User manual HSUN 500ATV SERVICE MANUAL

[. . . ] BRIEF INTRODUCTION TO FOUR-WHEELED CROSS-COUNTRY VEHICLE MODEL 500ATV Four-wheeled cross -country vehicle, model 500ATV is a full road condition vehicle which can be driven on every kinds of road conditions such as sand beach, grassland, forest, village, construction site country road , This maintenance manual of four-wheeled vehicle model 500ATV (Hereafter called cross -country vehicle for short) compiled by Chongqing Industries Co. , Ltd is specially provided for saler and technical staff of our Group. This manual mainly introduce the maintenance, removing and repairing method of cross-country vehicle and provide some relative technology and performance data. Because this manual can't collect the whole content of cross-country vehicle, it can only help maintainer of our group and it's saler have a basic understanding on working principle, maintenance procedure and repairing technology of cross-country vehicle. If you don't have this knowledge, when repairing cross-country vehicle, the condition of improper assembling and danger occurs after assembling are easily happened. [. . . ] (B)Check that the pinion gear turns clockwise. NOTE Be sure not to disassemble gear motor and remove the pinion gear. ()Installation steps The reversal steps of "Removal"steps and "Installation" steps , pay attention to the following points during installment. 1. When installing differential gear, lubricate the parts in the differential gear case. -80- 2. When installing the gear motor of differential gear, slide the shift fork sliding gear , which is installed to the differential gear, to the left to put it into the 2WD mode. 3. When installing the front constant velocity joint, lubricate the bearing, the spline. 4. Check the differential gear operation (1)Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. (2)Remove the wheel cap and cotter pin from the axle nut (right or left). (3)Measure the starting torque of the front wheel with the torque wrench. NOTE Repeat this step several times to obtain an average figure. During this test, the other front wheel will turn in the opposite direction. Front wheel starting torque: (differential gear preload): New unit: 17 25 Nm (1. 7 2. 5 m·kg, 12 18 ft·lb) Minimum: 10 Nm (1. 0 m kg, 7. 2 ft lb) · · (4)Out of specification Replace the differential gear assembly. (5)Within specification Install the new cotter pin and wheel cap. -81- . The rear constant velocity joint, final drive gear assembly and drive shaft 1. Rear constant velocity joint 2. Final drive gear case breather hose 3. Final drive gear assembly 4. Compression spring 5. Universal joint 6. Drive shaft -82- ()Removal steps of the rear constant velocity joint, final drive gear assembly and drive shaft 1. Removal Rear wheels WARNING Block the front wheels, and elevate the rear wheels by placing a suitable stand under the frame. 2. Removal Rear arm /Rear knuckle /Rear absorber 3. Removal Brake caliper assembly 4. Removal Rear constant velocity joint -83- 5. Removal Final drive gear assembly 6. Removal Drive shaft -84- ()Removal steps of the rear constant velocity joint Disassembling the rear constant velocity joint in the order below. Dust cover Circlip Boot band Boot band Dust boot Circlip Double off-set joint Snap ring Ball bearing Joint shaft assembly For assembly, reverse the disassembly procedure. -85- ()Removal steps of the final drive gear Disassembling the final drive gear in the order below. 1. Boss 3. Ring gear stopper 5. Bolt 7. Oil seal 9. Ring gear shim 11. Thrust washer 13. O-ring 15. Inner race 17. Bearing retainer 19. Pinion gear bearing housing 21. Oil seal 23. Bearing 2. Ring gear stopper shim 4. Bolt 6. Ring gear bearing housing 8. Bearing 10. Ring gear 12. Final drive pinion gear shim 14. Oil seal 16. Final drive pinion gear 18. Bearing 20. Final drive gear case 22. Bearing For assembly, reverse the disassembly procedure. -86- ()Removal steps of the universal joint Removing the universal joint (1)Remove the circlips (2)Place the U-joint in a press. (3)With a suitable diameter pipe beneath the yoke , press the bearing into the pipe as shown. NOTE It may be necessary to lightly tap the yoke with a punch. (4)Repeat the steps for the opposite bearing. NOTE (1)It may be necessary to lightly tap the yoke with a punch. (2)Use a universal joint holder -87- ()Inspection content 1. Checking the rear constant velocity joint Free play (thrust movement) Excessive play Replace the joint assembly. 2. Checking the rear drive shaft Bends Replace. WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft. 3. Checking the final drive gear (1)Check Final drive gear case¢Ù Ring gear bearing housing¢Ú Cracks/damage Replace. NOTE When the final drive gear case and/or the ring gear bearing housing are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear. (2)Check Gear teeth Pitting/galling/wear Replace the drive pinion gear and ring gear as a set. Oil seals O-rings Damage Replace. -88- (3)Check Bearings Damage Replace. 4. Checking the final drive gear operation Insert the double off-set joint into the final drive gear, and turn the gear back and forth. Unsmooth operation Replace the final drive gear assembly. ()Installation steps The reversal steps of "Removal"steps and "Installment" steps , pay attention to the following points during installment. 1. Installing the universal joint (1)Install the opposite yoke into the U-joint. (2)Apply wheel bearing grease to the bearings. The needles can easily fall out of their races. [. . . ] Check the bulb and bulb socket for continuity No continuity Continuity Replace the bulb and/or bulb socket. 2. Brake light switches Refer to "CHECKING THE SWITCH" No continuity Continuity Replace the brake light switch. 2. Voltage . Connect the pocket multimeter (DC 20 V) to the brake light couplers. Tester (+) lead Green/Yellow terminal 2 Tester (­) lead Green terminal 3 Turn the main switch to "ON". Fasten the front brake light switch or trample the rear brake light switch. Out of specification Check the voltage (12 V) of the "Green" and "Green/Yellow"leads on the bulb socket connector. The wiring circuit from the main switch to Continuity This circuit is not faulty. [. . . ]