Cub Cadet Challenger Series User manual

SERVICE MANUAL
Challenger 550 & 750

Foreword
Brief introduction to the service and maintenance handbook
for 550/750 Challenger UV
This manual gives methods to check, maintain and repair the Cub Cadet 550 & 750
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 may occur.
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 based on
the sample in design, and they are subject to changes according to the product’s
improvement without prior notice.

Chapter 1
General
Chapter 1
General
Chapter 3
Periodic
Maintenance and
Adjustments
Chapter 5
Chassis
Chapter 7
Engine
Management
System
Chapter 6
Electrical
Diagram
Chapter 8
Troubleshooting
INDEX
Chapter 2
Specifications
Chapter 4
Engine

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
Multi meter
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
Oil Pressure
Air Filter cleaning
Coolant Change
Coolant Bleeding
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
2-18
2-21
2-23
2-24
3-1
3-3
3-4
3-6
3-7
3-7
3-8
3-9
3-9
3-11
3-13
3-15
3-16
3-16
3-18
3-19

INDEX
Brake lines, Bleeding the Brake
3-21
Crankcase, Starter Motor and Oil
4-31
Select Lever Shift Rod adjustment
3-24
Filter
Checking Final Gear Oil
3-25
Crankcase
4-32
Adjusting Toe In
3-26
Bearings
4-33
Front Shock Adjustment
3-27
Inspection
4-34
Brake light switch adjustment
3-27
Assembly
4-35
Steering system Inspection
3-29
Crankshaft and Oil Pump
4-36
Oil Pump
4-37
Inspection
4-38
Installation
4-39
Transmission
4-40
Drive Axle Assembly
4-41
Engine
Chapter 4
Special Notes
Engine removal
Cylinder Head and Cover
Inspection, installation
Rocker Arm and Camshaft
4-1
4-2
4-3
4-4
4-6
Inspection
Installation
Middle Gear, Middle Drive Shaft
Middle Driven Shaft
Inspection
Installation
Chassis
4-42
4-43
4-44
4-45
4-46
4-47
Inspection
4-7
Chapter 5
Installation
4-8
Valves and Valve springs
4-9
Inspection
5-1
Inspection
4-10
Steering System
5-4
Installation
4-11
Steering Wheel Assembly
5-5
Cylinder and Piston
4-12
Disassembly, Inspection
5-6
Inspection
4-13
Installation
5-8
Installation
4-14
Brake System Inspection
5-9
Engine Cooling Fan and A.C.
4-15
Brake Line Removal
5-10
Magneto
Brake Disc Removal
5-11
Inspection
4-16
Inspection
5-12
Installation
4-17
Brake Pad Removal
5-13
Balancer Gears and Oil Pump
4-19
Installation
5-14
Gears
Front Brake Caliper Removal
5-15
Inspection
4-20
Brake Caliper Disassembly
5-16
Installation
4-20
Installation
5-17
Primary and Secondary Sheaves
4-21
Rear Brake Disc Removal
5-19
Primary Sheave
4-22
Inspection
5-20
Secondary Sheave
4-23
Rear Brake Caliper and Pads
5-21
Inspection
4-24
Rear Brake Pad Replacement,
5-23
Installation
4-25
Inspection
5-23
Clutch
4-27
Assembly and Installation
5-24
Disassembly
4-28
Brake Master Cylinder
5-26
Inspection
4-29
Inspection, Installation
5-27
Installation
4-30
Footrest Assembly
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
5-38
5-38
5-38
5-40
5-40
5-41
5-42
5-44
5-47
5-48
5-49
5-51
5-52
5-53
5-54
5-55
5-57
5-58
5-60
5-61
5-62
5-63
5-65
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 WZ 44 E B 123456
LWG
MDM
H
Manufacturer
UV below 750cc
UV above 750 cc
ZZ 550cc
WZ 750cc
44 DOT Check Digits
H 2017 Model Year
J 2018 Model year
K 2019 Model Year
L 2020 Model Year
M 2021 Model Year
A Manufacturing Plant A
B Manufacturing Plant B
12345 123456 Sequential Serial Number

General Information
1‐1
This manual provides complete information on maintenance, tune-up, repair and
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 may be working on the UV
for the first time.
Warnings, Cautions and Notes
The terms Warning, Caution and Note have specific meanings in this manual.
Warning
Emphasizes areas where injury or even death could result from
negligence.
Caution
Note
Emphasizes areas where equipment damage could result.
Disregarding a Caution could cause permanent
Mechanical damage, although injury is unlikely.
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.

General Information
1‐2
Description
1. Front bumper assy.
2. Headlights
3. Front shock absorber
4. Brake pump
5. Steering wheel
6. Left door comp.
7. Driver seat belt
8. Cargo bed
9. Rear shock absorber
10. Tail lights
11. Muffler
12. Invert bracket assy
13. Fuel tank cap
14. Passenger seat belt
15. Right door comp.
16. Drive select lever
17. Air filter case (engine and air
intake duct) Rear brake fluid
reservoir
18. Head turn signal lamp
19. Water cooler
20. Front turning lights
21. High/low beam lights
22. 2/4 WD
23. The front axle differential
24. Range gear shift lever
25. Parking brake
26. Emergency light
27. Left/right turning switch
28. Brake pedal
29. Accelerator pedal
30. Winch cable
31. Rear axle differential unlock/lock
32. Cover storage box
33. Hand hold
NOTE:
The vehicle you have purchased may
differ slightly from those in the figures
of this manual.

General Information
1‐3
Engine Identification Number
Part Three consists of Feature code I, year code, Feature code II, month code and serial
number.
Rear Spacer
Serial Number
Month Code
Feature Code II
Year Code
Feature Code I
Spacer
Feature Code I
Configuration
Code
Configuration
Code
φ140 Clutch, 1:5 Taper
0
φ150 Clutch, 1:7 Taper
1
φ150 Clutch, 1:7 Taper, CARB Comp.
2
Year Code
Year
Code
Year
Code
Year
Code
Year
Code
2010
A
2013
D
2016
G
2019
K
2011
B
2014
E
2017
H
2020
L
2012
C
2015
F
2018
J
2021
M
2
Feature Code II
Code Transmission Gear Ratios
0 41/21 Fixed Reduction +H（26/21）+L（35/17）
R 41/21 Fixed Reduction +H（30/18）+L（34/14）
2 42/19 Fixed Reduction +H（30/18）+L（34/14）
Month Code
Month
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Code
A
B
C
D
E
F
G
H
J
K
L
M