SANMEN COUNTY YONGFU MACHINE UTV650 User manual

UTV650
Maintenance Manual
SANMEN COUNTYYONGFU MACHINE CO.,LTD
Any copy or without written permission
or authorization of Yongfu is prohibited to use
the manual (version 1, Oct 2017).
All rights reserved

Foreword
This manual contains such content as introductions on
overhaul, maintenance, overhauling program,
dismantling, assembling, troubleshooting and service
data of UTV650
This manual will help you know the vehicle beter so
that you can assure your customers of fast and reliable
service.
This manual hass been prepareed 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
GROUP INDEX
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
2
COOLING SYSTEM
3
FUEL SYSTEM
4
DRIVE TRAIN
5
STEERING SYSTEM
6
SUSPENSION SYSTEM
7
BRAKES SYSTEM
8
ELECTRICAL SYSTEM
9
TROUBLESHOOTING
10
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.

1. GENERAL INFORMATION
1-1
1. GENERALINFORMATION
PRECAUTIONS ······································ 1-1
TECHNICAL SPECIFICATIONS·················· 1-3
TIGHTENING TORQUE···························· 1-7
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 corrosiveness, battery fluid (dilute sulphuric 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.
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.

1. GENERAL INFORMATION
1-2
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
Overall length
2930mm
Overall width
1400mm
Overall height
1830mm
Seat height
440mm
Wheelbase
1916mm
Ground clearance
300mm
Engine
Type
Single cylinder,four stroke,four valves,water
cooling+Oil cooling ,EFI
Number of valves
4
Cylinder diameter
96 mm
Piston stroke
86 mm
Compression ratio
10.3：1
Displacement
650cc
Maximum power
29kw/5250r/min
Maximum torque
57N.m/4250r/min
GEAR
L-H-N-R
Lubrication
Type
Lubricating system
Type of oil
SAE10W-40/SJ
Oil quantity
3700ml
Fuel
Type
Unleaded gasoline only 93# or higher
Fuel pressure
350 kpa
Fuel tank capacity
7.66 Gallons
Valve clearance
Intake
0.05 to 0.09mm
Exhaust
0.10 to 0.15mm
Diameter of valve rod(IN)
New
4.960 to 4.975mm
Service limit
4.930mm
Diameter of valve rod(EX)
New
4.945 to 4.965mm
Service limit
4.930mm
Valve seat contact width(IN)
New
1.05 to 1.35mm
Service limit
1.8mm
Valve seat contact width(EX)
New
1.25 to 1.55mm
Service limit
2mm
Valve guide diameter
New
5.000 to 5.015mm
Service limit
5.050mm
Free length of valve spring
New
40.5mm
Service limit
39mm
Rocker arm bore diameter
New
12.000 to 12.018mm
Service limit
12.030
Rocker arm shaft diameter
New
11.983 to 11.994
Service limit
11.97mm

1. GENERAL INFORMATION
1-4
Piston measurement
Size “A”
90.955 to 90.962mm
Size “B”
90.962 to 90.970mm
Cylinder measurement
Size “A”
90.995 to 91.003mm
Size “B”
91.003 to 91.010mm
Clearance of cylinder - piston
New
0.033 to 0.048mm
Service limit
0.090mm
Piston ring type
1st
Upper compression ring, rectangular
2nd
Lower compression ring, tapered face
3rd
Oil scraper ring
Piston ring end gap
New 1st
0.25 to 0.40mm
New 2nd
0.35 to 0.50mm
New 3rd
0.20 to 0.80mm
All service limit
1.50mm
Piston/ring groove clearance
New 1st
0.03 to 0.07mm
New 2nd
0.02 to 0.060mm
New 3rd
0.01 to 0.045mm
All service limit
0.15mm
Intake cam height
New
32.15 to 32.25mm
Service limit
32.09mm
Exhaust take cam height
New
31.95mm to 32.05mm
Service limit
31.92mm
Camshaft main bearing journal
New
34.95 to 34.975mm(Timing chain side)
21.959 to 21.980mm(Spark plug side)
Service limit
34.94mm(Timing chain side)
21.95mm(Spark plug side)
Camshaft main bearing journal
bore
New
35.000 to 35.025mm(Timing chain side)
22.000 to 22.021mm(Spark plug side)
Service limit
35.040mm(Timing chain side)
22.040mm(Spark plug side)
Crankshaft main journal
diameter
New
42.024 to 42.040mm
Service limit
42.000mm
Crankshaft radial clearance
Service limit
0.06mm
Crankshaft deflection
Service limit
0.07mm
Crankshaft pin diameter
New
40.009 to 40.025mm
Service limit
39.990mm
Connecting rod big end diameter
Service limit
40.100mm
Connecting rod big end radial
clearance
Service limit
0.09mm
Connecting rod big end axial
clearance
New
0.2 to 0.5mm
Service limit
0.6mm
Connecting rod small end
diameter
New
20.010 to 20.020mm
Service limit
20.060mm
Piston pin diameter
New
19.996 to 20.000mm
Service limit
19.980mm
Spark plug
Type/manufacturer
DCPR8E / NGK

1. GENERAL INFORMATION
1-5
Gap
Transmission type
Continuously variable ratio
Drive belt width
Service limit
Gearbox type
Gearbox oil
Capacity
Gear ratio
H
L
R
Capacity of cooling liquid
Type
Maximum load
Capacity of water
tank
Cooling liquid temperature
thermostat
Valve opening
Fan opening
Magneto generator output
Crankshaft position sensor value of resistance
Type
Pressure
Size Front
Size Rear
System
Type Front
Type Rear
New disk thickness
Minimum disk thickness
Maximum disk warpage
Operation
Front suspension
Rear suspension
Front shock absorber
Front shock absorber travel
Rear shock absorber
Rear shock absorber travel
Front differential
Front differential ratio
Rear axle
Rear axle ratio
Front differential oil capacity
Rear differential oil capacity

1. GENERAL INFORMATION
1-6
Electrical
Ignition system
EFI
Battery
Type
Maintenance Free
Voltage
12V
capacity
30AH
Fuses
Lock(fist shift)
10A
Fan
20A
Light relay
30A
Main relay
20A
Lock(second shift)
10A
Reserve power
15A
Driving lamp
10A
Head lamp
Fog light
Tail light
12V 21W/5W
Indicator light
Turn light
12V 10W

1. GENERAL INFORMATION
1-7
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
70(7.1)
Fastening nut of suspension arm
M10
70(7.1)
Bolt of rear shock absorber
M12
80(8.2)
Bolt of front shock absorber
M10
80(8.2)
Fastening nut of wheel rim
M10
80(8.2)
Nut of wheel hub
M22
300(30.6)
Bolt of rear brake/stop pump (calipers)
M10
80(8.2)
Bolt of brake/stop disc
M8
26(2.7）
Bolt of front brake/stop pump (calipers)
M10
80(8.2)
Lock nut of steering rod
M12
80(8.2)
Lock bolt of steering gearbox
M12
140(14.3)
Bolt of exhaust pipe
M8
30(3.1)
Fastening nut of rear differential
M10
80(8.2)
Fastening nut of front differential
M10
80(8.2)
Bolt of front propeller shaft flange
M8
40(4.1)
Bolt of front propeller shaft flange
M10
80(8.2)
Bolt of rear propeller shaft flange
M10
80(8.2)
Sparkplug
M12
20(2.0)
Watertemperaturesensor
M12
16(1.6)
Oilpressureswitch
M10
12(1.2)
Adjusting nut of valve clearance
M6
12(1.2)
Main pulley bolt
M12
100(10.2)
Driven pulley bolt
M10
60(6.1）
Magneto flywheel bolt
M16
150(15.3)
Be sure to use the proper tightening torque for the proper strength grade. Always torque screws, bolts and / or
nuts in a criss-cross sequence.

1. GENERAL INFORMATION
1-8
Magneto stator bolt
M6
12.5(1.3)
One way bolt
M8
30(3.1)
Engine oil drain plug
M12
20(2.0)
Gearbox oil drain plug
M12
20(2.0)
Decompression valve plug
M22
20(2.0)
Cylinder head bolt
M10
60(6.1）
Cylinder head bolt
M6
12.5(1.3)
Connecting rod bolt
M8
50(5.1)
Timing chain wheel bolt
M8
30(3.1)
Frontoutputshaft flange bolt
M8
30(3.1)
Rear output shaftflange bolt
M10
60(6.1)

2. PERIODIC MAINTENANCE
2-1
2. PERIODIC MAINTENANCE
MAINTENANCE SCHEDULE ······················2-1
AIR CLEANER ·········································2-3
VALVE CLEARANCE·································2-4
SPARK PLUG ···········································2-8
THROTTLE CABLE PLAY···························2-8
ENGINE OIL ············································2-9
FRONT REDUCER OIL······························· 2-11
REART REDUCER OIL ·······························2-12
STEERING SYSTEM··································2-12
BRAKING SYSTEM···································2-13
GEAR SHIFT············································2-15
COOLING SYSTEM ···································2-15
WHEELS·················································2-18
ENGINE COMPRESSION PRESSURE·············2-18
ENGINE OIL PRESSURE·····························2-19
SUSPENSION SYSTEM ······························2-20
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)
1,200
(750)
2,400
(1,500)
2,400
(1,500)
4,800
(3,000)
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 wet or 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
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

2. PERIODIC MAINTENANCE
2-2
ITEM
ROUTINE
Whichever
Comes first
INTIAL
EVERY
month
1
3
6
6
12
Km
(mi)
320
(200)
1,200
(750)
2,400
(1,500)
2,400
(1,500)
4,800
(3,000)
hours
20
75
150
150
300
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 operation and for leakage.
●Correct if necessary.
O
O
Steering system*
●Check operation and for looseness/Replace
if damage.
●Check toe-in/Adjust if necessary.
O
O
O
O
O
Rear knuckle pivots
and suspensionarms*
●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
2-3
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 left and right seats, gear shift handle.
Remove engine shield.
Release 4 clamps and remove air filter housing cover.
Loosen clamp and remove air filter.

2. PERIODIC MAINTENANCE
2-4
Blow low pressure compressed air on filter element to
clean it.
Properly reinstall removed parts in the reverse order of their removal. pay attention to the seal gasket of air filter
housing is not skew.
CAUTION
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.
Remove left and right seats, gear shift handle and
engine shield.
Remove spark plug cable and spark plug of both cylinders
Remove the valve cover of both cylinders
1. Distance screws
2. Valve cover
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 may be too high.
3.Inspect the air cleaner element for tears, a torn element must be replaced.

2. PERIODIC MAINTENANCE
2-5
Remove the plug screw and O-ring of magneto cover.
Remove the crankshaft position sensor.
1. Crankshaft position sensor
2. Screw
Valve clearance of cylinder 2
Use a 14 mm Allen key to turn crankshaft until piston 2,
rear is at TDC ignition.
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
0.05 to 0.09mm
Exhaust
0.10 to 0.15mm
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

2. PERIODIC MAINTENANCE
2-6
CAUTION
Valve clearance adjuster locknut:12N.m
Valve clearance of cylinder 1
Using a 14 mm Allen key, turn crankshaft 280 °
counterclockwise.
1. Allen key 14mm
2. Turn crankshaft 280°counterclockwise
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
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
0.05 to 0.09mm
Exhaust
0.10 to 0.15mm
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.
4. Adjustment screw
5. Adjustment nut
6. Feeler gauge
Valve clearance adjuster locknut:12N.m
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.
Securely tighten the locknut after completing adjustment.
Securely tighten the locknut after completing adjustment.

2. PERIODIC MAINTENANCE
2-7
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
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 idleposition 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
In case of out of range: → adjustment
Remove left and right seats, gear shift handle and
engine shield.
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
2-8
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.
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. Start engine and let idle for a few minutes.
3. Stop engine. Wait a few minutes to allow oil to flow
down to crankcase then check oil level.
4. Remove left and right seats, gear shift handle.
5. Remove engine shield
6. Remove dipstick and wipe clean stem.
7. Fully screw in dipstick to check oil level.
8. Remove dipstick and read oil level. Oil level must be
between minimum(2) and maximum(1) marks on
dipstick.
9. There is a capacity of 300 ml between the two marks.
Refill oil as necessary. Do not overfill.
10. Reinstall dipstick.

2. PERIODIC MAINTENANCE
2-9
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
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 then check oil level.
4. Remove left and right seats, gear shift handle.
5. Remove engine shield
6. Remove dipstick.
7. Raise the vehicle, support it securely. Place a
drain pan under the engine drain plug area.
8. Clean the drain plug area.
9. Unscrew drain plug then remove dipstick.
1) Drain plug
2) Gasket ring
10. Allow oil to drain completely from crankcase.
11. Clean the magnetic drain plug from metal shavings
and residue.
12. Install a new gasket ring on drain plug. Torque
drain plug to 20 N.m.
13. Remove oil filter screws, oil filter cover and oil
filter.
1) Oil filter screw
2) Oil filter cover
3) ring
4) Oil filter
14. Check and clean the oil filter inlet area for dirt and
other contaminations.
15. The installation is the reverse of the removal
procedure. Pay attention to install a new gasket on
oil filter cover.
16. Refill engine with a SAE 10W-40 API SJ
The engine oil can be very hot. Wait until engine oil is warm.
Dispose oil and filter as per your local environmental regulations.

2. PERIODIC MAINTENANCE
2-10
classification engine oil, Oil change capacity with
filter 1850mL.
17. Check the oil level with the dipstick. Refer to OIL
LEVEL VERIFICATION above.
18. Run engine to ensure oil filter and drain plug areas
are not leaking.
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. Ensure vehicle is on a level surface.
2. Drive vehicle for a few minutes.
3. Stop engine and wait a few minutes.
4. Remove left and right seats, gear shift handle.
5. Remove engine shield
FRONT DIFFERENTIAL OIL
To change the front differential oil, locate the vehicle
on a level posion and carry out the following steps.
Clean the oil level check plug area and remove the oil
level check plug.
REAR DIFFERENTIAL OIL
To change the rear differential oil, locate the vehicle on
a level posion 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