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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

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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.

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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

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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.

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KPUVCNNCVKQP"PQVG

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Ejckp"Kpurgevkop."Kpuvcnncvkop"cpf"Cflwuvmgpv"

1. Clean and Inspect chain and chain sprocket for wear.

PQVG

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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{"

"

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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 AT18X7-8FOR 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.

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Hkpcn"Ftkxg"Cuugmdn{"1. Drive in bearings to the AXLE TUBE. PQVG

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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)"