ODES UTV Desertcross 1000cc-3 User manual

UTV Desertcross 1000cc-3
Maintenance Manual
Shandong ODES Industry Co. Ltd.
Any copy or without written permission or authorization is prohibited to use
the manual (version 2, May 2020).
All rights reserved

Foreword
This manual contains such content as
introductions on overhaul, maintenance,
overhauling program, dismantling,
assembling, troubleshooting and service
data of UTV1000-7
This manual will help you know the vehicle
better so that you can assure your
customers of fast and reliable service.
This manual has been prepared on the
basis of the latest specifications at the time
of publication.If modifications have been
made sine then,differences may exist
between the content of this manual and the
actual vehicle.
Illustrations in this manual are used to show
the basic principles of operation and work
procedures.They may not represent the
actual vehicle exactly in detail.
Manufacturer reserves the right of no prior
notice on product improvement or
modification. Repair and maintenance shall
be carried out according to actual situation
of vehicle.
WARNING
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to
the mechanic and may render the
vehicle unsafe for the rider.
GROUP INDEX
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
2
ENGINE
3
COOLING SYSTEM
4
FUEL SYSTEM
5
DRIVE TRAIN
6
STEERING SYSTEM
7
SUSPENSION SYSTEM
8
BRAKES SYSTEM
9
ELECTRICAL SYSTEM
10
TROUBLE SHOOTING
11

1.GENERAL INFORMATION
1-
1
1. GENERAL INFORMATION
PRECAUTIONS.................................... 1-1
TECHNICAL SPECIFICATIONS...............1-3
TIGHTENING TORQUE.........................1-6
PRECAUTIONS
1. Do not make engine under operation at a closed place or place with poor ventilation for a
long time.
2. If engine stops operation, please do not touch it or silencer to avoid burning.
3. Due to high corrosive, battery fluid (dilute sulfuric acid) may cause burns to skin and eyes.
In case of splashing it to skin, please clean it with water and see the doctor immediately. In
case of splashing it to clothes, please wash it with water immediately. Keep battery fluid far
away from Children.
4. Cooling liquid is toxic. Do not drink it or splash it to skin, eyes and clothes. once splashing
it to skin, please wash it with a lot of soapy water. In case of splashing it to eyes, please
wash eyes immediately and see the doctor. In case of drinking cooling liquid, resulting in
vomit, please see the doctor. Keep cooling liquid far away from children.
5. Wear proper working suit, boots and hat. If necessary, please wear long-sleeve working
suit and gloves for operation.
6. Gasoline is highly inflammable. No smoking or firing. At the same time, fire sparks shall be
avoided. Vaporized gasoline is explosive as well. Operation shall be carried out at places
with good ventilation.
7. Battery may produce explosive hydrogen in charging. Please ensure charging at places
with good ventilation.
8. Use legal parts, lubricating oil and lubricating grease.
9. Before overhauling, please clean soil and dust.
10. Keep accessories of each part well for correct assembly.
11. Replace dismantled gasket, O-shaped ring, piston pin retainer and cotter pin.
12. Retainer of rubber ring may be deformed after dismantling. So, please do not use loose
and soft retainer.
13. Please wash and dry dismantled parts. Use lubricant on the surface of moving parts. For
correct installation, please measure data well in dismantling process.
14. If do not know length of screw, please install screws one by one to ensure their
corresponding depth.
15. Pre-tighten bolts and nuts and then tighten them with designated torque from the big to the
small and from the inside to the outside.

1.GENERAL INFORMATION
1-
2
16. Check whether rubber parts are aged. If necessary, replace them. Keep rubber parts far
away from grease.
17. If necessary, special tools can be used.
18. Rotate inside and outside races of bearing to ensure flexibility of balls.
a) If axial or radial resistance is too large, please replace it. If there is concave-convex on
the surface, please use oil for washing. If no effect is achieved with washing, please
replace it.
b) If bearing cannot be clamped tightly in pressing into machine or axle, please replace
bearing.
19. Please install a side dust proof bearing at correct direction. In installation of open or
double-face dust proof bearing, pay attention to that marks of manufacturer shall be
outward.
20. In cleaning and drying bearing, please keep bearing support still. Before installation,
please carry out lubrication with oil or lubricating oil.
21. Please correct install elastic retaining ring. Assembling after opening can ensure
installation of snap ring into slot.
22. After assembly, please check whether all parts are of perfect tightening and flexible
movement.
23. Brake fluid and coolant may damage shell and plastic and rubber parts. In case of being
splashed by them, please use water for washing.
24. In installing pipeline, please insert them to bottom of connecting pipeline. In installing pipe
clamp, please install them to groove if there is. As for pipeline or pipe clamp that cannot be
tightened, please replace them.
25. Do not mix soil or dust into engine and/or hydraulic braking system.
26. Before installation, please clean gasket and spacer of engine shell. Use oil stone to polish
scratch of joint face evenly.
27. Do not twist or bend too much cable. Twisted or damaged cables may cause inflexible
operation.
28. In assembling protective caps of parts, insert cap into groove if any.

1.GENERAL INFORMATION
1-
3
TECHNICAL SPECIFICATIONS
Item
Parameter
Dimensions
UTV1000-7
Overall length
3339mm(131.457in)
Overall width
1782mm(70.157in)
Overall height
1935mm(76.18in)
Seat height
517mm(20.354in)
Wheelbase
2322mm(91.417in)
Ground clearance
318mm(12.52in)
Engine
Type
Two-cylinder, 4-stroke,SOHC, water cooling
Number of valves
8(mechanical adjustment)
Cylinder diameter
91 mm(3.583in)
Piston stroke
75 mm(2.953in)
Compression ratio
10.3：1
Displacement
976cc
Maximum power
637Kw/6500rpm
Maximum torque
100N.m/5500 rpm
Idle speed
1250rpm
Lubrication
Type
Wet tank lubrication, oil filters can be changed
Oil pressure
0.07-0.25MPa at 1250rpm
Type of oil
SAE10W-50/SJ
Oil quantity
2200mL
Replacement of
capacity
2000mL
Fuel
Type
Unleaded gasoline only 93# or higher
Fuel pressure
350 kpa
Fuel tank capacity
48L
Valve clearance
Intake
0.06 to 0.10mm(0.0024in to 0.0039in)
Exhaust
0.11 to 0.15mm(0.0039in to 0.0059in)
Diameter of valve rod (IN)
New
4.966 to4.980mm(0.196in to 0.196in)
Service limit
4.930mm(0.194in)
Diameter of valve rod (EX)
New
4.956 to 4.970mm(0.195in to 0.1957in)
Service limit
4.930mm(0.194in)
Valve seat contact width (IN)
New
1.05 to 1.35mm(0.0413in to 0.053in)
Service limit
1.80mm(0.0709in)
Valve seat contact width (EX)
New
1.25 to 1.55mm（0.0492in to 0.061in）
Service limit
2.00mm(0.0787in)
Valve guide diameter
New
4.998to 5.018mm(0.1968in to 0.1976in)
Service limit
5.050mm(0.1988in)
Free length of valve spring
New
40.81mm(1.607in)
Service limit
39.00mm(1.5354in)

1.GENERAL INFORMATION
1-
4
Rocker arm bore diameter
New
12 .036to 12.050mm(0.4739in to 0.4744in)
Service limit
12.060mm(0.4748in)
Rocker arm shaft diameter
New
12.00 to 12.018mm(0.4724in to 0.473in)
Service limit
11.990mm(0.472in)
Piston measurement
New
90.950 to 90.966mm(3.5807in 3.5813in)
Service limit
90.850mm(3.576in)
Cylinder measurement
Size “A”
91.955 to 91.003mm(3.6203in to 3.5830in)
Size “B”
91.0031 to 91.010mm(3.5830in)
Intake cam height
New
32.96 to 33.16mm(1.2976in to 1.3055in)
Service limit
32.94mm(1.2969in)
Exhaust take cam height
New
32.86mm to 33.06mm(1.2937in to 1.3016in)
Service limit
32.84mm(1.2929in)
Crankshaft main journal
diameter
New
42.024 to 42.040mm(1.6545in to 1.6551in)
Service limit
42.000mm(1.6535in)
Crankshaft radial clearance
Service limit
0.06mm(0.0024in)
Crankshaft deflection
Service limit
0.07mm(0.0028in)
Crankshaft pin diameter
New
41.986 to 42.010mm(1.653in to 1.654in)
Service limit
41.967mm(1.6522in)
Connecting rod big end radial
clearance
Service limit
0.09mm(0.0035in )
Connecting rod small end
diameter
New
22.010 to 22.020mm(0.8665in to 0.8669in)
Service limit
22.050mm(8.681in)
Piston pin diameter
New
21.996 to 22.00mm(0.8660in to 0.8661in)
Service limit
21.980mm(0.8654in)
Spark plug
Type/manufacturer
NGK CPR8EA-9
Gap
0.7-0.9mm(0.0276-0.0354in )
Transmission type
CVT(Continuously Variable Transmission)
Continuously variable ratio
0.63to3.06
Drive belt width
Service limit
30.00mm(1.1811in)
Gearbox type
Dual range(H/L) with park, neutral and reverse
Gearbox oil
Capacity
450mL(GL-4-90)
Gear ratio
H
3.36
L
5.84
R
7.15
Cooling liquid temperature
thermostat
Valve opening
65C◦
Fan opening
82C◦
Magneto generator output
520W@6000rpm
Crankshaft position sensor value of resistance
774 to 946 Ω@20℃
Tire
Type
Tubeless
Pressure
97 to 124KPa
Size Front
27×9–14(Rim 14×7.5)
Size Rear
27×11–14(Rim 14×9)

1.GENERAL INFORMATION
1-
5
Brakes
System
Front and rear unified
Type Front
Dual disc brake
Type Rear
Dual disc brake
New disk thickness
5.0mm(0.197in)(Front) 5.0mm(0.197in)(Rear)
Minimum disk thickness
5.0mm(0.197in)(Front) 5.0mm(0.197in)(Rear)
Maximum disk warpage
0.2mm(0.0079in)
Operation
Foot operation
Suspension and shock absorber
Front suspension
Double wishbone
Rear suspension
Double wishbone
Front shock absorber
Coil spring / oil damper
Front shock absorber travel
130mm(5.118in)
Rear shock absorber
Coil spring /oil damper
Rear shock absorber travel
160mm(6.30in)
Drive train
Front differential
Shaft driven/single auto-lock differential
Front differential ratio
3.67:1
Rear axle
Shaft driven/single differential
Rear axle ratio
3.67:1
Front differential oil capacity
180mL(GL-4-90)
Rear differential oil capacity
220mL(GL-4-90)
Electrical
Ignition system
EFI-DELPHI
Battery
Type
Maintenance Free
Voltage
12V
capacity
45AH
Fuses
Reversing Light
15A
Fan
30A
Lock(second shift)
20A
Reserve power
20A
EFI system meter
30A
Lighting
20A
EPS
15A
Rear drive control
10A
Electric top
40A
Top light
20A
Seat heating
15A
Head lamp
12V 30W/20W
Fog light
12V 6W
Tail light
12V 1.8W
Indicator light
12V 0.4W
Turn light
12V 6W

1.GENERAL INFORMATION
1-
6
TIGHTENING TORQUE
Locking devices ( e.g.: 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.
In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the
following recommended torque value:
Grade
Torque( N·m)
M6
M8
M10
M12
M14
M16
4.6
4～5
10～12
20～25
36～45
55～70
90～110
5.6
5～7
12～15
25～32
45～55
70～90
110～140
6.8
7～9
17～23
33～45
58～78
93～124
145～193
8.8
9～12
22～30
45～59
78～104
124～165
193～257
10.9
13～16
30～36
65～78
110～130
180～201
280～330
12.9
16～21
38～51
75～100
131～175
209～278
326～434
CAUTION
As for important tightening torques , please refer to following standards.
Installation location
Specifications (mm)
Torque N.m(kgf.m)
Fastening bolt of engine
M10
60-65(44.3-48)
Fastening nut of suspension arm
M12
78-100(57.6-73.8)
Bolt of rear shock absorber
M12
78-100(57.6-73.8)
Bolt of front shock absorber
M10
60-65(44.3-48)
Fastening nut of wheel rim
M12
90-110(66.4-81.2)
Nut of wheel hub
M22/M24
280-300(206.7-221.4)
Bolt of rear brake/stop pump (calipers)
M10
60-65(44.3-48)
Bolt of brake/stop disc
M8
24-28(17.7-20.7）
Bolt of front brake/stop pump (calipers)
M10
60-65(44.3-48)
Lock nut of steering rod
M12
120-140(88.6-103.3)
Lock bolt of steering gearbox
M12
140(103.3)
Bolt of exhaust pipe
M8
18-26(13.3-19.2)
Fastening nut of rear differential
M10
80(59)
Fastening nut of front differential
M10
80(59)
Bolt of front propeller shaft flange
M8
35-40(25.8-29.5)
Bolt of front propeller shaft flange
M10
70-80(51.7-59)
Sparkplug
M12
18(13.3)
Be sure to use the proper tightening torque for the proper strength grade. Always torque
screws, bolts and / or nuts in a crisscross sequence.

1.GENERAL INFORMATION
1-
7
Water temperature sensor
M12
16(11.8)
Oilpressureswitch
M10
12.5(9.2)
Adjusting nut of valve clearance
M6
12(8.9)
Main pulley bolt
M12
100(73.8)
Driven pulley bolt
M10
60(44.3）
Magneto flywheel bolt
M16
150(110.7)
Magneto stator bolt
M6
12.5(9.2)
One way bolt
M8
30(22.1)
Engine oil drain plug
M12
20(14.76)
Gearbox oil drain plug
M12
20(14.76)
Decompression valve plug
M22
20(14.76)
Cylinder head bolt
M10
60(4.4）
Cylinder head bolt
M6
12.5(9.2)
Connecting rod bolt
M8
50(36.9)
Timingchainwheel bolt
M8
30(22.1)
Frontoutput shaft flange bolt
M8
30(22.1)
Rearoutput shaftflangebolt
M10
60(4.4）

2.PERIODIC MAINTENANCE
2-
2
2. PERIODIC MAINTENANCE
MAINTENANCE SCHEDULE ············ 2-1
AIR CLEANER ·································2-3
VALVE CLEARANCE······················· 2-4
SPARK PLUG ··································2-7
THROTTLE CABLE PLAY················· 2-8
ENGINE OIL ····································2-9
FRONT DIFFERENTIAL OIL ············· 2-11
REAR DIFFERENTIAL OIL ·················2-12
STEERING SYSTEM······················· 2-12
BRAKING SYSTEM··························· 2-14
GEAR SHIFT ·································2-15
COOLING SYSTEM ··························2-15
WHEELS······································· 2-18
ENGINE COMPRESSION PRESSURE·2-19
ENGINE OIL PRESSURE················· 2-20
SUSPENSION SYSTEM ····················2-21
MAINTENANCE SCHEDULE
In order to maintain the best performance and economical performance of vehicles,
suggestions on intervals for necessary regular maintenance are listed. Following maintenance
is calculated in km, mile and hour based on firstly appeared data.
However, keep in mind that if the vehicle isn’t used for a long period of time, the month
maintenance intervals should be followed.
Items marked with an asterisk should be performed by a dealer as they require special tools
and technical skills.
In case of complicated road conditions, regular maintenance shall be carried for vehicles.
ITEM
ROUTINE
Whichever
Comes first
INTIAL
EVERY
month
1
3
6
6
12
Km
(mi)
320
(200)
1200
(750)
2400
(1500)
2400
(1500)
4800
(3000)
hours
20
75
150
150
300
Valves*
● Check vale clearance.
● Adjust if necessary.
O
O
O
O
Cooling system
● Check coolant leakage.
● Repair if necessary.
● Replace coolant every 24 months.
O
O
O
O
O
Spark plug
● Check condition.
● Adjust gap and clean.
● Replacement every 24 months
O
O
O
O
O
Air filter elements
● Clean.
● Replacement every 24 months
Every 20-40 hours
(More often in dusty areas)
Crankcase
breather system*
● Check breather hose for cracks or
damage.
● Replace if necessary.
O
O
O
Exhaust system*
● Check for leakage.
● Tighten if necessary.
● Replace gasket(s) if necessary.
O
O
O

2.PERIODIC MAINTENANCE
2-
3
Fuel line*
● Check fuel hose for cracks or damage..
● Replacement fuel hose every 48 months
● Replacement fuel filter every 24 months
O
O
O
Engine oil
● Replace (Check oil level every month) .
O
O
O
O
Engine oil filter
● Replace.
O
O
O
Differential and
gearbox oil
● Check oil level/oil leakage.
● Replacement every 24 months.
O
O
Brake*
●Check operation/brake pad wear/fluid
leakage.
●Brake fluid needs to be above the lowest
position.
●Correct if necessary. Replace pads/disk if
worn to the limit.
O
O
O
O
O
Accelerator pedal*
●Check operation and free play.
O
O
O
O
O
Wheels*
●Check balance/damage/ run out
●Repair if necessary.
O
O
O
O
Wheel bearings*
●Check bearing assemblies for looseness
or damage..
●Replace if damaged.
O
O
O
O
Front and rear
Suspension*
●Check no deformation and looseness.
●Correct if necessary.
O
O
Steering system*
●Check operation and no looseness.
●Repair if damage.
●Check toe-in/Adjust if necessary.
O
O
O
O
O
Rear knuckle
pivots and
suspension arms*
●Lubricate with lithium-soap-based
grease.
O
O
O
Drive shaft
universal joint*
●Lubricate with lithium-soap-based
grease.
O
O
O
Engine mount*
●Check for cracks or damage.
●Correct bolt tightness.
O
O
O
Front and rear
axle boots*
●Check operation.
●Replace if damage.
O
O
Stabilizer
bushings*
●Check for cracks or damage.
O
O
O
Fittings and
fasteners*
●Check all chassis fittings and fasteners.
●Correct if necessary.
O
O
O
O
O
Battery
●End connection
O
O
O
O
Lamp and
steering indication
●Operation
O
O
O
O
O

2.PERIODIC MAINTENANCE
2-
4
AIR CLEANER
In case of driving in dusty environment, air filter shall be cleaned regularly. It is of great
possibility to accelerate wear to engine if there is not filtering element or worn filtering element
is used. So, please keep air filter under good conditions all the time. If vehicle is used in dusty
area, inspect more frequently than specified in MAINTENANCE SCHEDULE.
If the air cleaner is clogged with dust,intake resistance will be increased,with a resultant
decrease in power output and an increase in fuel consumption. never remove or modify any
component in the air filter housing. The engine management system is calibrated to operate
specifically with these components. Otherwise, engine performance degradation or damage
can occur.Check and clean the air cleaner element in the following manner:
Remove the middle seat.
Release 4 clamps and remove air filter
housing cover.
CAUTION:PREVENT CLAMPS FROM FALLING.
Loosen clamp and remove air filter.
Blow low pressure compressed air on filter
element to clean it.
Properly re-install removed parts in the reverse order of their removal. pay attention to the seal
gasket of air filter housing is not skew.
CAUTION
1. If liquid /deposits are found, squeeze and dry the foam filter.
Replace filter element if damaged.
2. Do not start engine if liquid or deposit are found. If there is oil in the air filter housing,
check engine oil level. Oil level or temperature may be too high.
3. Inspect the air cleaner element for tears, a torn element must be replaced.

2.PERIODIC MAINTENANCE
2-
5
VALVE CLEARANCE
Excessive valve clearance results in valve noise and insufficient valve clearance results in
valve damage and reduced power.
Check the intake and exhaust valve clearances at the distances indicated above and adjust the
valve clearances to specification,if necessary.
Valve clearance is to be checked when the engine is cold.The intake and exhaust valves must
be checked an adjusted when the piston is at TOP-DEAD –CENTER(TDC) on the compression
stroke.
Lift the rear cargo bed.
Remove middle seat, seat back guard.
Remove spark plug cable and spark plug of
both cylinders.
Remove the valve cover of both cylinders.
1. screws
2. Valve cover
3. Gasket
Remove the crankshaft position sensor.
1. Crankshaft position sensor
2. Screw

2.PERIODIC MAINTENANCE
2-
6
Valve clearance of cylinder 2
Use a 14 mm Allen key to turn crankshaft
until piston 2, rear is at TDC ignition.
When rear piston is at TDC ignition, marks on
magneto flywheel “2” and on the magneto
cover are aligned.
1. Mark “2” on magneto flywheel
2. Notch on magneto cover
3. Crankshaft position sensor location
At TDC ignition, the printed marks on the
camshaft timing gear have to be parallel to
cylinder head base. If not, use Allen key to turn
crankshaft 360°
1. Printed marks on camshaft timing gear
2. Cylinder head base
Insert the feeler gauge between the valve
stem end and adjusting screw on the
rocker arm to check the clearance.
If the valve clearance is out of specification,
adjust valves as follows.
Valve clearance
Intake
0.06 to 0.10mm(0.00236 to 0.00394 inches)
Exhaust
0.11 to 0.15mm(0.00433 to 0.00591 inches)
Use mean valve of exhaust/intake to ensure a
proper valve adjustment.
Hold the adjustment screw at the proper
position and torque the locking nut.
Repeat the procedure for each valve.
1. Adjustment screw
2. Adjustment nut
3. Feeler gauge
CAUTION
Valve clearance adjustment locknut:12N.m(8.856Lbf.ft)
Securely tighten the locknut after completing adjustment.

2.PERIODIC MAINTENANCE
2-
7
Valve clearance of cylinder 1
Using a 14 mm Allen key, turn crankshaft
280 °counterclockwise.
1. Allen key 14mm
2. Turn crankshaft 280°counterclockwise
Until marks on magneto flywheel “1” and
magneto cover are aligned.
1. Mark “1” on magneto flywheel
2. Notch on magneto cover
3. Location of crankshaft position sensor
At TDC ignition, the printed marks on the
camshaft timing gear have to be parallel to
cylinder head base as per following
illustration.
TYPICAL
1. Printed marks on camshaft timing gear
2. Cylinder head base

2.PERIODIC MAINTENANCE
2-
8
Insert the feeler gauge between the valve
stem end and adjusting screw on the
rocker arm to check the clearance.
If the valve clearance is out of specification,
adjust valves as follows.
Valve clearance
Intake
0.06 to 0.10mm
(0.00236 to 0.00394 inches)
Exhaust
0.11 to 0.15mm
(0.00433 to 0.00591 inches)
Use mean valve of exhaust/intake to ensure a
proper valve adjustment.
Hold the adjustment screw at the proper
position and torque the locking nut.
Repeat the procedure for each valve.
1.Adjustment screw
2.Adjustment nut
3. Feeler gauge
Valve clearance adjuster locknut:12N·m(8.856Lbf.ft)
CAUTION
Install the valve cover of both cylinders, spark plug cable and spark plug of both cylinders, the
plug screw and O-ring of magneto cover and the crankshaft position sensor.
SPARK PLUG
In case of serious wear or burn to electrode or burn to insulator by spark plug or damage to
thread etc, please replace it with new spark plug
In case of carbon deposit, please use proper tools for cleaning.
Spark plug gap
Use clearance gauge to measure
clearance of spark plug.
In case of exceeding designated range,
then adjust the gap.
Spark plug gap: 0.7-0.9mm
(0.028-0.035inches)
Securely tighten the locknut after completing adjustment.

2.PERIODIC MAINTENANCE
2-
9
Spark plug heat range
Check the spark plug heat range by observing the electrode color. If the electrode of the
spark plug is appearing wet or dark color, replace the spark plug with a hotter type one. If it is
white or appearing glazed, replace the spark plug with a colder type one.
Standard type: DCPR8E / NGK
Colder type: DCPR9E / NGK
Hotter type: DCPR7E / NGK
CAUTION
THROTTLE CABLE PLAY
Before starting the engine, check the gas pedal to be sure it is operating correctly. Make sure
the gas pedal fully returns to the idle position as soon as it is released.
Check the free play and adjust if needed. Press the throttle to make sure it moves smoothly
without sticking and snaps back automatically when it is released Check to see that the gas
pedal operates correctly. It must operate smoothly and fully spring back to the idle position
when released. Have a dealer repair if necessary for proper operation.
Check throttle pedal free play:
3 - 5mm(0.118-0.197inches)
In case of out of range: → adjustment
Lift the rear cargo bed.Remove middle seat,
seat back guard plate.
Loose throttle cable (bracing cable).
Turn adjuster to adjust free play of throttle
pedal.
After adjustment, tighten nut.
If free play after adjustment cannot reach
designated requirement or there is viscosity for
throttle valve, replace it with new throttle cable.
In order to avoiding damaging cylinder cap thread, firstly use hands to tighten spark plug and
then use spark plug wrench to tighten cylinder cap with designated torque.

2.PERIODIC MAINTENANCE
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10
ENGINE OIL
Oil level verification
Strictly follow this procedure, otherwise wrong oil
level may be indicated.
1. Ensure vehicle is on a level surface.
2. The engine must be cold.
CAUTION
3. Lift the rear cargo bed.
4. Remove dipstick and wipe clean stem.
5. Fully screw in dipstick to check oil level.
6. Remove dipstick and read oil level. Oil
level must be between minimum and
maximum marks on dipstick.It should
be near or equal to the upper mark.
7. There is a capacity of 300 ml between
the two marks. Refill oil as necessary
and recheck oil level. Do not overfill.
8. Wipe any spillage.Install and propery
tighten the dipstick.
9. Lower the rear cargo bed.
Replace engine oil
Prior to change the oil, ensure vehicle is on a level surface. Oil and oil filter must be replaced at
the same time. Oil change and oil filter replacement should be done with a warm engine.
WARNING
CAUTION
The engine oil can be very hot. Wait until engine oil is warm.
Dispose oil and filter as per your local environmental regulations.
If just stop engine,Wait at least half hours to allow oil to flow down to crankcase then
check oil level.

2.PERIODIC MAINTENANCE
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11
1. Ensure vehicle is on a level surface.
2. Start engine and let idle for a few minutes.
3. Stop engine. Wait a few minutes to allow
oil to flow down to crankcase.
4. Lift the rear cargo bed.
5. Remove dipstick.
6. Raise the vehicle, support it securely.
Place a drain pan under the engine drain
plug area.
7. Clean the drain plug area.
8. Unscrew drain plug then remove dipstick.
1) Drain plug
2) Gasket ring
9. Allow oil to drain completely from
crankcase.
10. Clean the magnetic drain plug from metal
shavings and residue.
11. Install a new gasket ring on drain plug.
Torque drain plug to 30 N.m(22Lbf.ft).
12. Remove oil filter screws, oil filter cover and
oil filter.
1) Oil filter screw
2) Oil filter cover
3) ring
4) Oil filter
13. Check and clean the oil filter inlet area for
dirt and other contamination.
14. The installation is the reverse of the
removal procedure. Pay attention to install
a new gasket on oil filter cover.
15. Refill engine with a SAE 10W-40 API SJ
classification engine oil, Oil change
capacity with filter 2200mL.
16. Check the oil level with the dipstick. Refer
to OIL LEVEL VERIFICATION above.
17. Run engine to ensure oil filter and drain
plug areas are not leaking.

2.PERIODIC MAINTENANCE
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12
CAUTION
Replace gearbox oil
Prior to change the gearbox oil, ensure vehicle is
on a level surface, should be done with a warm
engine.
1. Drive vehicle for a few minutes.
2. Ensure vehicle is on a level surface.
3. Stop engine and wait a few minutes.
4. Lift the rear cargo bed.
5. Remove the oil level check plug.
6. Place an oil pan under the gearbox
case, and then drain oil completely by
removing the drain plug.
7. Tighten the drain plug to 20
N.m(14.76Lbf.ft).
8. Pour the specified oil(GL-4-90) about
360~450mL by syringe through the oil
level check hole.
9. Tighten the oil level check dipstick.
FRONT DIFFERENTIAL OIL
To change the front differential oil, locate the
vehicle on a level position and carry out the
following steps.
Clean the oil level check plug area and remove
the oil level check plug.
In order to expand service life of vehicle, please use grade SJ standard engine oil conforming
to API with its viscosity indication being SAE10W/40. If viscosity of engine does not reach SAE
10W/40, make corresponding selection according to drawing.
Oil level check plug
Oil level check plug
Drain Plug