Explorer Patriot 430 User manual

SERVICE MANUAL
PATRIOT 430

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This service manual contains the technical data of each component
inspection and repair for the EXP PATRIOT 430 ATV. The manual is
shown with illustrations and focused on “Service Procedures”, “Operation
Key Points”, and “Inspection Adjustment” so that provides technician with
service guidelines.
If the style and construction of the ATV, EXP PATRIOT 430 ATV, are
different from that of the photos, pictures shown in this manual, the actual
vehicle shall prevail. Specifications are subject to change without notice.

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HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and system
inspection & service for EXP PATRIOT 430 ATV. In addition, please refer to the manual
contents in detailed for the model you serviced in inspection and adjustment.
Chapter.1 includes general information and trouble diagnosis.
Chapter 2 includes service maintenance information and special tools manual.
Chapter 3~11 includes engine and driving systems.
Chapter 12 includes cooling system.
Chapter 13~16 includes assembly frame body.
Chapter 17 includes electrical equipment.
Chapter 18 includes wiring diagram.
Please see index of content for quick having the special parts and system information.

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SERIAL NUMBER
Frame number:
                             
Engine number:

Home page Contents

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CONTENTS Page Content Index
1-1 ~ 1-18 GENERAL INFORMATION 1
2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 2
3-1 ~ 3-8 LUBRICATION SYSTEM 3
4-1 ~ 4-12 FUELSYSTEM 4
5-1 ~ 5-6 ENGINEREMOVAL 5
6-1 ~ 6-16 CYLINDER HEAD/VALVE 6
7-1 ~ 7-8 CYLINDER/PISTON 7
8-1 ~ 8-14
ಯ
V
ರ
BELT DRIVING SYSTEM 8
9-1 ~ 9-12 FINAL DRIVING MECHANISM 9
10-1 ~ 10-10 ALTERNATOR/STARTINGCLUTCH
10
11-1 ~ 11-8 CRANKSHAFT/ CRANKCASE 11
12-1 ~ 12-12 COOLINGSYSTEM
12
13-1 ~ 13-14 BODYCOVER 13
14-1 ~ 14-14 FRONT BRAKE AND FRONT WHEEL 14
15-1 ~ 15-10 STEERING/FRONT SUSPENSION 15
16-1 ~ 16-18 REAR BRAKE/REAR WHEEL / REAR CUSHION 16
17-1 ~ 17-22 ELECTRICAL EQUIPMENT 17
18-1 ~ 18-2 ELECTRICAL DIAGRAM
18

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1. Symbols and Marks 1-1
2. General Safety 1-2
3. Service Precautions 1-4
4. Specifications 1-16
5. Torque Values 1-17
6. Troubles Diagnosis 1-19
7. Lubrication Points 1-24
1. Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service
is needed. In case supplemental information of procedures is needed for these symbols and
marks, explanations will be added to the text instead of using the symbols or marks.
Warning Means that serious injury or even death may result if procedures are not
followed.
Caution Means that equipment damages may result if procedures are not followed.
Engine oil Limits to use SAE 10W-40 API SG class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
Grease Chassis grease is recommended.
Gear oil Gear oil serials are recommended. (Gear oil SAE 80/90 is recommended )
Locking sealant Apply sealant; medium strength sealant should be used unless otherwise
specified.
Oil seal Apply with lubricant.
Renew Replace with a new part before installation.
Brake fluid Use recommended brake fluid DOT4.
Special tools Special tools
Correct Meaning correct installation.
Wrong Meaning wrong installation.
Indication Indication of components.
Directions Indicates position and operation directions

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2. General Safety
Carbon monoxide
If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed
area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to
use an extractor.
Caution
Exhaust contains toxic gas which may cause one to lose consciousness and even result in death.
Gasoline
Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or
spark should be allowed in the work place or where gasoline is being stored.
Caution
Gasoline is highly flammable, and may explode under some conditions, keep it away from children.
Used engine oil
Caution
Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it
might not be verified. We recommend that you wash your hands with soap and water right after
contacting. Keep the used oil beyond reach of children.
Hot components
Caution
Components of the engine and exhaust system can become extremely hot after engine running.
They remain very hot even after the engine has been stopped for some time. When performing
service work on these parts, wear insulated gloves and wait until cooling off.
Battery
Caution
xBattery emits explosive gases; Flame is strictly prohibited. Keeps the place well ventilated
when charging the battery.
xBattery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do
not be spray on your eyes or skin. If you get battery acid on your skin, flush it off
immediately with water. If you get battery acid in your eyes, flush it off immediately with
water and then go to hospital to see an ophthalmologist.
xIf you swallow it by mistake, drink a lot of water or milk, and take some laxative such as
castor oil or vegetable oil and then go to see a doctor.
xKeep electrolyte beyond reach of children.

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Brake pad
Do not use an air hose or a dry brush to clean components of the brake system; use a vacuum
cleaner or the equivalent to avoid dust flying.
Caution
Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system
Brake fluid
Caution
Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the
brake fluid beyond reach of children.

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3. Service Precautions
Always use with EXP genuine parts and recommended oils. Using non-designed parts for EXP
ATV may damage the ATV.
Special tools are designed for remove and install of components without damaging the parts being
worked on. Using wrong tools may result in parts damaged.
When servicing this ATV, use only metric tools. Metric bolts, nuts, and screws are not
interchangeable with the English system, using wrong tools and fasteners may damage this
vehicle.
Clean the outside of the parts or the cover before removing it from the ATV. Otherwise, dirt and
deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to
cause damage.
Wash and clean parts with high ignition point solvent, and blow dry with compressed air. Pay
special attention to O-rings or oil seals because most cleaning agents have an adverse effect on
them.

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Never bend or twist a control cable to prevent unsmooth control and premature worn out.
Rubber parts may become deteriorated when old, and prone to be damaged by solvent and oil.
Check these parts before installation to make sure that they are in good condition, replace if
necessary.
When loosening a component which has different sized fasteners, operate with a diagonal
pattern and work from inside out. Loosen the small fasteners first. If the bigger ones are loosen
first, small fasteners may receive too much stress.
Store complex components such as transmission parts in the proper assemble order and tie them
together with a wire for ease of installation later.
Note the reassemble position of the important components before disassembling them to ensure
they will be reassembled in correct dimensions (depth, distance or position).
Components not to be reused should be replaced when disassembled including gaskets metal seal
rings, O-rings, oil seals, snap rings, and split pins.

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The length of bolts and screws for assemblies, cover plates or boxes is different from one another,
be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its
length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt.
Bolts for the same assembly should have the same length.
Tighten assemblies with different dimension fasteners as follows: Tighten all the fasteners with
fingers, then tighten the big ones with special tool first diagonally from inside toward outside,
important components should be tightened 2 to 3 times with appropriate increments to avoid
warp unless otherwise indicated. Bolts and fasteners should be kept clean and dry. Do not apply
oil to the threads.
When oil seal is installed, fill the groove with grease, install the oil seal with the name of the
manufacturer facing outside, and check the shaft on which the oil seal is to be installed for
smoothness and for burrs that may damage the oil seal.

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Remove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the
contact surface has any damage.
The ends of rubber hoses (for fuel, vacuum, or coolant) should be pushed as far as they can go to
their connections so that there is enough room below the enlarged ends for tightening the clamps.
Connector
Rubber and plastic boots should be properly reinstalled to the original correct positions as
designed.
The tool should be pressed against two (inner and outer) bearing races when removing a ball
bearing. Damage may result if the tool is pressed against only one race (either inner race or outer
race). In this case, the bearing should be replaced. To avoid damaging the bearing, use equal force
on both races.
(Both of these examples can result in bearing damage)

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Lubricate the rotation face with specified lubricant on the lubrication points before assembling.
Check if positions and operation for installed parts is in correct and properly.
Make sure service safety for each other when conducting by two persons.
Do not let parts fall down.
Before battery removal operation, it has to remove the battery negative ᧩) cable firstly. Tools like
open-end wrench do not contact with body to prevent from short-circuit and create spark.

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After service completed, make sure all connection points is secured. Battery positive (+) cable
should be connected firstly.
And the two posts of battery have to be greased after connected the cables.
Make sure that the battery post caps are located in properly after the battery posts had been
serviced.
If fuse burned, it has to find out the cause and solved it. And then replace with specified capacity
fuse.

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When separating a connector, it locker has to Insert the terminal completely, unlocked it first. Then,
conduct the service Check if the terminal is covered by the boot. Do not let boot open facing up.
Do not pull the wires as removing a connector or wires. Hold the connector body.
Make sure if the connector pins are bent, extruded or loosen.
Insert the connector completely. If there are two lockers on two connector sides, make sure the
lockers are locked in properly. Check if any wire loose.
Check if the connector is covered by the twin connector boot completely and secured properly.

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Before terminal connection, check if the boot is crack or the terminal is loose.
Secure wires and wire harnesses to the frame with respective wire bands at the designated
locations. Tighten the bands so that only the insulated surfaces contact the wires or wire
harnesses.
Wire band and wire harness have to be clamped secured properly.
Do not squeeze wires against the weld or its clamp.

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Do not let the wire harness contact with rotating, moving or vibrating components as routing the
harness.
Keep wire harnesses far away from the hot parts.
Route wire harnesses to avoid sharp edges or corners and also avoid the projected ends of bolts
and screws.
Route harnesses so that they neither pull too tight nor have excessive slack.

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Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner.
Thoroughly clean the surface where tape is to be applied.
Secure the rubber boot firmly as applying it on wire harness.
Never use wires or harnesses which insulation has been broken. Wrap electrical tape around the
damaged parts or replace them.
Never clamp or squeeze the wire harness as installing other components.

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Do not let the wire harness been twisted as installation.
Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack,
be rubbed against or interfere with adjacent or surrounding parts in all steering position.
Before operating a test instrument, operator should read the operation manual of the instrument.
And then, conduct test in accordance with the instruction.

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With sand paper to clean rust on connector pins/terminals if found.And then conduct connection
operation later.