………………………………………………………………… 259
SEAT ………………………………………………………………………………………… 266
FUEL TANK………………………………………………………………………………… 269
CHAPTER 6
ELECTRICAL COMPONENTS
ELECTRICAL SYSTEM MALFUNCTION INSPECTION ……………………………… 272
ELECTRICAL………………………………………………………………………………… 273
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ELECTRICAL COMPONENTS…………………………………………………………… 273
Checking the switch…………………………………………………………………… 275
Checking the switch continuity………………………………………………………… 276
Checking the bulbs and bulb sockets ……………………………………… 277
IGNITION SYSTEM………………………………………………………………………… 277
Circuit diagram…………………………………………………………………………… 277
Troubleshooting……………………………………………………………………… 278
ELECTRIC STARTING SYSTEM………………………………………………………… 281
Circuit diagram………………………………………………………………………… 282
Troubleshooting……………………………………………………………………… 283
STARTER MOTOR………………………………………………………………………… 285
CHARGING SYSTEM……………………………………………………………………… 286
Circuit diagram………………………………………………………………………… 286
Troubleshooting……………………………………………………………………… 287
LIGHTING SYSTEM………………………………………………………………………… 288
Circuit diagram………………………………………………………………………… 288
Troubleshooting……………………………………………………………………… 289
Checking the lighting system…………………………………………………… 290
SIGNALING SYSTEM……………………………………………………………………… 291
Circuit diagram………………………………………………………………………… 291
Troubleshooting……………………………………………………………………… 292
Checking the signal system……………………………………………………… 293
COOLING SYSTEM………………………………………………………………………… 300
Circuit diagram………………………………………………………………………… 300
Troubleshooting……………………………………………………………………… 301
2WD/4WDSELECTINGSYSTEM………………………………………………………… 303
Circuit diagram………………………………………………………………………… 303
Troubleshooting……………………………………………………………………… 304
CHAPTER 7
ENGINE MANAGEMENT SYSTEM
INTRODUCTION

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ELECTRICAL COMPONENTS…………………………………………………………… 273
Checking the switch…………………………………………………………………… 275
Checking the switch continuity………………………………………………………… 276
Checking the bulbs and bulb sockets ……………………………………… 277
IGNITION SYSTEM………………………………………………………………………… 277
Circuit diagram…………………………………………………………………………… 277
Troubleshooting……………………………………………………………………… 278
ELECTRIC STARTING SYSTEM………………………………………………………… 281
Circuit diagram………………………………………………………………………… 282
Troubleshooting……………………………………………………………………… 283
STARTER MOTOR………………………………………………………………………… 285
CHARGING SYSTEM……………………………………………………………………… 286
Circuit diagram………………………………………………………………………… 286
Troubleshooting……………………………………………………………………… 287
LIGHTING SYSTEM………………………………………………………………………… 288
Circuit diagram………………………………………………………………………… 288
Troubleshooting……………………………………………………………………… 289
Checking the lighting system…………………………………………………… 290
SIGNALING SYSTEM……………………………………………………………………… 291
Circuit diagram………………………………………………………………………… 291
Troubleshooting……………………………………………………………………… 292
Checking the signal system……………………………………………………… 293
COOLING SYSTEM………………………………………………………………………… 300
Circuit diagram………………………………………………………………………… 300
Troubleshooting……………………………………………………………………… 301
2WD/4WDSELECTINGSYSTEM………………………………………………………… 303
Circuit diagram………………………………………………………………………… 303
Troubleshooting……………………………………………………………………… 304
CHAPTER 7
ENGINE MANAGEMENT SYSTEM
INTRODUCTION

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Ems (engine management system) …………………………………………………… 305
Typical components of EMS………………………………………………………………305
Layout of EMS components………………………………………………………………305
COMPONENTS OF EMS
Electronic control unit …………………………………………………………………… 306
Multec 3.5 injectors ……………………………………………………………………… 307
Throttle body assembly(with stepper motor) …………………………………………311
Engine coolant temperature sensor ……………………………………………………313
Intake air pressure and temperature sensor …………………………………………313
Oxygen sensor ………………………………………………………………………… 314
Ignition coil……………………………………………………………………………… 314
Fuel pump module…………………………………………………………………………318
EMS FAULT DIAGNOSIS
EME fault diagnosis ………………………………………………………………………324
Fault code list………………………………………………………………………………324
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING………………………………………………… 326
Fuel system ………………………………………………………………………………326
Electrical system ………………………………………………………………………… 326
Compression system …………………………………………………………………… 327
POOR IDLE SPEED PERFORMANCE ………………………………………………… 327
Poor idle speed performance…………………………………………………………… 327
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ……………………………… 328
Poor medium and high-speed performance………………………………………… 328
FAULTY GEAR SHIFTING………………………………………………………………… 328
Shift lever does not move ……………………………………………………………… 328
Jumps out of gear……………………………………………………………………… 328
ENGING OVERHEATING…………………………………………………………………… 329
Overheating……………………………………………………………………………… 329
FAULTY BRAKE…………………………………………………………………………… 329
Poor braking effect……………………………………………………………………… 329
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SHOCK ABSORBER MALFUNCTION………………………………………………… 330
Loss of damping function……………………………………………………………… 330
UNSTABLE HANDLING…………………………………………………………………… 330
Unstable handling……………………………………………………………………… 330
LIGHTING SYSTEM………………………………………………………………………… 330
Head light is out of work………………………………………………………………… 330
Bulb burnt out…………………………………………………………………………… 331
Error display of meter…………………………………………………………………… 331
CHAPTER 9
WIRING DIAGRAM
WIRING DIAGRAM…………………………………………………………………… 332
WIRING EFI DIAGRAM…………………………………………………………………… 333
IGNITION SYSTEM CIRCUIT DIAGRAM…………………………………………………334
ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM…………………………………335
LIGHTING SYSTEM CIRCUIT DIAGRAM………………………………………………336
SIGNALING SYSTEM CIRCUIT DIAGRAM………………………………………………337
2WD/4WD SELECTION SYSTEM CIRCUIT DIAGRAM…………………………………338

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SHOCK ABSORBER MALFUNCTION………………………………………………… 330
Loss of damping function……………………………………………………………… 330
UNSTABLE HANDLING…………………………………………………………………… 330
Unstable handling……………………………………………………………………… 330
LIGHTING SYSTEM………………………………………………………………………… 330
Head light is out of work………………………………………………………………… 330
Bulb burnt out…………………………………………………………………………… 331
Error display of meter…………………………………………………………………… 331
CHAPTER 9
WIRING DIAGRAM
WIRING DIAGRAM…………………………………………………………………… 332
WIRING EFI DIAGRAM…………………………………………………………………… 333
IGNITION SYSTEM CIRCUIT DIAGRAM…………………………………………………334
ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM…………………………………335
LIGHTING SYSTEM CIRCUIT DIAGRAM………………………………………………336
SIGNALING SYSTEM CIRCUIT DIAGRAM………………………………………………337
2WD/4WD SELECTION SYSTEM CIRCUIT DIAGRAM…………………………………338

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GENERAL INFORMATION
-1-
GENERAL INFORMATION
The text provides complete information on maintenancetune-up repair and overhaulHundreds of
photographs and illustrations created during the complete disassembly of four wheel utility terrain
venires (UTV) guide the reader through every jobAll procedures are in step-by-step format and
designed for the reader who may be working on the UTV for the first time.
WARNINGS, CAUTIONS AND NOTES
The terms WARNING, CAUTION and NOTE have specific meaning in this manual.
WARNING: emphasizes areas where injury or even death could result from negligence.
Mechanical damage may also occur. WARNINGS are to be taken seriously
CAUTION: emphasizes areas where equipment damage could result. Disregarding a
CAUTION could cause permanent mechanical damage. though injury is unlikely.
NOTE: provides additional information to make a step or procedure easier or clearer.
Disregarding a NOTE could cause inconvenience. but would not cause
equipment damage or injury.

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GENERAL INFORMATION
-2-
DESCRIPTION
1. Headlights
2. Air filter case (engine and air
intake duct)Rear brake fluid
reservoir
3. Brake pump
4. EPS
5. Air spring
6. Parking brake lever
7. Battery
8. Driver seat belt
9. The intake air tube clutch
10. Cargo bed
11. Rear shock absorber
12. Rear turning lights
13. Rear bumper assy.
14. Muffler
15. Rear wheel
16. Engine
17. Passenger seat belt
18. Fuel tank cap
19. Ignition switch
20. Passenger handrail
21. Front wheel
22. Front shock absorber
23. Water and oil radiator
24. Front bumper assy.
25. Driver seat
26. Horn switch
27. Steering wheel
28. Brake pedal
29. Accelerator pedal
30. Drive select lever
31. Speedmeter
32. DC socket
33. Passenger seat
NOTE:
The vehicle you have purchased may
differ slightly from those in the figures of
this manual.

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GENERAL INFORMATION
-3-
IDENTIFICATION CODE
Frame No.
Frame No. is carved on the right side of front
main frame
Engine No.
Engine NO. Is carved on the right side of the
engine, Figure.

-4-
GENERAL INFORMATION
- 4 -
SAFETY
Professional mechanics can work for years and never sustain a serous injury or mishap. Follow
these guidelines and practice common sense to safely service the utility terrain venires
1. Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain
carbon monoxide. an odorless, colorless and tasteless poisonous gas. Carbon monoxide levels
build quickly in small enclosed areas and can cause unconsciousness and death in a short time.
Make sure to properly ventilate the work area or operate the UTV side
2. Never use gasoline or any extremely flammable liquid to clean parts. Refer to cleaning parts and
handling Gasoline Safely in this section
3. Never smoke or use a torch in the vicinity of flammable liquids, such as gasoline or cleaning
solvent.
4. If welding or brazing on the UTV the fuel tank to a safe distance at least 50ft.(15m) away.
5. Use the correct type and size of tools to avoid damaging fasteners.
6. Keep tools clean and in good condition. Replace or repair worn or damaged equipment.
7. When loosening a tight fastener, be guided by what would happen if the tool slips.
8. When replacing fasteners, make sure the new fasteners are the same size and strength as the
original ones.
9. Keep the work area clean and organized.
10. Wear eye protection anytime the safety of the eyes is in question. This includes procedures that
involve drilling, grinding, hammering, compressed air and chemicals.
11. Wear the correct clothing for the job. Tie up or cover long hair so it does not get caught in moving
equipment.
12. Do not carry sharp tools in clothing pockets.
13. Always have an approved fire extinguisher available. Make sure it is rated for gasoline (Class B)
and electrical (Class C) fires.
14. Do not use compressed air to clean clothes, the UTV or the work area. Debris may be blown into
the eyes or skin. Never direct compressed air at anyone. Do not allow children to use or play with
any compressed air equipment.
15. When using compressed air to dry rotating parts, hold the part so it does not rotate. Do not allow
the force of the air to spin the part. The air jet is capable of rotating parts at extreme speed. The
part may disintegrate of become damaged, causing serious injury.
16. Do not inhale the dust created by brake pad and clutch wear. These particles may contain
asbestos. In addition, some types of insulating materials and gaskets may contain asbestos.
Inhaling asbestos particles is hazardous to one’s health.
17. Never work on the UTV while someone is working under it.
Handling Gasoline Safely
Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop.
Because gasoline is used so often, many people forget it is hazardous. Only use gasoline as fuel
for gasoline internal combustion engines. Keep in mind when working on the machine, gasoline is
always present in the fuel tank fuel line throttle. To avoid a disastrous accident when working
around the fuel system, carefully observe the following precautions:

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GENERAL INFORMATION
- 5 -
1. Never use gasoline to clean parts. Refer to Cleaning Parts in this section.
2. When working of the fuel system, work outside or in a well-ventilated area.
3. Do not add fuel to the fuel tank or service the fuel system while the UTV is near open flames,
sparks or where someone is smoking .Gasoline vapor is heavier than air, it collects in low areas
and is more easily ignited than liquid gasoline.
4. Allow the engine to cool completely before working on any fuel system component.
5. Do not store gasoline in glass containers. If the glass breaks, a serious explosion of fire may
occur.
6. Immediately wipe up spilled gasoline with rags. Store the rags in a metal container with a lid until
they can be properly disposed of, or place them outside in a safe place for the fuel to evaporate.
7. Do not pour water onto a gasoline fire. Water spreads the fire and makes it more difficult to put out.
Use a class B, BC or ABC fire extinguisher which are dedicated to extinguish the gasoline fire.
8. Always turn off the engine before refueling. Do not spill fuel onto the engine or exhaust system.
Do not overfill the fuel tank. Leave an air space at the top of the tank to allow room for the fuel to
expand due to temperature fluctuations.
Cleaning Parts
Cleaning parts is one of the more tedious and difficult service jobs performed in the home garage.
Many types of chemical cleaners and solvents are available for shop use. Most are poisonous and
extremely flammable. To prevent chemical exposure, vapor buildup, fire and serious injury, observe
each product warning label and note the following:
1. Read and observe the entire product label before using any chemical. Always know what type of
chemical is being used and whether it is poisonous and/or flammable.
2. Do not use more than one type of cleaning solvent at a time. If mixing chemicals is required,
measure the proper amounts according to the manufacturer.
3. Work in a well-ventilated area.
4. Wear chemical-resistant gloves.
5. Wear safety glasses.
6. Wear a vapor respirator if the instructions call for it.
7. Wash hands and arms thoroughly after cleaning parts.
8. Keep chemical products away from children and pets.
9. Thoroughly clean all oil, grease and cleaner residue from any part that must be heated.
10. Use a nylon brush when cleaning parts. Metal brushes may cause a spark.
11. When using a parts washer, only use the solvent recommended by the manufacturer. Make sure
the parts washer is equipped with a metal lid that will lower in case of fire.
Warning Labels
Most manufacturers attach information and warning labels to the UTV. These labels contain
instructions that are important to personal safety when operating, servicing, transporting and storing
the UTV. Refer to the owner’s manual for the description and location of labels. Order replacement
labels from the dealers or manufacturer if they are missing or damaged.

-6-
GENERAL INFORMATION
- 6 -
SERIAL NUMBERS
Serial and identification numbers are stamped on various locations on the frame engine throttle
body. Record these numbers in the Quick Reference Data section in the front of the manual. Have
these numbers available when ordering parts.
FASTENERS
Proper fastener selection and installation is important to ensure the motorcycle operates as
designed and can be serviced efficiently. The choice of original equipment fasteners is not arrived at
by chance. Make sure replacement fasteners meet all the same requirements as the originals
Many screws. Bolts and studs are combined with nuts to secure particular components. to indicate
the size of a nut. Manufactures specify the internal diameter and the thread pitch
The measurement across two flats on a nut or bolt indicates the wrench size
WARNING
Do not install fasteners with a strength
classification lower than what was originally
installed by the manufacturer doing so may cause
equipment failure and or damage
Torque Specifications
The material used in the manufacturing of the UTV may be subjected to uneven stresses if the
fasteners of the various subassemblies are not installed and tightened correctly. Fasteners that are
improperly installed or work loose can cause extensive damage. it is essential to use an accurate
torque wrench as described in this chapter
Self-Locking Fasteners
Several types of bolts. Screws and nuts incorporate a system that creates interference between
the two fasteners. Interference is achieved in various ways. The most common types are the nylon
insert nut and a dry adhesive coating on the threads of a blot.
Self-locking fasteners offer greater holding strength than standard fasteners, which improves their
resistance to vibration.All self-locking fasteners cannot be reused. The materials used to from the lock
become distorted after the initial installation and removal. Discard and replace self-locking fasteners
after removing them. Do not replace self-locking fasteners with standard fasteners.
Washers
The two basic types of washers are flat washers and lock washers. Flat washers are simple discs
with a hole to fit a screw or bolt. Lock washers are used to prevent a fastener from working loose.
Washers can be used as spacers and seals. Or can help distribute fastener load and prevent the
fastener from damaging the component
As with fasteners. When replacing washers make sure the replacement washers are of the same
design and quality