Post on 30-Aug-2020
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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EJCRVGT" " 6"D"EJCUUKU"CVV"72"1":2"1"322"1"372"
"
4.1 FRONT WHEEL / HUB / DRUM BRAKE 4.2 A-RM REPLACEMENT 4.3 FINAL DRIVE 4.4 SWING ARM
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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603"HTQPV"YJGGN1"JWD"
"
"
1 TIRE FRONT
2 COTTER PIN
3 BOLT M10X1.25X20
4 CASTLE NUT M12X1.25
5 WASHER
6 VALVE
7 WHEEL FRONT
8 OIL SEAL
9 SPACER 1
10 BEARING 6002Z
11 SPACER 2
12 HUB ASSY
13 BEARING 6003Z
14 BRAKE CAM
15 RETURN SPRING
16 BRAKE SHOE SET
17 BRAKE PANEL. LEFT/ RIGHT
18 BRAKE ARM. LEFT/ RIGHT
19 SPRING. LEFT/ RIGHT
22 RUBBER CAP
HTQPV"YJGGN"TGOQVCN 1. Place the vehicle on level ground with engine off and fuel off, set the parking brake, 2. Loosen the 4 bolts (3), but not removal. 3. Elevate front end and safely support machine under frame area, Removal the bolts. 4. Remove the front wheel.
Inspect all wheels for runout and damage.
HTQPV"JWD"TGOQVCN 1. Remove the wheel as described above. 2. Remove the RUBBER CAP (22), and cotter pin. 3. Loosen and remove the CASTLE NUT (4) and washer. 4. (Release the front parking brake) Removal the front hub. HTQPV"JWD1"FTWO1"DTCMG"UJQG1"DTCMG"RCPGN1"DTCMG"ECO"cpf"CTO" "KPURGEVKQP Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or roughness is evident. Inspect the whole hub for damage replace if necessary. Inspect the drum/ shoes and springs/ panel/ cam/ arm for any damage or fracture, replace if necessary. See the CHAPTER 2 MAINTENANCE for the service limit of the brake shoe and drum. PQVG< Replace the brake shoes as a set either is worn to the limit.
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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JWD"DGCTKPI"TGRNCEGOGPV"1. Remove the oil seals. 2. Remove the SPACER 1. 3. Remove the bearings. 1. Apply grease to the bearings. 2. Drive the bearing 6002Z in first, seal side facing out, 3. Put in the SPACER 2. 4. Drive the bearing 6003Z in, seal side out, 5. Install pgy"ugcn"into hub (with numbers facing out) until flush with end of seal bore. Do not damage the surface of the seal. Coat the lip with special grease. PQVG0"Drive the bearing 6002Z in first. Tgxgtug"vjg"yjggn"cpf"jwd"tgmoxcn"rtoegfwtg"hot"kpuvcnncvkop0"""FTWO"DTCMG" "Fkucuugmdn{"PQVG< If the brake shoes are going to reinstalled, they must be installed in their original locations. Mark the brake shoes with “R U”, “L U”, “L U”, “L L”. R-right, L-left, U-upper, L-lower """Cuugmdn{"1. Install the BRAKE CAM, notch facing the
center of the BRAKE PANEL. 2. Install the SHOE SET. 3. Install the BRAKE ARM. align the point mark to the notch. PQVG: Always replace the shoes as a set. Replace the brake shoes as a set either is worn to the limit. PQVG< If reinstalling old brake shoes, install them into their correct locations on the brake
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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panel. Refer to the “R U”, “L U”, “L U”, “L L” *marks made in the Note of Disassembly. *R-right, L-left, U-upper, L-lower PQVG< If new linings are bring installed, file off the leading edge of each shoe a little so that the brake will not grab when applied.
6040" " C/TO"TGRNCEGOGPV"
1 A-ARM PIVOT SHAFT RIGHT
2 A-ARM PIVOT SHAFT SEALED RING
3 BUSHING 1
4 GREASE FITTING
5 GREASE FITTING CAP
6 BUSHING 2
7 NUT M10X1.25
8 A-ARM PIVOT SHAFT CAP
9 COTTER PIN2.5X20
10 A-ARM RITGHT
11 BOLT M10X1.25X48
12 A-ARM RUBBER BUSHING
13 CASTLE NUT M10X1.25
14 A-ARM PIVOT SHAFT LEFT
15 A-ARM LEFT
16 FRONT SHOCK ABSORBER
17 BOLT M10X1.25X38
18 NUT M10X1.25
"TGOQVCN" 1. Remove wheel/ hub as described above. 2. Remove CAP (8), COTTER PIN (9), CASTLE NUT (13), and removal the PIVOT SHAFT
(14/ 1). 3. Remove BOLTS (17) and removal FRONT SHOCK ABSORBER. 4. Remove 4 bolts (11) and removal A-ARM. KPURGEVKQP"Clean and Inspect the bushing 1, bushing 2, A-ARM RUBBER BUSHING, FRONT SHOCK RUBBER BUSHING and the PIVOT SHAFT for nicks, scratches, or damage. Replace if necessary.
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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KPUVCNNCVKQP"PQVG<" Always use new A-ARM PIVOT SHAFT SEALED RING for re-installation. Apply grease on A-ARM PIVOT SHAFT Reverse the hub removal procedure for installation.
605"HKPCN"FTKVG
TGCT"YJGGN" "Tgmoxcn 1. Place the vehicle on level ground with engine off and fuel off, set the front parking brake, 2. Loosen the 4 bolts (3), but not removal. 3. Elevate rear end and safely support machine under frame area, Removal the bolts. 4. Removal the wheel. Kpurgevkop Inspect all wheels for runout and damage. Kpuvcnncvkop" "Reverse the wheel removal procedure for installation. FTKVG"EJCKP" "
Ejckp"Tgmoxcn
1. Place the vehicle on level ground with engine off and fuel off, set the front parking brake,
2. Rotate rear wheel to place master link in accessible position between two sprockets.
3. Remove the rear wheels as described above.
4. Loosen, but not removal the four mounting bolts. Loosen the chain adjuster.
5. Slide the retaining clip of the master link and remove clip and side plate.
6. Slide master link out and remove the chain.
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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Ejckp"Kpurgevkop."Kpuvcnncvkop"cpf"Cflwuvmgpv"
1. Clean and Inspect chain and chain sprocket for wear.
PQVG<"To clean the chain, remove the chain from the ATV, dip it in solvent, and clean out
as much dirt as possible. Take the chain out of the solvent and dry it. Immediately lubricate
the chain to prevent rust.
2. If sprockets are worn, replace sprockets and chain as a set.
3. Replace guards if damaged.
4. Slide the pin portion of the master link(3) in to each end of chain to be connected.
5. Slide the side plate(2) portion of the master link on to the pins.
6. Slide the retaining clip(1) on to the pins until clip snaps securely in to place.
ECWVKQP<"The master link should be installed with the open end of the retaining clip (1)
facing away from direction of chain rotation (4).
7. Turn the chain adjuster to obtain 1/4(6mm)’’ to 3/8’’(10mm) chain flex. To tighten the
chain, turn the chain adjuster clockwise. To loosen the chain, turn the chain adjuster count
clockwise and push the rear axle forward.
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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8. Securely tighten the mounting bolts.
Votswg"Urgekhkecvkopu< 41-44Ft.Lbs (55-60N.m)
9. Recheck the chain tension: At the center point between the two sprockets, push and pull
the chain and note total flex. If flex is more than 1/2’’ (12mm), readjust chain.
10. Apply proper type spray-on chain lubricant thoroughly inside and outside plates and
rollers of chain. Move ATV as needed to access entire chain.
HKPCN"FTKVG" "Tgmoxcn"
1. Remove wheels, chain as described above.
2. Remove the 4 M12X1.25X28 mounting bolts.
3. Remove the final drive assembly from the swing arm,
Kpuvcnncvkop"
Reverse the removal procedure for installation. Adjust"chain tension as described above.
Securely tighten the mounting bolts (1).
Votswg"Urgekhkecvkopu< 41-44Ft.Lbs (55-60N.m)"
Hkpcn"Ftkxg"Fkucuugmdn{"
"
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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1 REAR AXLE
2 COTTER PIN
3 CASTLE NUT M16X1.5
4 WASHER 1
5 REAR HUB
6 SPROCKET
7 HUB. SPROCKET
8 BOLT M10X1.25X28
9 SPACER RIGHT
10 BOLT M10X1.25X20
11 BRAKE DISC FLANGE
12 NUT M10X1.25
13 SPECER LEFT
14 AXLE TUBE
15 SPACER
16 BEARING
17 OIL SEAL, REAR AXLE
18 TIRE REAR AT19X7-8
TIRE REAR AT18X7-8(FOR EUROPE)
19 SPROCKET 2
20 CHAIN
21 CHAIN COVER
22 BOLT M6X75
23 BOLT M6X10
24 RUBBER STICK
25 BRACKET
26 RUBBER CAP
27 RIM REAR
28 PLUG
29 BOLT M10X1.25X28
1. Remove the RUBBER CAP (26) and cotter pin. 2. Loosen and removal the CASTLE NUT (3) and washer. 3. Remove the rear hub. 4. Remove the SPACER RIGHT (9) and SPACER LEFT (13). 5. Remove the BRAKE DISC with FLANGE and removal the sprocket. 6. Remove the rear axle. Hkpcn"Ftkxg"Kpurgevkop"Remove the oil seal from the AXLE TUBE. Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or roughness is evident. Inspect the whole things for damage replace if necessary.
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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Hkpcn"Ftkxg"Cuugmdn{"1. Drive in bearings to the AXLE TUBE. PQVG<"Drive the bearing which near the brake disc first by press the bearing outer race, then put in the SPACER (15) and drive in another bearing by press the bearing both inner and outer race till it touch the SPACER (15). 2. Install new oil seals. 3. Install the rear axle from the brake disc side. 4. Reverse the rest procedure for installation till the hub. 5. Screw in the left side castle nut and align the hole to the notch of the nut. Install the right
side castle nut and securely tighten the nut, install a new cotter pin. 6. Securely tighten the left nut and install a new cotter pin. Votswg"Urgekhkecvkopu< 60-63Ft.Lbs ( 80-85N.m ) 7. Install the rubber cap.
"
606"UYKPI"CTO
1 SWINGARM ASSY
2 SWING ARM PIVOT BUSHING
3 SEAL
4 SWING ARM PIVOT BUSHING 3
5 SWING ARM PIVOT
6 NUT M14X1.25
7 DISK BRAKE MANTLE
8 BOLT M8X12
9 CHAIN WHEEL MANTLE
10 CHAIN ADJUSTER
11 BOLT M10X1.25X28
12 NUT M6
Tgmoxcn" "1. Removal rear shock absorber. 2. Removal NUT (6), washer, and SWING ARM PIVOT (5).
EJCRVGT"6D"EJCUUKU" " " " " " " " " " " " " " " " " " " " " " " " " " CVV"UGTVKEG"OCPWCN"42281 version number 0601
CHAPTER 4 CHASSIS PAGE. 4-
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Kpurgevkop"Inspect the SWING ARM PIVOT BUSHINGs and the SWING ARM PIVOT shaft for nicks, scratches, or damage. Replace if necessary. Kpuvcnncvkop"Reverse the removal procedure for installation. Povg0"Install pgy"seal."Coat the lip, bush, and pivot with grease. Votswg"Urgekhkecvkopu< NUT(6) M14X1.25: 40-44Ft.Lbs (55~60N.m )"" " " " " " " " " " " " " " " " " " " " " " Bolt for rear shock absorber: 21-24Ft.Lbs (28~32N.m)"