Cub Cadet Challenger Series User manual

SERVICE MANUAL
Challenger 500
Challenger 700

Foreword
Brief Introduction to the Service and MaintenanceHandbook
500/700 Challenger Utility Vehicles
This manual gives methods to check, maintain and repair the Cub Cadet 500 &700
utility vehicles (UV’s), and supplies some relevant techniques and performance
data.
Please read the handbook through and fully understand it; otherwise, any
improper repairing could cause problems, and/or an accident mayoccur.
Proper use and maintenance will reduce malfunctions, and help the vehicle
remain at its best performance level.
The standards, procedures and specifications mentioned in this manual are basedon
the sample in design, and they are subject to changes according to theproduct’s
improvement without prior notice.

INDEX
Chapter 8
Troubl eshooti ng
Wi ri ng
Di agram
Chapter 6
El ectri cal
Chapte
r
7
Engi ne
Management
S
y
stem
Chapte
r
4
Engi ne
Chapte
r
5
Chassi s
Chapter 2
Speci ficati ons
Chapter 3
Peri odi c
Mai ntenance
and
Adj ustments
I ndex Chapter 1
General

INDEX
General Information
Chapter 1
Warning, Caution, Note
Description
Vehicle Identification Code, Engine
Number
Safety
Handling Gasoline, Cleaning Parts
Warning Labels, Serial Numbers,
Fasteners
Self-Locking Fasteners, Washers,
Cotter Pins, Snap Rings and E-
clips
Shop Supplies
Lubricants and Fluids,
Engine Oils, Greases, Brake Fluid
Coolant, Cleaners, Degreasers,
and solvents
Gasket Sealant, Gasket Remover,
Thread Locking Compound
Basic Tools
Screwdrivers
Wrenches
Adjustable Wrenches, Sockets,
Ratchets, and Handles
Impact Drivers
Allen Wrenches
Torque Wrenches, Torque
Adapters
Pliers, Snap Ring Pliers
Ignition Grounding Tool
Precision Measuring Tools
Feeler Gauge, Calipers
Micrometers
Adjustment and Care
Metric Micrometer
Standard Micrometer
Telescoping and Small Bore
Gauges
Dial Indicator, Compression Gauge
Multimeter
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-11
1-11
1-12
1-13
1-14
1-15
1-15
1-16
1-17
1-17
1-18
1-19
1-20
1-20
1-21
1-22
1-23
1-24
Electrical System Fundamentals
Voltage
Resistance, Amperage
Basic Service Methods
Removing Frozen Fasteners
Removing Broken Fastener
Stud Removal, Removing Hoses
Bearings
Removal
Installation
Interference Fit
Seal Replacement
Storage
Area Selection
Preparing the UV for storage
Returning the UV to Service
Specifications
Chapter 2
General Specifications
Engine Torque Specifications
Chassis Torque Specifications
General Torque Specifications
Chassis Lubrication points
Periodic Maintenance
Chapter 3
Periodic Maintenance Table
Periodic Maintenance
Engine
Valve Clearance
Spark Plug
Compression Test
Engine oil
Oil Change
Air Filter cleaning
Coolant Change
V-Belt Inspection
Replacement
Cleaning the Spark Arrester
Adjustment of the Parking Brake
Brake Fluid Level check
1-24
1-24
1-25
1-25
1-27
1-27
1-28
1-28
1-29
1-30
1-31
1-32
1-32
1-33
1-33
2-1
2-13
2-16
2-18
2-19
3-1
3-3
3-4
3-6
3-7
3-8
3-9
3-11
3-12
3-15
3-16
3-16
3-17
3-18

INDEX
Brake lines, Bleeding the Brake
Select Lever Shift Rod adjustment
Brake light switch adjustment
Final Gear oil Change
Tow In adjustment
CV Boot inspection
Steering system Inspection
Rear Shock adjustment
Tire inspection
Headlight Bulb replacement
Tail Light Bulb replacement
Engine
Chapter 4
Special Notes
Engine removal
Cylinder Head and Cover
Inspection, installation
Rocker Arm and Camshaft
3-19
3-20
3-20
3-21
3-22
3-23
3-23
3-24
3-24
3-24
3-25
4-1
4-2
4-3
4-4
4-6
Crankcase, Starter Motor and Oil
Filter
Crankcase
Bearings
Inspection
Assembly
Crankshaft and Oil Pump
Oil Pump
Inspection
Installation
Transmission
Drive Axle Assembly
Inspection
Installation
Middle Gear, Middle Drive Shaft
Middle Driven Shaft
Inspection
Installation
Chassis
4-30
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
4-39
4-40
4-41
4-42
4-43
4-44
4-45
4-46
Inspection 4-7
Chapte
r
5
Installation 4-8
Val
v
es and Valve springs 4-9 Inspection 5-1
Inspection 4-10 Steering S
y
stem 5-4
Installation 4-11 Steering Wheel
A
ssembly 5-5
C
y
linde
r
and Piston 4-12 Disassembl
y
, Inspection 5-6
Inspection 4-13 Installation 5-8
Installation 4-14 B
r
ake S
y
stem Inspection 5-8
Engine Cooling Fan and
A
.C. 4-15 B
r
ake Line Removal 5-10
Magneto B
r
ake Disc Removal 5-11
Inspection 4-16 Inspection 5-12
Installation 4-17 B
r
ake Pad Removal 5-13
Balance
r
Gea
r
s and Oil Pump 4-18 Installation 5-14
Gea
r
sF
r
ont B
r
a
k
eCalipe
r
Remo
v
al 5-15
Inspection 4-19 B
r
ake Calipe
r
Disassembly 5-16
Installation 4-19 Installation 5-17
Prima
r
y and Seconda
r
y Sheaves 4-20 Rea
r
B
r
ake Disc Remo
v
al 5-19
Prima
r
y Shea
v
e4-21 Inspection 5-20
Seconda
r
y Shea
v
e4-22 Rea
r
B
r
ake Calipe
r
and Pads 5-21
Inspection 4-23 Rea
r
B
r
ake Pad Replacement, 5-23
Installation 4-24 Inspection 5-23
Clutch 4-26
A
ssembly and Installation 5-24
Disassembly 4-27 B
r
ake Mas
t
e
r
C
y
linde
r
5-26
Inspection 4-28 Inspection, Ins
t
allation 5-27
Installation 4-29 Foot
r
est
A
ssembly 5-28

INDEX
Front Wheel and Tire
Rear Wheel
Inspection, Installation
Transmission Front Bridge
Front Bridge Removal
Disassembly
CV Joint Inspection
Differential Gear and Gear Motor
Operation
U-Joint Assembly
Differential Gear Motor Adjustment
Front Bridge Installation
Rear Bridge
Rear Differential Removal
Gear Shift Mechanism
Adjustment
Front Suspension and A-Arm
Inspection, Installation
Rear Suspension
Rear A-Arm
Inspection, Installation
Cooling System
Inspection, Coolant replacement
Water Pump Assembly
Disassembly, Inspection
Assembly
Seat Assembly
Fuel System
Fuel Pump Inspection
Electrical
Chapter 6
Components
Battery
Lead Acid Battery Charging
Maintenance Free Battery
Charging
Checking Fuses
Switch Inspection
Switch Locations
Bulbs and Sockets
Ignition Circuit Diagram
Ignition Troubleshoot
Starting Circuit Diagram
5-30
5-31
5-32
5-33
5-34
5-37
5-37
5-38
5-39
5-39
5-40
5-41
5-42
5-45
5-46
5-47
5-49
5-50
5-51
5-52
5-53
5-55
5-56
5-58
5-59
5-60
5-62
5-66
6-1
6-3
6-4
6-6
6-7
6-8
6-9
6-10
6-11
6-12
6-15
Brake Master Cylinder
Inspection, Installation
Footrest Assembly
Starter Motor Troubleshoot
Starter Motor Removal
Charging Circuit Diagram
Charging System Troubleshoot
Lighting Circuit Diagram
Signaling Circuit Diagram
Cooling Circuit Diagram
2WD / 4WD Select Circuit Diagram
Engine Management
System Chapter 7
Components
E.C.U.
Fuel Injectors
Installation Guidelines
Replacement
Cleaning Procedure
Throttle Body
Engine Coolant Temperature
Sensor
Oxygen Sensor
Fuel Pump Module
Inspection
Removal, Installation
Fuel Leak Check
E.M.S. Fault Codes
Troubleshooting
Chapter 8
Spark Test
Fuel System Check
Compression Test
Engine Overheating
Engine Noises
Cylinder Leak Down
Electrical checks
Intermittent Problems
E.C.U.
5-26
5-27
5-28
6-16
6-17
6-18
6-19
6-20
6-21
6-22
6-23
7-1
7-2
7-3
7-3
7-5
7-6
7-7
7-7
7-8
7-8
7-9
7-10
7-10
7-11
8-1
8-2
8-2
8-3
8-4
8-5
8-7
8-8
8-9

Vehicle Identification Number
LWG MD SZ 44 E B 123456
LWG
MD
MH
Manufacturer
UV below 750 cc
UV above 750 cc
SZ
TZ 500cc
YZ
700cc
44 DOT Check Digits
A 2010 Model Year
B 2011 Model year
C 2012 Model Year
D 2013 Model Year
E 2014 Model Year
A Manufacturing Plant A
B Manufacturing Plant B
123456 Sequential Serial
Number

General Information
1‐1
This manual provides complete information on maintenance, tune-up, repairand
overhaul. Hundreds of photographs and illustrations created during the complete
disassembly of Utility Vehicles (UV) guide the reader through every job. All
procedures are in step by step format and designed for the reader who maybe
working on the UV for the first time.
Warnings, Cautions and Notes
The terms Warning, Caution and Note have specific meanings in thismanual.
Warning
Emphasizes areas where injury or even death could resultfrom
negligence.
Caution
Emphasizes areas where equipment damage could result.
Disregarding a Caution could cause permanent
mechanical damage, although injury isunlikely.
Note
Provides additional information to make a step or procedureeasier
or clearer. Disregarding a Note could cause inconvenience, but
would not cause equipment damage orinjury.

General Information
1‐2
Description
Note
The vehicle you have purchased may
differ slightly from those in the
figures of this manual.
1. Headlights
2. Frontshockabsorberadjustingring
3. Brakefluidreservoir
4. Airfilterelement(insideairintakeduct)
5. V‐beltcase
6. Driverseat
7. Driverseatbelt
8. Sparkplug
9. Cargobed
10. Tail/brakelights
11. Rearshockabsorberadjustingring
12. Cargobedreleaselever
13. Sparkarrester
14. Passengerseatbelt
15. Passengerseat
16. Oilfilter
17. Engineoildipstick
18. Battery
19. Fuses
20. Coolantreservoir
21. Radiatorcap
22. Fuelcap
23. Lightswitch
24. Steeringwheel
25. Choke
26. Ignitionswitch
27. On‐commandfour‐wheeldriveand
Differentiallockswitches
28. Multi‐functiondisplayunit
29. AuxiliaryDCoutlet
30. Driveselectlever
31. Parkingbrakelever
32. Acceleratorpedal
33. Brakepedal

General Information
1‐3
Identification Code
Vehicle Identification Number
Vehicle Identification number is
stamped in the lower right side of
the frame.
Engine Number
Engine number is printed on a
white tag on top of the clutch
cover.