2013 DTV `SHREDDER` SERVICE MANUAL
Contents
1. YOO OOK G 2 4 SS FA LAN MENS 277 L aa 555 nn 7 Yj 5 5556 Y 220204 2 lt SR SS 5 NY Za lt RS 55 RRA 1 49 SS 2 0000 DA 1 Remove Spring Holder Cap and Spring E Ta r 2 Slide Moveable Sheave Assembly to one end of Main Shaft 4 INIA 1 0 AN AS 71 3 remove 3 exposed Moveable Sheave Keys 4 Slide Moveable Sheave Assembly back the other way and remove remaining 3 Moveable Sheave Keys 5 Slide Moveable Sheave assembly off Main Shaft and remove Spring Holders 6 Pullapart Moveable Sheaves To Disassemble Roller Weight Guide Assembly 1 Remove Roller Weight Guide Assembly Roll Pins 2 Slide all Roller Weights to centre of assembly 3 Rotate Inner Guide Plate on Outer Ring 4 Remove all Roller Weights and Sliders 72 Assembly Transmission Driver Assembly Prior to reassembling be sure to e Cleanallparts and inspect for wear and damage e Replace any broken worn or damaged parts e EnsureallSlidershave smooth action but not excessive pl2. FINALDRIVE CHAIN DRIVE SPROCKET HUB MOUNTING BOLT NUTS M6 8 10 7 5 TRACK DRIVE SPROCKET HUB MOUNTING BOLT NUTS M6 8 10 7 5 32 2 4 Vehicle System Maintenance 2 5 1 Brake Pads Fluid Use only DOT 4 0 or DOT 5 1 brake fluid 33 2 5 2 Tracks Track Removal 1 Remove 2 front rein wheel caps 3 Pull off 2 front outer ig LA S SN XN 0 4 Pull track off front inner bogie wheels first a remove completely ORS 2 N Track Installation Install tracks in reverse order of removal e Ensure drive lugs on inside of track are properly engaged in Track Drive Sprocket e Ensure track is sitting correctly on upper and lower bogie wheels e Push front of track onto 2 front inner Bogie Wheels e Rotate the track slightly while pushing front end on will help it slide onto bogie wheels e Reinstall front outer Bogie Wheels e Spray inside surface of tracks with an automotive tire shine product to reduce the friction with the Bogie Wheels and improve performance 34 Adjusting Track Tension NOTE proper track tension is not a precise science If the track is too loose it will derail during hard turning If it is too tight it will rob too much power from the Engine 1 Unclamp front Swingarm 2 Turn adjustment screw until track reaches proper tension N F 4 IT Pa M AAJ AU SAN AU TTSS TAN hx
3. SEE mm i m SA gt uL CS Handle Bar Front Handle Cover Back Handle Cover Air Filter Airbox Rubber Cap Skid Plate Battery Clamps Battery 12 6 Y X 2 gt PN SO eub S ANA Fay Y M lt SS 2 4 N 4 p N gt a 7 se n A wy gt ON N N Y S TD a O it 8 Upper Bogie Wheels Axle Track Guards 13 Airbox Transmission Case Support Bracket 4 Rear Deck Pivot Assembly __ I O 14 Rear Pivot Tube Front Pivot Tube Collar 15 Choke Upper Bogie Wheel Axle Upper Bogie Wheel Spacer Upper Bogie Wheel 16 Engine 1 4 3 N 2 lt REX Ao e BEAN MM rn Engine Damper Pad 17 Rear Swingarms 1 4 4 Right Side NOAA 5 lt Q SNA Swingarm Chain Sprocket Chain Tensioner 4 gt pO O 4 o Un gt ym C gt pO o 4 LA Q I 4 E O O o Y i lt 9 B Chain Guard Axle Bolt 12 20 18 Left Side Swingarm Chain Sprocket Chain Tensioner 4 gt O O Put UN gt O gt O 5 LN Q 23 I O O o Y
4. 62 Service Information As a general rule e Belts should be replaced every 100 hours of operation e Driver Sheaves should be replaced every 50 hours of operation due to ramp wear and all other sheaves about every 100 hours e Steering Rod should be replaced every 100 hours of operation In dirty environments transmission components will wear out faster 64 Specifications 2 mmni i ii S SECTION A SCALE 1 show steering rod specs bushing specs Torque Values Special Tools e pin type face spanner wrench 35mm span 6mm pin 65 Removal Transmission 1 Remove left side Subframe see Left Side 5 Remove outer belt Subframe Removal section 2 Remove transmission case intake duct and Track Guard 6 Remove crank bolt and outer shaft collar You will need a pin type face spanner wrench 6mm pin 35mm span or adjustable 4 Remove outer transmission case 5 7 gasket if you don t have a replacement 7 Remove transmission driver sheave assembly Be careful not to damage the Be sure to pull the case off straight Tap assembly case lightly with a mallet to break the 66 8 Remove inner fixed sheave and spacer 12 Remove transmission steering sheave disc assembly 9 Remove right side Subframe see Right 13 Remove 4 transmission mounting Side Subframe Removal section screws 10 Remov
5. WIB MB 81 3 7 3 Carburetor a Gh 82 3 8 Wiring EE 84 Troubleshooting Guide Mi 99 WEB 85 4 1 Steering Alignmegp gem Eee 85 4 2 Poor 5 V PEE 87 4 3 Tracks _ 87 4 4 Engine Has Poor Throttle 4 lt 88 4 5 mume Har 89 4 6 idle too 89 1 General Information 11 Headlight Function and Battery Charging Model with headlights NOTE headlights are always on when engine is running Turns battery charging function ON battery will only charge while vehicle is running and this switch is on Turns headlights ON when engine is not running Always oper
6. TRACKS TRACK DRIVE SPROCKETS TRACK DRIVE SPROCKET HUB MOUNTING BOLTS BRAKE LEVER FREE PLAY BRAKES PADS ROTORS Replace if any part of the track drive sprocket is These should be tightened periodically because brakes fully Note the left side pads and rotor are more exposed to the elements and may wear out quicker Be sure to check the splitter T connection is not leaking fluid See chain sprocket replacement section BRAKE LINES FLUID LEVEL CHAINS SPROCKETS PINIONS L CHAIN GUIDE ASSEMBLIES I L Ensure the idle sprocket is securely fit to and running smoothly on the bearing otherwise replace entire assembly It is critical that this drain tube and its plug are reinstalled after being emptied Ensure intake cover screen is present and secure FASTENERS AIR FILTER AIRBOX DRAIN TUBE AIRBOX SCREEN HANDLE TOOTH LOCK Check for full engagement of teeth Both top and MECHANISM HANDLE LOCK amp THROTTLE CABLES HANDLE LOCK BOLT DECK FUEL TANK amp LINES STEERING LINKAGE SHOCKS FASTENERS THROTTLE CABLE bottom half should be replaced as a pair if any teeth are broken damaged or worn Ensure cable had smooth action and returns naturally Ensure this is tight Check for cracks forming under the stomp pads Check for leaks Reinstall or replace if necessary Ensure steering performance is not degraded over time If necessary tighten all fasteners in deck pivot assemblies st
7. Place 3 Moveable Sheave Keys around one end of Main Shaft engaging with one Spring Holder as shown and hold them in place with one hand Slide Moveable Sheave Assembly onto Main Shaft orientation not important until it comes up against the Moveable Sheave Keys then push the Keys into the slots of the Moveable Sheave until they are 74 flush with the conical sheave face 5 Place remaining 3 Moveable Sheave Keys around other end of Main Shaft engaging with other Spring Holder as shown 6 B Slide Moveable Sheave Assembly carefully back into centre of Main Shaft ensuring all Keys are properly seated and flush with the belt contact surface Insert Spring into centre of Driver Assembly compress and install Spring Holder Cap A LA BQ lt 2 75 3 6 Steering System Assembly Drawing ME w rt QA 195 Lower Ball Joint Stud Steering Knuckle Lower Ball Joint Lower Jam Nut Steering Tie Rod 6 ____ 8 UpperBallJointStud o 9 Rear Deck Pivot 76 Service Information Follow disconnection instructions carefully Avoid loosening screws 1 8 10 11 whenever possible These screws have been installed with permanent thread locker prevent them from loosening over time due to the high transmitted and cyclic loads Any amount of play in the steering linkage system will greatly reduce the steering func
8. 7 32 2 4 Vehicle System 9 33 25 1 Blake Pads Fluic 33 2 5 2 o e ni e 34 2 5 3 eria C 36 2 5 4 38 2 5 5 A WE MCS Ue 5 __________ 39 2 5 6 s a _ ____ eee 41 215 7 Speed Caria 42 2 5 8 SS A 43 2 5 9 Carburetor Climate a iei ____ ______ 45 2 5 10 Engine Idle speted toi 45 2 5 11 Lubrication and seal tries 46 210 T T ias 48 o _______ _______________ 5 49 3 1 General 49 3 2 SUD TSS I u MN 51 3 3 Subiramis sRISI SIC tc 54 3 4 Rear SWINE ERIS R l nln t _ __________ 57 3 5 ello a gt 59 3 6 Steering System 76 aia nn rr err te re 78 3 7 1 Valve Clearance MEI WEB 80 3 7 2 Ignition Pickup Sensor Gap
9. LLI 2013 DTV SHREDDER SERVICE MANUAL Contents 1 General tora stands 4 1 0 a E O E O A 5 1 3 important Informa O RR E 6 m T TET 7 5 9 ie we 10 1 7 General Assembly 11 1 4 1 c r m m 11 1 4 2 rm l uuu us SSA 14 1 4 3 Engine RIAS EB 17 1 4 4 Rear Swingarms Neben eee 18 1 4 5 Steering System amp s a 20 1 4 6 Subframes 22 1 4 7 sgg c 05 27 1 4 8 Handle WA CAMA A 28 General Maintenzfs9 A WA 9 29 2 1 Maintenance 9 29 2 2 Stapgleushtorque 31 2 3
10. fre ol re Ll Prec 3 Re clamp front Swingarm NOTE a good indicator of appropriate track tension is to wiggle the front upper section between the front and upper bogie wheels up and down by hand The range of motion should be from 20 30mm without too much effort N lt N N S a ft NN m LA 4 1 35 2 5 3 Chain Tension 1 loosen axle bolt Chains adjust tension nut to increase or decrease chain tension Af O gt The chain slack should be between 5 15mm 0 2 0 6in 5 15mm 0 2 0 6in x OE n Ge re tighten lock nut 36 Chain Sprocket Inspection Inspect the drive chain for wear rust bound links proper lubrication and tension Inspect the sprocket and pinion for worn broken or damaged teeth Replace chain and sprocket together if there is a problem with either Hold the chain at the farthest rear point of the sprocket at pull as shown If the chain can be pulled higher than the teeth of the sprocket then replace the chain sprocket and pinion Chain and Sprocket Sprocket Ware Diagram Worn 37 2 5 4 Throttle Freeplay Remove handle covers Loosen jam nut on throttle cable housing end Adjust long nut screw in to increase free play screw out to decrease free play Tighten jam nut 5 Replace covers Note Make sure throttle snaps back to idle when throttle lever is r
11. BPROES spark plug To inspect the spark plug remove the plug cap then remove the spark plug from the engine Inspect the plug for carbon deposits and clean if necessary If plug shows excessive carbon replace the plug CAUTION Dirt can damage the engine if it enters the spark plug hole Make sure the spark plug hole is covered after removing plug MAINTENANCE Use a thickness feeler to inspect the spark plug gap 2 The spark plug gap should be 0 6 0 7mm 0 024 0 028 in Re install the inspected plug or new plug until fingertight Finish tizhtening plug with a wrench Ifthe plug is a new plug tizhten approximately 1 2 turn more with the wrench If plug is an old plug tighten approximately 1 8 turn more with a wrench 41 2 5 7 Idle Speed Adjustment Idle speed adjustment The dle speed should be setat 2000 200 RPMs To adjust the idle speed 1 locate the dle adjustment silver finger knob located on the Right hand side of the vehicle just under the deck 2 Allow the engine to warm up approximately 10 minutes 3 With the engine running turn the dle adjustment knob in or out at small increments until the correct idle is achieved Note A service center can perform this adjustment A diagnostic tachometer is required for this adjustment 42 2 5 8 Engine Oil 1 221 Engine oil level should be checked before each ride or minimum every 5 hours of operation It should be repla
12. O co o x lt jn Grease Nipple 20 19 1 4 5 Steering System Em 7 2 DIS 7 ls E Lower Ball Joint Stud Steering Knuckle Lower Ball Joint Lower Jam Nut Steering Tie Rod Upper Jam Nut Upper Ball Joint Upper Ball Joint Stud 9 Rear Deck Steering Adjustment Wheel Bolt 20 Rear Deck Pivot x d 2292052 22 KON es GINA ALA ALEA Xx 22 gt or CG 2 JN SAS CPs RAZA AES LAND z 7 7 PEE lt lt SAUS NZ 7 xd ROA RISA N 222 WY A TO x Py X M I D 8277272572 NOG 22 2 lt 82 no RAZA w N PS 2 NI N 45 LM RU KR 21 1 4 6 Left Side Subframes 22 Left Side Middle Suspension Sub Assembly 23 Right Side 24 25 Left Side Middle Suspension Sub Assembly 26 1 4 7 Airbox 27 1 4 8 Handle 6 j Brkeleverr ss 8 Engine Kill Switch Lanyard SS 28 2 General Maintenance 2 1 Maintenance Schedule INSPECT amp CLEAN ADJUST REPLACE TIGHTEN AS NECESSARY L LUBRICATE R REPLACE DS DEALER SERVICE BEFORE FIRST 5 EVERY 10 EVERY EVERY 100 EACH HRS OF HRS OR 3 50 HRS HRS OR 1 RIDE USE MONTHS OR 6 YEAR MONTHS GENERAL
13. 1 Engine Cover Vent Plugs these rubber plugs prevent snow from being sucked into the engine compartment and forming ice around the engine The image below shows the right side Subframe missing but it is not necessary to remove any components to install the Engine Cover Vent Plugs These should be firmly pressed into place until the embossments are securely engaged in the corresponding holes in the Engine Cover 2 Ice Breakers these parts prevent the buildup of ice inside the Track Drive Sprocket Ice formation inside the Track Drive Sprocket will eventually prevent the Track from properly engaging in the Drive Sprocket and stretch the Track enough to stop it from rotating and possibly stalling the engine To install the Breakers disassemble the left and right Rear Swingarm Assemblies see Rear Swingarm section of General Maintenance chapter and attach with 2 screws to inside of Rear Swingarm 1 5 Technical Specifications Dimensions amp Weights Overall Width 678mm 27 Overall Length handle up down 1321mm 52 1150mm 45 Overall Height handle up down 1270mm 50 584mm 23 111kg 245lbs 113kg 250lbs Powertrain Biased Dual Belt Type Continuously Variable Transmission 10 tooth 47 tooth Sealed O ring Dual Hydraulic Disc P Gross weight Maximum Payload Transmission Chain Pinion Chain Sprocket Chain Type Brakes Fuel type High Octane Unleaded Gasoline 91 AKI USA 95 RO
14. T Check for continuity with a tester NOTE fihere is continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness Use the tester on the connector as shown WARNING Never run an engine in an enclosed area Carbon monoxide exhaust gas is poisonous and can cause severe injury or death Always start engines outdoors Gasoline is extremely flammable and explosive under certain conditions Battery electrolyte is poisonous It contains sulfuric acid Serious bums can result from contact with skin eyes or clothing Always keep alert and wear protection Exhaust system components are very hot during and after use of ATV Never service when the engine is warm or hot Escaping steam from cooling system or hot oil from the machine can cause severe burns The engine must be cool before service Crate of the ATV and parts in the ATV maybe have sharp edge always pay attention and wear protection 50 3 2 Subframes Left Side Removal Subframes Left Side Remove track see section xx 5 Remove chain sprocket circlip and chain Remove chain see section xx and sprocket x nh Z s SN SS es A ERAN 99 gt des D FA REN 2 4 fo PA 9 NY Pa Remove chain guide s AA y 7 Ca Gy O lt 2 gt
15. gt 3 4 A F a E o 5 r 4 37 Er n Y gt 7 i2 3 r I Yi T g P f N gt Sie 3 2 0 5 0 020 10 11 12 13 Ignition Pickup Sensor Gap Recheck gap after tightening screws to ensure Pickup Sensor did not shift Readjust if necessary Reinstall Recoil Cover assembly Reinstall Engine Side Cover Reinstall Carburetor rubber Intake Elbow Reinstall Engine Intake Duct It is critical that the Intake Duct is securely fastened to the rubber Carburetor Intake Elbow and to the Airbox with NO gaps present Use grease on the mating surfaces to help seal the connections 14 Reinstall right side Subframe assembly ensor gap should be set to 0 5 mm 0 020 in 3 7 3 Carburetor Components 6 _ NeedleJetRetainingSpring 8 9 Throttle Valve Slide 82 Removal Carburetor alb dE Remove right Subframe Remove Engine intake duct Remove right Side Cover Remove right Brake Rotor Replacing Changing Jets 1 2 Remove Float Bowl screws 4 Unscrew Pilot Jet and replace Adjusting Needle Jet 5 Unscrew the Mixing Chamber Top and pull out the Throttle Valve Slide assembly Compress the Throttle Valve Slide Spring and disconnect Throttle Cable end from the Throttle Valve Slide through th
16. N rest of world 3 8 L 1 Gal 5W 30 Synthetic 600ml DOT 4 Fuel Tank Capacity Engine Lubrication Brake Fluid Engine Type Lifan Rhino 4 stroke Spark Ignition Fuel Gasoline No Cylinders 1 196 cc 68mm Displacement Bore Stroke Compression Ratio 59mm 9 6 1 0 051 mm 0 002 in 0 076 mm 0 003 in 12 5 hp 6000 rpm 13 Ibf ft 5500 rpm Splash Forced Air 1900 rpm 100 rpm Ignition System Transistorized with CDI 20 deg BTDC up to 3800 rpm 27 deg BTDC after 0 5 mm 0 020 in NGK BPR 5ES Carburetor Mikuni 22 mm round slide 137 5 12 5 Centre Initial setting 2 4mm Valve Clearance Intake Exhaust Max Power Max Torque Lubrication system Cooling Idle speed Type Ignition Timing Ignition Pick Up Gap Spark Plug Type Main Jet Idle Jet Needle Jet Groove Position Fuel Mixture Regulation Screw Throttle Cable Free play 12 V Li Fe Battery 1 6 Standards This product is in conformity with the following European standards Machinery Directive 206 42 EC Directive 2004 108 EC Applied Harmonized Standards EN ISO 12100 CE ACC attestation of compliance 12 12 82909 001 10 1 7 General Assembly Drawings 1 4 1 General p b 6 Wee cA ATRAS 7 6 57 p Bogie Wheel Pivot Tube End Cap Bogie Wheel Cap 11 4 AY LL 4 4 c 232 M
17. allows the Engine to load and unload which helps the parts to seat properly It is essential to place some stress on the Engine during the break in process however too much stress could cause damage to the Engine components Be careful not to load the Engine too much 3 Avoid riding in excessively dirty or dusty environments during the break in period The DTV Engine should be filled by the dealer service department with 600 ml of regular 5W 20 oil for break in purposes This oil should be drained after 5 hrs of operation and replaced with 600 ml of 5W 30 full synthetic oil During the next 5 hours of operation do not appl more than throttle ensure the engine is not allowed to idle while the DTV is stationary since there is less air flow to allow for cooling After 10 hours of service the DTV should be brought to an authorized dealer for a full overhaul and service Maintenance required as part of the initial service is outlined in the maintenance schedule Timely performance of this maintenance will help make sure your DTV will have the best service life and performance of the Engine 1 3 Important Information It is critical to follow the recommended break in and maintenance schedule If part replacement is necessary always replace with genuine BPG parts from an authorized BPG dealership Whenever oil seals gaskets O rings crush washers self locking nuts and circlips are removed they should be replaced with new o
18. alve Clearance 1 Hold the Rocker Arm Pivot with a wrench and loosen the Rocker Arm Pivot Lock Nuts 2 Adjust Rocker Arm Pivot until the correct valve clearance is achieved Intake 0 051 mm 0 002 in Exhaust 0 076 mm 0 003 in 3 Tighten the rocker Arm Pivot Lock Nut while holding the Rocker Arm Pivot 5 Check the valve clearance with feeler gauge between the rocker and the lash cap on top of the valve stem AL 4 ROCKER ARM M ROCKER ARM PIVOT LOCK NUT 4 Pull Engine over a few times manually with pull start cord 5 Recheck the valve clearance to ensure that the Rocker Arm Pivot did not move when the Lock Nut was tightened FEELER GAUGE al A 2211 W 7 Da En c Es SO 80 3 7 2 access the Pickup Sensor Remove the right side Subframe assembly Remove the Engine Intake Duct and Carburetor rubber Intake Elbow Remove the Engine Side Cover Remove the Engine Recoil Cover assembly 4 screws Loosen the Ignition Pickup Sensor mounting screws very slightly Place a 0 5 mm 0 020 in feeler gauge between the magnet of the Pickup Sensor and one of the raised steel inserts on the flywheel Push the sensor firmly but gently against the feeler gauge and tighten the Pickup Sensor mounting screws The ignition Pickup S OW P a PET 21 k As 74 4 5 gt A y Y J Qh y 3 77
19. armed up Use pull start NOTE the Carburetor is set up from factory for 20 degrees C at sea level Check the following if engine will not start or is hard to start Ensure Carburetor Jets are sized correctly for the particular climate temperature and altitude Ensure the fuel tank petcock is in the ON position during normal operation Because the RESERVE position draws fuel from the very bottom of the tank there is the possibility for contaminants to be drawn into the petcock and block or disrupt the fuel flow ON OFF RESERVE If all of the above are ok take your DTV to an authorized dealer or service centre 89
20. ate vehicle with this switch ON Battery disconnect stops battery discharge Use when vehicle will be parked for more than 2 weeks Turns headlights OFF when engine is not running Model with NO headlights Battery charging function ON battery will only charge while vehicle is running and this switch is on Always operate vehicle with this switch ON Battery disconnect stops battery discharge Use when vehicle will be parked for more than 2 weeks NOTE The battery has an automatic low voltage cut off switch If the battery stops working use the manual pull start cord to start the engine press the top charging button and ride the vehicle for approximately 15 minutes or until the battery is recharged 1 2 Engine Break In The initial 10 hours of operation are the most important the life of the DTV Proper operation during this break in period will help assure maximum life of the Engine The following guidelines will explain the proper break in procedures 1 Allow the Engine few minutes before riding This allows the oil to circulate throughout the Engine which lubricates the components During the first 5 hours of operation do not apply more than throttle Do not run the engine for more than 30 minutes at a time Allow for a cool down period of 15 minutes before operating again Make sure to vary the Engine speed during the break in period This
21. ay on Inner Plate after Roller Weight Guide Assembly is reassembled e Check that all roll pins are present and fully engaged e Check ramp surfaces of Moveable Sheaves for excessive wear or rutting from Roller Weights If excessive wear or rutting is visible replace Moveable Sheaves e Ensure alignment marks dimples on inside of each Moveable Sheave are facing each other as shown Enea aaa 42 522 ES lt lt XA s X 2222 4 sb 7 lt Coe 2 A 2 104 px gt x gt Ses lt N SOS gt NSS S gt 55 lt lt SS lt gt lt 92 22 Alignment Mark dimple Alignment Mark dimple 25 LA lt 2 2226 SEES CES Tu tI P 4 lt gt 2 gt SUSIE 22 EROS EA Cross section view of Driver Assembly 73 1 Reassemble Moveable Sheave Assembly ensuring the alignment marks are facing each other as shown Alignment mark Male Moveable Sheave engagement with Roller Weight Guide Assembly Female Moveable Sheave engagement with Roller Weight Guide Assembly Place Spring Holders together and slide inside Main Shaft in exact direction and orientation shown ensuring slots in Main Shaft and square holes in Spring Holders are lined up
22. be sure to e Use permanent thread locking compound on all bolts holding plastic Track Drive Sprocket to Sprocket Hub and torque to specified torque see specific torque values in General Maintenance Chapter 58 3 5 Transmission Assembly Drawing Inner transmission case Torque Sensing Sheave Inner Right Side Drive Shaft 4 Driven Spring 6 Inner RightSide Helix K lt Cb Cd 2 2 2 22000 Oy OB OO ORAS OE gt WH Ye Ail N e EM SNE NS MR AN LI ETZ iS s 2 lt I Es lt lt AD IS 2 UT 22522 LAG HOE 255552 ROI ROO ZZ 4 272 255 AT ESA y pus lt lt 2 NN lt lt A SS 2020 2 2222 SORE 2 25 RA 2 S x 55 e SECTION A A SCALE 1 1 5 gt SS 55555 2956 2 ROOK 2 27 La 2525 5 ROS No S ES RS SS KS Sc 52772 ex Inner Driven Pulley Assembly Inner Driven Pulley Assembly 60 Transmission Case 4 Driver Clutch Assembly Y Y O 6 Y I 9 Outer Shaft Collar I o O 61 Roller Weight Guide Plate Roller Weight A A EN 4
23. ce if cracked or worn e Check the shock spring preload collars are tight against the spring Disassembly Subframes Right Side Assembly Subframes Right Side Reassemble in reverse order of disassembly Prior to reassembling be sure to e Clean all parts and inspect for wear and damage e Replace any broken worn or damaged parts 56 3 4 Rear Swingarms Right Side qn o 57 Service Information Lubricate grease fittings every 10 hours of regular use General Info Torque Values Removal Rear Swingarms The Subframe must be removed to remove the Rear Swingarm refer to Subframe Removal procedures section xx Separate Rear Swingarm by removing plastic Pivot Tube Sleeve Be sure to take note of the orientation and position of the Swingarm relative to the subframe as well as the position of the plastic spacers and Pivot Tube Sleeve Installation Rear Swingarms Prior to installation be sure to e Cleanallparts and inspect for wear and damage e Replace any broken worn or damaged parts e Ensure all fasteners are tight pay special attention to bolts and nuts holding plastic Track Drive Sprocket 5 6 to Sprocket Hub 11 e Checkball bearings 15 in Sprocket Hub for wear e Check Chain Drive Sprocket for wear see section xx Disassembly Rear Swingarms e See assembly drawing above Assembly Rear Swingarms e Assemble in reverse order of disassembly Prior to reassembling
24. ced every 10 hours of operation or 3 months whichever comes first Use 5w 30 full synthetic oil 1 Remove deck 8 screws 2 Twist off and pull out oil dipstick wipe with a clean rag and re insert Remove again and check oil level and cleanliness 3 If oil level is low add more to within the hatched section on the end of the dipstick If oil is dirty and needs to be replaced 4 To drain Engine oil remove the front skid plate 4 screws Raising the machine up a little by supporting it under the tracks or hoisting it by the upper frame rails might make this easier WAN AZ Ty 5 Place empty container underneath crankcase drain tube to catch the oil Be sure it is large enough to hold up to 600ml of oil 6 Remove crankcase drain tube threaded plug be sure to hold the drain tube with a wrench so that it does not rotate with the threaded plug and allow to drain for a few minutes Tilting the machine forward by a few degrees may help to get the most oil to flow out 43 Replace threaded plug using new crush washer Fill Engine with 600ml of 5w 30 full synthetic oil verify level using dipstick and reassemble machine in reverse order 44 2 5 9 Carburetor Climate Adjustment The jets in the Carburetor are sized for efficiency for approximately 20 degree Celsius ambient temperature and sea level They may need to be changed for other climate
25. ck and place a long wooden block against the lower shock mount and tap it with a mallet while pulling at the front of the subframe simultaneously Installation Subframes Right Side Reinstall in reverse order of removal Before reinstalling subframe be sure to e Checkallfasteners are tight Pay close attention to the front shock mounting bracket bolts the steering knuckle cavity inside end cap This must be fastened securely but be sure not to over torque the 3 screws as they are threaded into aluminum Follow recommended torque in Torque Specifications section Track drive sprocket fasteners Because the track drive sprocket is made of plastic and under high torque loads the fasteners are more prone to loosening It is a good idea to check and tighten each one e Remove and clean all plastic pivot bushings and spacers e Apply a thin film of assembly grease on pivot tubes and all plastic pivot bushings and spacers e Inspect the plastic track drive sprocket for damage e Clean and inspect the chain sprocket for wear Replace if necessary see section xx e Clean and lubricate the chain e Clean chain guide and idler sprocket assembly and check for excessive wear e Checkthe steering knuckle free play and sliding action see Disassembly for details e Check the grease in the steering knuckle cavity for debris Wipe off and re grease if necessary e Checkthe integrity of the front Swingarm rubber damper pad Repla
26. e groove Remove Needle Jet Retaining Spring from inside the Throttle Valve Slide Remove the Needle Jet Move Needle Jet Clip up or down depending on desired performance change NOTE The Needle Jet affects fuel delivery in the to throttle range Disconnect Throttle Cable from top of Carburetor Remove Carburetor 2 nuts Unscrew Main Jet and replace Reinstall Float Bowl Standard Factory D Setting Middle Clip position Move Clip up to lower Needle Jet and reduce fuel delivery down to raise clip and increase fuel delivery 83 3 8 Wiring Diagram LED Light R DI CDI DJ70414 2 8 21 DIT70314 2 8 21 07221 3 5 Rectifier a e DI70614 2 8 11 A WEGE Es 6 lt 4 i Insulating tape 50 0721 24 le 50 100 a 50 150 50 Magneto PVC Pipe 5 Black 07 2 8 21 Black Heat resistant 100 150 Sleeving Black Heat resistant Sleeving 50 n T II lH 5 5 4 B Y B 6 T AY Mii TTD q Start Relay Ignition Coil LED Light L 07221 3 54 07221 4 0 DJ431 64 07627 6 07211 4 0A Grounding Red Line Green Line PVC Pipe L 950m0 6 6 With Protector 701 350 x Black Heat resistant Sleeving 07022 17 8 11 84 4 Troubleshooting Guide 4 1 Steering Alignment If steering seems to be biased to one side more than the other
27. e right Track Guard and Engine Intake Duct system 14 Loosen transmission support bracket clamp bolt and wedge bracket open a little with a flathead screwdriver 67 15 Remove inner transmission case assembly Be sure to hold the brake rotor with one hand to help guide it off straight while pulling the inner transmission case assembly free 68 Installation Transmission Reinstall in reverse order of removal NOTE Do nottry to force Transmission Case Assembly halves together using the bolts Manually turn output Driveshafts while pushing Transmission Case halves together to allow Transmission Belts to move out on the Driven Sheaves which allows the case halves to mate naturally Before reinstalling transmission be sure to e Check Steering Rod Bushing wear Replace bushing if necessary Steering Rod Bushing should be inspected every 10 hours of operation as a general rule and lubricated with chain lube Lubrication can be applied without disassembly if applied while bushing is still hot immediately after operation Replace bushing when it is worn A good Steering Rod bushing should have no free play on the Steering Rod In dirty environments the bushing will wear out faster e Check belts for excessive wear damage Replace if necessary Belts should be replaced every 100 hours of operation as a general rule In dirty environments the belts will wear out faster Check sheave faces for wea
28. ections are secure Inspect filter with each oil change Replace when deformation is present on the roller weight ramp surfaces Replace when wear is present at needle bearing or bushing running surfaces Remove drain plug to ensure no liquid present after riding in rain or after washing Remove any debris build up inside case Apply grease to all air duct connections and check they are securely fastened INSPECT amp CLEAN ADJUST REPLACE TIGHTEN AS NECESSARY L LUBRICATE REPLACE DS DEALER SERVICE 30 2 2 Standard torque values FASTENER TYPE TORQUE N m Ibf ft 5mm BOLT amp 6 N m 4 5 6mm BOLT 10 N m 7 5 Ibf ft 8mm BOLT amp NUT 25 N m 18 31 2 3 Specific torque values FASTENER SIZE TORQUE N m Ibf ft CRANK BOLT 40 30 UPPER ENGINE MOUNTNUTS M8 4 30 22 LOWER ENGINE CRADLE MOUNTSCREWS M8 4 30 22 EXHAUST HEADER ATTACHMENT NUTS 25 18 TRANSMISSION ___________ 2 TRANSMISSION CASE MOUNTING SCREWS 4 30122 pO Wh STERNGUNKAGE J STEERING KNUCKLE CAVITY END CAP SCREWS M3 6 _ 1 07 8 Up p GA 22 HANDLEBARYOKEBOLTS M8 4 _ 3022 FRONT SHOCK MOUNT BRACKET SCREWS M8 4 _ 3002 REARSHOCKMOUNTNUTS M8 4 _ 3002 oo MOUNTING SCREWS M8 4 _ 3002 FRONTBOGIEWHEELLUGBOLTS 0 8 400
29. eering linkage system and steering knuckle cavity end caps Ensure spring preload collars and all mounting fasteners are tight Ensure cable had smooth action and returns naturally Ensure enough free play so throttle is not opened when handle folded down Check for wear Replace if necessary STEERING ROD BUSHING Low STEERING ROD NEEDLE BEARINGS LLL D lt INDEM D d masa LOT 0 _ 29 STEERING KNUCKLE BUSHING FUEL FILTER BOGIE WHEELS BEARINGS GREASE FITTINGS MIDDLE SUSPENSION MAIN PIVOT BUSHINGS rotation in bushing same orientation or replace if unsure Check behind covers and remove build up Check side to side play of the middle suspension assembly and ensure scissor arms are not scraping against Engine intake duct ENGINE OIL LEVEL ENGINE OIL CRANKCASE VENTILATION TUBE CARBURETOR FLOAT BOWL CARBURETOR VALVE CLEARANCE SPARK PLUG IDLE SPEED AIR INTAKE DUCT SYSTEM CRANKSHAFT CAMSHAFT CONNECTING ROD PISTON RINGS CYLINDER HEAD ASSEMBLY PCV VALVE IGNITION COIL GAP TRANSMISSION BELTS TRANSMISSION CASE GASKET DRIVER SHEAVES ALL OTHER SHEAVES STEERING ROD TRANSMISSION CASE DRAIN PLUG TRANSMISSION CASE AIR INTAKE DUCT SYSTEM BEFORE FIRST 5 EVERY10 EVERY50 EVERY 100 ITEM EACH HRS OF HRSOR3 HRSOR6 HRS OR 1 RIDE USE MONTHS MONTHS YEAR 600 ml 5W 30 full synthetic oil Idle speed 2000 100 rpm Check all conn
30. eleased Note The thumb throttle should have 2 4mm 0 08 0 16 of free play 38 2 5 5 Filter 1 Turn off fuel petcock 2 Tip machine on its side preferably left side down so fuel can not flow into Engine air intake duct or raise up to allow access to the front skid plate 3 Remove front skid plate screws VW x4 EM X NN N b N V A T m Le ii SST E YT 5574 le N N Q s 14 lt 4 A M 7 UN 5 Pull off rubber airbox Na tj Y SV Ss Inspect air filter and foam pre filter for excessive trapped dust and dirt If filters are dirty clean air filter with water flushing it from the inside and then blow dry from the inside with compressed air Clean the foam pre filter using air filter cleaner and reapply 39 foam filter oil before slipping it back inserted in the open end when replaced over the air filter 2 J J J J 1 HH Y Inspect Airbox for cracks or leaks and repair or replace if necessary Reinstall air filter and reassemble machine in reverse order Drain the airbox tube if necessary and ensure it is securely fastened to the airbox with the plug completely 2 5 6 Spark Plug NGK BPR5ES 0 6 0 7 mm 0 024 0 028 in Spark Plug This DTV comes equipped with an NGK
31. ery charger and place it in a contained vessel such as a metal box In case the battery terminals are contaminated clean the terminals with a dry cloth before use Otherwise power failure or charge failure may occur due to the poor connection between the battery and the electronic circuitry of the instrument Be aware discarded batteries may cause fire 100 discharged the battery and tape the battery terminals to insulate them before disposal 48 3 Service 3 1 General Information PREPARATION FOR REMOVAL PROCEDURES 1 Remove all dirt mud dust and foreign material before removal and disassembly 2 Use proper tools and cleaning equipment 3 When disassembling the machine always keep mated parts together This includes gears cylinders pistons and other parts that have been mated through normal wear Mated part must always be reused or replaced as an assembly 4 During machine disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire REPLACEMENT PARTS Use only genuine parts for all replacements Use recommended oil and grease for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality GASKETS OIL SEALS AND O RINGS 1 Replace all gaskets seals and O rings when overhauling the engine All gasket surfaces oil seal lips and O rings
32. ery charger specifically for that purpose Do not reverse the positive and negative terminals Do not connect the battery to an electrical outlet Do not dispose the battery in fire or heat Do not short circuit the battery by directly connecting the positive and negative terminals with metal objects such as wire Do not transport or store the battery together with metal objects such as necklaces hairpins etc Do not strike or throw the battery against hard surface Do not directly solder the battery Dot not pierce the battery with a nail or other sharp object Never disassembling the battery in any way CAUTIONS Do not use or leave the battery at very high temperature for example at strong direct sunlight or in a vehicle in extremely hot weather Otherwise it can overheat or fire or its performance will be degenerate and its service life will be shortened Do not use it in a location where static electricity is rich otherwise the safety devices may be damaged causing a harmful situation In case the electrolyte getting into the eyes due to the leakage of battery do not rub the eyes Rinse the eyes with clean running water and seek medical attention immediately Otherwise it may injure eyes or cause a loss of sight If the battery gives off an odor generates heat becomes discolored or deformed or in any way appear abnormal during use recharging or storage immediately remove it from the device or batt
33. ing one Even at low speeds the steering will only work while also applying some throttle t can be counter intuitive but completely necessary very similar to steering a jetski It can take time to learn this skill and timid riders will have the most difficulty If the DTV has poor steering response even after the above technique is applied 1 Ensure there are no rocks or debris 5 Ensure the Steering Knuckle cavity block the action of the deck or the end caps are securely fastened rotation of the tracks 6 Ensure Steering Knuckle cavity is 2 Make sure the Steering Tie Rod ball filled with grease and Steering joints are not loose or broken Knuckle action is smooth 3 Ensure the Steering Adjustment When vehicle is not moving the Wheel is secure 5 4 Ensure the Rear Deck Pivot knuckle pn have inn Assembly is not loose bushings not 4 6mm of total trave worn pivot bolt not loose 4 3 Tracks Coming Off 1 Ensure track tension is adjusted 4 Ensure bogie wheels are not correctly damaged or missing 2 Ensure Track Drive Sprockets are not 5 Ensure Upper Bogie Wheel Axles are worn out or damaged not loose 3 Ensure Tracks are not damaged 87 4 4 Engine Has Poor Throttle Response NOTE the Carburetor is set up from factory for 20 deg C at sea level 1 Ensure all connections in the Engine Always switch petcock back after air intake system are tight and the rubber Carburetor elbow is securely attached to the Carbure
34. it can be brought back into alignment by adjusting the length of the steering tie rod Lower Ball Joint Stud Lower Jam Nut Upper Ball Joint Stud Rear Deck Pivot Wheel Bolt Wheel Set Screw Wheel IMPORTANT Avoid loosening screws 1 8 10 11 whenever possible These screws have been 6 installed with permanent thread locker prevent them from loosening over time due to the high transmitted and cyclic loads Any amount of play in the steering linkage system will greatly reduce the steering function 85 Setting Steering Alignment 1 Remove deck If steering is biased to the left 2 Remove right side track guard lengthen linkage to centre it 3 Loosen upper and lower ball joint jam f steering is biased to the right nuts NOTE lower end of tie rod is reverse threaded Using a wrench on the flats at the upper end of the tie rod turn rod to adjust the linkage length Turning the rod clockwise if standing on right side of machine will shorten the linkage and counter clockwise will lengthen it shorten linkage to centre it Re tighten jam nuts Reinstall Deck Test steering by riding in clockwise and counter clockwise circles and comparing the turning radius of each at a moderate speed Repeat steps 1 through 7 if further adjustment is necessary Reinstall track guard and deck 86 4 2 Poor Steering Response The DTV may feel unresponsive at low speeds for anybody not accustomed to rid
35. must be cleaned 2 Properly oil all mating parts and bearings during reassembly Apply grease to the oil seal lips LOCK WASHERS PLATES AND COTTER PINS Replace all lock washers plates and cotter pins after removal Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification BEARINGS AND OIL SEALS Install bearings and oi seals so that the manufacturers marks or numbers are visible When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liberally when installing if appropriate 1 oil seal CAUTION Do not use compressed air to spin the bearings dry This will damage the bearing surfaces 1 Bearing CIRCLIPS 1 Check all circlips carefully before reassembly 49 Always replace piston pin clips after one use Replace distorted circlips When installing a cicipi make sure that the sharp edged comer 2 is positioned opposite the thrust 8 it receives See sectional view Shaft CHECKING OF CONNECTIONS Dealing with stains rust moisture etc on the connector 1 Disconnect Connector 2 Dry each terminal with an air blower 3 Connect and disconnect the connector two or three 4 Pull the lead to check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinset the terminal into the connector 6 Connect Connector The two connectors click together
36. nes Be sure to remove any residual material and clean mating surfaces before installing new gaskets It is critical to the function of the machine that all circlips are properly fitted When installing new external circlips be very careful not to expand them any more than is necessary to slip over the shaft After installing any new circlip always ensure its groove is clean and free of debris and the clip completely seats in its groove rotate to check Always use a calibrate torque wrench to tighten all fasteners to their specified torques When installing a part with several bolts nuts or screws start them all in their holes by hand and tighten them to a snug fit Then tighten opposing pairs of bolts progressively and evenly in a diagonal criss cross pattern starting from the inside working out to the specified torque This is to avoid distortion of the part causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of turn and then remove them Check the torque values chart for the specified torques Cylinder Head tighten bolts progressively in an X pattern Crankcase Cover tighten bolts progressively in a criss cross pattern Transmission case tighten bolts progressively as shown in Transmission Installation section of General Maintenance chapter 1 4 Winter Operation It is critical to install the following components prior to operating the DTV in snow
37. ntegrity of the front Swingarm rubber damper pad Replace if cracked or worn Check the shock spring preload collars are tight against the spring Disassembly Subframes Left Side Assembly Subframes Left Side Reverse order of disassembly Prior to reassembling be sure to Clean all parts and inspect for wear and damage Replace any broken worn or damaged parts 53 3 3 Subframes Right Side Removal Subframes Right Side 1 Remove deck 8 screws A AAE EI ves Q gt y 5 A Ni y pe ub 2 MEA bolts 7 A 27 3 Loosen upper tie rod jam nut and unscrew upper ball joint assembly from tie rod so lt A lp Remove right side track see Track Removal in General Maintenance Chapter Remove upper shock mount nut 1 gt Remove steering knuckle cavity outside end cap 54 Remove steering knuckle bolt 10 Push drive sprocket assembly forward to DS put slack in the chain then pull chain lt 732 3 forward off pinion and place on outside Remove 4 Its me clamping bo ON gt rs Y 5 11 Remove subframe assembly Ensure exposed parts of pivot tubes are clean Pull evenly at both front and rear pivot tube Do not hammer on parts as they are cast aluminum and can crack necessary remove the sho
38. r or damage Replace if necessary As a general rule Sheaves should be replaced every 100 hours of operation In dirty environments sheaves will wear out faster Check Driver Sheave Ramps for wear or damage Replace if necessary As a general rule Driver Sheaves should be replaced every 50 hours of operation due to Ramp wear In dirty environments sheaves will wear out faster 69 Check wear steering rod at needle bearing and bushing running surfaces Replace rod if necessary Steering Rod and drive shafts should be replaced every 100 hours of operation as a general rule In dirty environments the rod will wear out faster Check needle bearing seal integrity Replace if necessary In dirty environments seal will wear out Grease needle bearings Replace if necessary In dirty environments needle bearings will wear out faster It is a good idea to rebuild the Driver Assembly to check for worn and damaged parts Moveable Sheave Roller Weight ramp surfaces should be checked about every 10 hours of operation for rutting Replace Moveable Sheaves if rutting is evident Also ensure Roller Weights slide freely and Sliders are not damaged Tighten Transmission case bolts progressively as follows 70 Disassembly Transmission Driver Assembly 2 f 22 Z LR ORR OR IRS QI lt o 55 SS 4 ESSE VAS
39. ring rod fastened to the steering knuckle before the transmission support bracket and Engine can be fastened to the frame Failure to follow this procedure will cause undue stresses on the steering rod and will cause bushing failure in the Transmission Case e Place Engine on Engine cradle in frame with 4 mount bolts loose e Reinstall transmission see transmission section of Service Chapter leaving the transmission Axle Housing Clamp Bolt on the Transmission Support Bracket loose e Reinstall Subframes and secure to frame e Adjust Engine position so that Steering Rod lines up with Steering Knuckle and fasten securely e Tighten Transmission Axle Housing Clamp Bolt on the Transmission Support Bracket e Tighten Engine mount bolts 4 e Reconnect ignition wire starter motor wires throttle cable and fuel line e Reinstall deck 8 screws 79 3 7 1 Valve Clearance Valve Clearance should be checked after the first 5 hours of operation and then after every 10 hours of operation NOTE Valve clearance should always be checked when the Engine is cold ambient temperature Checking Valve Clearance Remove Deck Remove Cylinder Head Valve Cover 4 bolts 3 Remove Spark Plug clean around plug 4 Turn Engine over using the pull cord until the piston is at TDC top dead centre on the compression stroke This is visible through spark plug hole Note that air will escape and rocker arms will be parallel Setting V
40. s or altitudes See Carburetor section under Engine service chapter for instructions on how to replace jets 2 5 10 Engine Idle speed Engine idle speed is adjusted with the silver finger knob on the right side of the machine 45 2 5 11 Lubrication and seal points Front Swingarms V Y Oi mo SY E i TSG JL LH Rear Swingarm LO TI 2 E Co sa A KY KY A f S s IU i a De EA DNS 4 j of NY D XS AA YA gt eo 7 E Z N N AN SA SA RUT RRR 46 RH Rear Swingarm e IN 277 3 lt gt DESARRO aL HA EX WE CER 7 2 ST 47 2 5 12 Battery 4000mAh 12 8V Li Po WARNINGS The battery will fire explode or leak if not strictly observing this item described below 99 444 not immerse the battery in water seawater and keep the battery in cool dry environment during stands by period Do not mix using the battery with one off battery such as dry battery or different performance toqether Keep all batteries out of the reach of little children Consult a doctor immediately if a battery is swallowed Do not use or leave the battery near a heat source such as fire or heater When re charging use the batt
41. sI NS p 2 SQ S ND LY NS V lt D NIZA Qu XA s Z ys EY 51 Remove 4 subframe clamping bolts EPIS Ox 1 j o C 4 Remove subframe assembly Ensure exposed parts of pivot tubes are clean Pull evenly at both front and rear pivot tube Do not hammer on parts as they are cast aluminum and can crack If necessary remove the shock and place a long wooden block against the lower shock mount and tap it with a mallet while pulling at the front of the subframe simultaneously 52 Installation Subframes Left Side Reinstall in reverse order of removal Before reinstalling subframe be sure to Check all fasteners are tight Pay close attention to the front shock mounting bracket bolts Track drive sprocket fasteners Because the track drive sprocket is made of plastic and under high torque loads the fasteners are more prone to loosening It is a good idea to check and tighten each one Remove and clean all plastic pivot bushings and spacers Apply a thin film of assembly grease on pivot tubes and all plastic pivot bushings and spacers Inspect the plastic track drive sprocket for damage Clean and inspect the chain sprocket for wear Replace if necessary see section xx Clean and lubricate the chain Clean the chain guide and idler sprocket assembly and check for excessive wear Check the i
42. tion Disconnecting Steering System NOTE disconnection of the steering system is necessary in order to remove the right side Subframe assembly Remove Deck 5 Turn Steering Tie Rod counter Remove 4 Rear Deck Pivot mounting clockwise if standing on right side of screws machine until it pulls out of both 3 Remove right side Track Guard Upper and Lower Ball Joints Loosen Upper and Lower Jam Nuts Reconnection Steering System Reconnection is reverse order of disconnection Follow Steering Alignment instructions in the Troubleshooting Guide section to realign the steering 77 3 7 Engine Assembly Drawings XT N SIA Frame Engine 5 Engine Damper Pad Removal Engine Remove the deck 8 screws Remove the subframes from both sides see subframe section in Service chapter Remove Side Covers Remove Engine intake duct Remove transmission intake duct A Er P Remove transmission see transmission section of Service chapter Installation Engine 7 Disconnect fuel line from Carburetor 8 Disconnect throttle cable from Carburetor 9 Disconnect ignition wire from Engine 10 Disconnect starter motor wires 11 Remove Engine mount bolts 4 from bottom 12 Remove Engine WARNING The position of the Engine Transmission assembly in the frame is set by the Steering Rod Knuckle The subframes must be securely fastened to the frame and the stee
43. tor and not kinked Ensure Air Filter is not blocked Ensure there is sufficient fuel Fuel Petcock may get blocked with debris if itis on reserve Pull fuel line momentarily off petcock to determine if fuel is flowing freely refueling never operate on RESERVE for longer than necessary Ensure the Throttle Cable is operating properly and opens closes fully Ensure spark plug is not fouled Ensure Carburetor Jets are sized correctly for the particular climate temperature and altitude 88 4 5 Engine Hard to Start when Engine is cold 1 Pullthe choke forward if starting the Engine from cold Let the Engine idle for about 2 minutes while it warms up Push in the choke before riding 2 Ensure the emergency Engine Kill Switch Lanyard is securely in place 3 Spark plug Check for spark and ensure plug is not fouled 4 Push pull the unit to straighten transmission 5 Throttle not stuck open you should hear the slide closing at carburetor 6 Ifthe starter motor is weak or does not work ensure the battery is switched on and fully charged See Headlight Function and Battery Charging section in General Information chapter 4 6 Engine idle too high low Engine suddenly starts revving high 1 Ensure choke knob has been pushed back to off position Throttle cable is not stuck open Adjust idle with remote manual adjustment knob ra 9 NOTE Electric Start should only be used after the Engine has been w
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