2013 DTV `SHREDDER` SERVICE MANUAL

2013 DTV ‘SHREDDER’
SERVICE MANUAL
1
Contents
1.
2.
General Information ............................................................................................................................. 4
1.2.
Engine Break-In ............................................................................................................................. 5
1.3.
Important Information .................................................................................................................. 6
1.4.
Winter Operation .......................................................................................................................... 7
1.5.
Technical Specifications ................................................................................................................ 9
1.6.
Standards .................................................................................................................................... 10
1.7.
General Assembly Drawings ....................................................................................................... 11
1.4.1.
General ................................................................................................................................ 11
1.4.2.
Frame .................................................................................................................................. 14
1.4.3.
Engine.................................................................................................................................. 17
1.4.4.
Rear Swingarms................................................................................................................... 18
1.4.5.
Steering System................................................................................................................... 20
1.4.6.
Subframes ........................................................................................................................... 22
1.4.7.
Airbox .................................................................................................................................. 27
1.4.8.
Handle ................................................................................................................................. 28
General Maintenance ......................................................................................................................... 29
2.1
Maintenance Schedule ............................................................................................................... 29
2.2
Standard torque values ............................................................................................................... 31
2.3
Specific torque values ................................................................................................................. 32
2.4
Vehicle System Maintenance ...................................................................................................... 33
2.5.1.
Brake Pads/Fluid ................................................................................................................. 33
2.5.2.
Tracks .................................................................................................................................. 34
2.5.3.
Chains .................................................................................................................................. 36
2.5.4.
Throttle Freeplay................................................................................................................. 38
2.5.5.
Air Filter............................................................................................................................... 39
2.5.6.
Spark Plug............................................................................................................................ 41
2.5.7.
Idle Speed Adjustment ........................................................................................................ 42
2.5.8.
Engine Oil ............................................................................................................................ 43
2.5.9.
Carburetor Climate Adjustment.......................................................................................... 45
2.5.10.
Engine Idle speed ................................................................................................................ 45
2
3.
2.5.11.
Lubrication and seal points ................................................................................................. 46
2.5.12.
Battery................................................................................................................................. 48
Service ................................................................................................................................................. 49
3.1
General Information ................................................................................................................... 49
3.2
Subframes – Left Side ................................................................................................................. 51
3.3
Subframes – Right Side ............................................................................................................... 54
3.4
Rear Swingarms........................................................................................................................... 57
3.5
Transmission ............................................................................................................................... 59
3.6
Steering System .......................................................................................................................... 76
3.7.
Engine.......................................................................................................................................... 78
3.7.1.
Valve Clearance ................................................................................................................... 80
3.7.2.
Ignition Pickup Sensor Gap ................................................................................................. 81
3.7.3.
Carburetor ........................................................................................................................... 82
3.8.
4.
Wiring Diagram ........................................................................................................................... 84
Troubleshooting Guide ....................................................................................................................... 85
4.1
Steering Alignment ..................................................................................................................... 85
4.2
Poor Steering Response .............................................................................................................. 87
4.3
Tracks Coming Off ....................................................................................................................... 87
4.4
Engine Has Poor Throttle Response ............................................................................................ 88
4.5
Engine Hard to Start .................................................................................................................... 89
4.6
Engine idle too high/low ............................................................................................................. 89
3
1. General Information
1.1.
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 operate 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.
4
1.2.
Engine Break-In
The initial 10 hours of operation are the most important in 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 DTV Engine to warm up a few
minutes before riding. This allows the
oil to circulate throughout the Engine
which lubricates the components.
2. During the first 5 hours of operation do
not apply more than ½ throttle. Do not
run the engine for more than 30
minutes at a time. Allow for a cooldown period of 15 minutes before
operating again. Make sure to vary the
Engine speed during the break-in
period. This 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
4. 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.
5. During the next 5 hours of operation do
not appl more than ¾ throttle.
6. ensure the engine is not allowed to idle
while the DTV is stationary since there
is less air flow to allow for cooling.
7. 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.
5
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 ones. 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
6
1.4.
Winter Operation
It is critical to install the following components prior to operating the DTV in snow
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.
7
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 Ice 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.
Left side
Right side
8
1.5.
Technical Specifications
Overall Width
Overall Length (handle up/down)
Overall Height (handle up/down)
Gross weight
Maximum Payload
Transmission
Chain Pinion
Chain Sprocket
Chain Type
Dimensions & Weights
678mm (27")
1321mm (52") / 1150mm (45")
1270mm (50") / 584mm (23")
111kg (245lbs)
113kg (250lbs)
Powertrain
Biased Dual Belt-Type Continuously Variable Transmission
10 tooth
47 tooth
Sealed O-ring
Brakes Dual Hydraulic Disc
Fuel type
Fuel Tank Capacity
Engine Lubrication
Brake Fluid
Type
Fuel
No. Cylinders
Displacement
Bore
Stroke
Compression Ratio
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
Battery
Fluids
High Octane Unleaded Gasoline
91 AKI (USA)/95 RON (rest of world)
3.8 L (1 Gal)
5W-30 Synthetic (600ml)
DOT 4
Engine
Lifan "Rhino" - 4-stroke Spark Ignition
Gasoline
1
196 cc
68mm
59mm
9.6:1
0.051 mm (0.002 in)/0.076 mm (0.003 in)
12.5 hp @ 6000 rpm
13 lbf-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 – 4 mm
Electrical
12 V Li-Fe
9
1.6.
Standards
This product is in conformity with the following European standards:




EC Machinery Directive (206/42/EC)
EC EMC Directive (2004/108/EC)
Applied Harmonized Standards: EN ISO 12100
CE AOC (attestation of compliance) #12 12 82909 001
10
1.7.
General Assembly Drawings
1.4.1.
#
1
2
3
4
5
General
Name
Deck
Bogie Wheel
Track
Pivot Tube End Cap
Bogie Wheel Cap
11
#
1
2
3
4
5
6
8
9
Name
Handle Bar
Front Handle Cover
Back Handle Cover
Air Filter
Airbox Rubber Cap
Skid Plate
Battery Clamps
Battery
12
#
1
2/3
5/9
Name
Muffler
Upper Bogie Wheels/Axle
Track Guards
13
1.4.2.
#
2
3
4
5
7
Frame
Name
Airbox
Transmission Case Support Bracket
Rear Deck Pivot Assembly
Front Deck Pivot Assembly
Handle Pivot Bumpers
14
#
2
3
Name
Rear Pivot Tube
Front Pivot Tube Collar
15
#
4
Name
Choke
#
1
2
3
Name
Upper Bogie Wheel Axle
Upper Bogie Wheel Spacer
Upper Bogie Wheel
16
1.4.3.
#
1
2
5
Engine
Name
Frame
Engine
Engine Damper Pad
17
1.4.4.
Rear Swingarms
Right Side
#
1
2
3
4/5
9
11
12
20
Name
Swingarm
Chain Sprocket
Chain Tensioner
Track Drive Sprocket
Sprocket Hub
Grease Nipple
Chain Guard
Axle Bolt
18
Left Side
#
1
3
4
5/6
11
15
20
Name
Swingarm
Chain Sprocket
Chain Tensioner
Track Drive Sprocket
Sprocket Hub
Axle Bolt
Grease Nipple
19
1.4.5.
#
1
2
3
4
5
6
7
8
9
10
11
12
Steering System
Name
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
Rear Deck Pivot
Steering Adjustment Wheel Bolt
Steering Adjustment Wheel Set Screw
Steering Adjustment Wheel
20
Rear Deck Pivot:
Front Deck Pivot:
21
1.4.6.
Subframes
Left Side
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.
#
1
4
6
7
8
14/15
Handle
Name
Gas Tank
Gas Cap
Brake Lever
Throttle Housing
Engine Kill-Switch Lanyard
Fuel Petcock
28
2. General Maintenance
2.1 Maintenance Schedule
I = INSPECT & CLEAN/ADJUST/REPLACE/TIGHTEN AS NECESSARY
BEFORE
EACH
RIDE
ITEM
FIRST 5
HRS OF
USE
EVERY 10
HRS OR 3
MONTHS
L = LUBRICATE
EVERY
50 HRS
OR 6
MONTHS
GENERAL
TRACKS
I
TRACK DRIVE SPROCKETS
I
R
TRACK DRIVE SPROCKET HUBMOUNTING BOLTS
BRAKE LEVER FREE PLAY
I
R
REMARKS
R
Replace if tears or other damage is visible
Replace if any part of the track drive sprocket is
broken, damaged, or severely worn
These should be tightened periodically because
are clamping plastic under high loads
Ensure brake lever has proper action to engage
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
BRAKES PADS/ROTORS
R
CHAINS/SPROCKETS/PINIONS
I/L
R
CHAIN GUIDE ASSEMBLIES
I/L
R
FASTENERS
I
AIR FILTER
Ensure the idle sprocket is securely fit to and
running smoothly on the bearing, otherwise
replace entire assembly
I
I
AIRBOX DRAIN TUBE
DS = DEALER SERVICE
EVERY 100
HRS OR 1
YEAR
I
BRAKE LINES/FLUID LEVEL
R = REPLACE
R
I
AIRBOX SCREEN
I
HANDLE TOOTH-LOCK
MECHANISM
I
L
HANDLE LOCK & THROTTLE
CABLES
HANDLE LOCK BOLT
I
L
I
DECK
It is critical that this drain tube and its plug are
reinstalled after being emptied
Ensure intake cover screen is present and secure
R
R
Check for full engagement of teeth. Both top and
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
I
Check for cracks forming under the stomp pads
FUEL TANK & LINES
I
Check for leaks. Reinstall or replace if necessary
STEERING LINKAGE
I
SHOCKS (+FASTENERS)
I
THROTTLE CABLE
I
L
STEERING ROD BUSHING
I
L
Ensure steering performance is not degraded
over time. If necessary, tighten all fasteners in
deck pivot assemblies, steering 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 NEEDLE
BEARINGS
R
I
R
29
STEERING KNUCKLE BUSHING
I
FUEL FILTER
Check anti-rotate set screw is tight, and no
rotation in bushing.
If filter is removed, ensure it is re-installed in the
same orientation, or replace if unsure
Check behind covers and remove build-up
R
BOGIE WHEELS/BEARINGS
I
GREASE FITTINGS
L
MIDDLE SUSPENSION MAIN
PIVOT BUSHINGS
I
R
Check side to side play of the middle suspension
assembly and ensure scissor-arms are not
scraping against Engine intake duct
ENGINE
ENGINE OIL LEVEL
I
ENGINE OIL
R
CRANKCASE VENTILATION TUBE
R
600 ml 5W-30 full synthetic oil
I
CARBURETOR FLOAT BOWL
I
CARBURETOR
R
VALVE CLEARANCE
I
I
DS
SPARK PLUG
I
I
R
IDLE SPEED
I
Idle speed 2000 +/- 100 rpm
AIR INTAKE DUCT SYSTEM
I
Check all connections are secure
CRANKSHAFT
R
CAMSHAFT
R
CONNECTING ROD
R
PISTON (+RINGS)
R
CYLINDER HEAD ASSEMBLY
R
PCV VALVE
I
I
Inspect filter with each oil change
IGNITION COIL GAP
I
TRANSMISSION
TRANSMISSION BELTS
I
TRANSMISSION CASE GASKET
R
DRIVER SHEAVES
R
ALL OTHER SHEAVES
I
R
STEERING ROD
I
R
TRANSMISSION CASE DRAIN
PLUG
TRANSMISSION CASE
I
AIR INTAKE DUCT SYSTEM
I
ITEM
R
Replace when deformation is present on the
roller weight ramp surfaces
I
BEFORE
EACH
RIDE
L
FIRST 5
HRS OF
USE
EVERY 10
HRS OR 3
MONTHS
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
EVERY 50
HRS OR 6
MONTHS
I = INSPECT & CLEAN/ADJUST/REPLACE/TIGHTEN AS NECESSARY
EVERY 100
HRS OR 1
YEAR
L = LUBRICATE
REMARKS
R = REPLACE
DS = DEALER SERVICE
30
2.2 Standard torque values
FASTENER TYPE
TORQUE (N-m, lbf-ft)
5mm HEX BOLT & NUT
6mm HEX BOLT & NUT
8mm HEX BOLT & NUT
10mm HEX BOLT & NUT
12mm HEX BOLT & NUT
5mm SCREW
6mm SCREW
8mm SCREW
6 N-m, 4.5 lbf-ft
10 N-m, 7.5 lbf-ft
25 N-m, 18 lbf-ft
50 N-m, 37 lbf-ft
85 N-m, 63 lbf-ft
6 N-m, 4.5 lbf-ft
10 N-m, 7.5 lbf-ft
25 N-m, 18 lbf-ft
31
2.3 Specific torque values
FASTENER
SIZE
QTY
TORQUE N-m (lbf-ft)
ENGINE
CRANK BOLT
UPPER ENGINE MOUNT NUTS
LOWER ENGINE CRADLE MOUNT SCREWS
EXHAUST HEADER ATTACHMENT NUTS
M10
M8
M8
M8
1
4
4
2
40 (30)
30 (22)
30 (22)
25 (18)
TRANSMISSION
TRANSMISSION CASE MOUNTING SCREWS
M8
4
30 (22)
STEERING LINKAGE
STEERING KNUCKLE CAVITY END CAP SCREWS
STEERING SENSITIVITY ADJUSTMENT WHEEL SCREWS
STEERING ROD END SCREW
STEERING TIE-ROD JAM NUTS
M3
M6
M6
M8
6
2
1
2
1 (0.7)
10 (7.5)
10 (7.5)
25 (18)
CHASSIS
HANDLE BAR YOKE BOLTS
HANDLE LOCK BODY BOLT/NUTS
HANDLE LOCK ARM BOLT
FRONT SHOCK MOUNT BRACKET SCREWS
BALL-JOINT STUD
REAR SHOCK MOUNT NUTS
REAR DECK-PIVOT MOUNTING SCREWS
FRONT BOGIE WHEEL LUG BOLTS
M8
M8
M8
M8
M8
M8
M8
M10
4
3
1
4
2
4
4
8
30 (22)
30 (22)
30 (22)
30 (22)
25 (18)
30 (22)
30 (22)
40 (30)
FINAL DRIVE
CHAIN DRIVE SPROCKET HUB-MOUNTING BOLT/NUTS
TRACK DRIVE SPROCKET HUB-MOUNTING BOLT/NUTS
M6
M6
8
8
10 (7.5)
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 bogie wheel caps
3. Pull off 2 front outer bogie wheels
2. Remove 2 front outer bogie wheel
screws
4. Pull track off front inner bogie wheels
first, then remove completely
Track Installation:
Install tracks in reverse order of removal.






Ensure drive lugs on inside of track are properly engaged in Track Drive Sprocket
Ensure track is sitting correctly on upper and lower bogie wheels
Push front of track onto 2 front inner Bogie Wheels
Rotate the track slightly while pushing front end on will help it slide onto bogie wheels
Reinstall front outer Bogie Wheels
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
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.
35
2.5.3.
Chains
Chain Tension
1. loosen axle bolt
3. adjust tension nut to increase or
decrease chain tension.
2. loosen lock nut
4. The chain slack should be between 5 –
15mm (0.2 – 0.6in)
5. 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.
37
2.5.4.
Throttle Freeplay
1. Remove handle covers
2. Loosen jam nut on throttle cable
housing end
3. Adjust long nut (screw in to increase
free play, screw out to decrease free
play)
4. Tighten jam nut
5. Replace covers
Note: Make sure throttle snaps back to idle
when throttle lever is released.
Note: The thumb throttle should have 2 4mm (0.08”-0.16”) of free play.
38
2.5.5.
Air 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
4. Pull off rubber airbox cap
5. Reach into airbox and pull off air filter
3. Remove front skid plate screws (x4)
6. Inspect air filter and foam pre-filter for
excessive trapped dust and dirt
7. 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 prefilter using air filter cleaner and reapply
39
foam filter-oil before slipping it back
over the air filter
8. Inspect Airbox for cracks or leaks and
repair or replace if necessary
9. Reinstall air filter and reassemble
machine in reverse order
10. Drain the airbox drain tube if necessary,
and ensure it is securely fastened to the
airbox, with the plug completely
inserted in the open end when replaced
40
2.5.6.
Spark Plug
41
2.5.7.
Idle Speed Adjustment
42
2.5.8.
Engine Oil
1.1.1.
Engine oil level should be checked before
each ride, or minimum every 5 hours of
operation. It should be replaced every 10
hours of operation, or 3 months, whichever
comes first. Use 5w-30 full synthetic oil.
machine up a little by supporting it
under the tracks or hoisting it by the
upper frame rails might make this
easier.
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.
5. Place an 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.
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
43
7. Replace threaded plug using a new
crush washer.
8. 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 climates 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:
LH Rear Swingarm:
46
RH Rear Swingarm:
Steering Knuckle:
47
2.5.12.
Battery
Type: 4000mAh 12.8V Li-Po
48
3. Service
3.1 General Information
49
50
3.2 Subframes – Left Side
Removal: Subframes – Left Side
1. Remove track (see section xx)
2. Remove chain (see section xx) and
rubber end cap from pivot tube
5. Remove chain sprocket circlip and chain
sprocket
6. Remove brake caliper (2 bolts)
3. Remove upper shock mount bolt
7. Remove brake rotor
4. Remove chain guide
51
8. Remove 4 subframe clamping bolts
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.
9. Remove subframe assembly. Ensure
exposed parts of pivot tubes are clean.
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 integrity 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)
4. Remove right side track (see Track
Removal in General Maintenance
Chapter)
5. Remove upper shock mount nut
2. Unbolt steering adjustment wheel (2
bolts)
6. Remove steering knuckle cavity outside
end cap
3. Loosen upper tie rod jam nut and
unscrew upper ball joint assembly from
tie rod
54
7. Remove steering knuckle bolt
10. Push drive sprocket assembly forward to
put slack in the chain, then pull chain
forward off pinion and place on outside
of pinion
8. Remove 4 subframe clamping bolts
9. Loosen right side Axle nuts and Chain
Tensioner nuts
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. 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.
55
Installation: Subframes – Right 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
- 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.
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 steering knuckle free play and sliding action (see “Disassembly” for details)
Check the grease in the steering knuckle cavity for debris. Wipe off and re-grease if
necessary
Check the integrity 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 – Right Side
Assembly: Subframes – Right Side
Reassemble in 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
56
3.4 Rear Swingarms
Assembly Drawings
Right Side
Left Side
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:





Clean all parts and inspect for wear and damage
Replace any broken, worn or damaged parts
Ensure all fasteners are tight – pay special attention to bolts and nuts holding plastic
Track Drive Sprocket [5/6] to Sprocket Hub [11]
Check ball bearings [15] in Sprocket Hub for wear
Check Chain Drive Sprocket for wear (see section xx)
Disassembly – Rear Swingarms

See assembly drawing above
Assembly – Rear Swingarms

Assemble in reverse order of disassembly
Prior to reassembling, be sure to:

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
#
1
2
3
4
6
Name
Inner transmission case
Torque-Sensing Sheave
Inner (Right Side) Drive Shaft
Driven Spring
Inner (Right Side) Helix
59
Inner Driven Pulley Assembly
Inner Driven Pulley Assembly
60
#
2
4
5
6
7/8
9
10
Name
Inner Transmission Case
Driver Clutch Assembly
Gasket
Spacer
Driver Fixed Sheave
Outer Shaft Collar
Crankshaft Bolt
61
#
1
2
3
4
5
Name
Roller Weight Guide Plate
Roller Weight Guide Outer Ring
Roller Weight
Slider
Roll Pin
62
63
Service Information
As a general rule:
 Belts should be replaced every 100 hours of operation
 Driver Sheaves should be replaced every 50 hours of operation due to ramp wear, and
all other sheaves about every 100 hours.
 Steering Rod should be replaced every 100 hours of operation.
In dirty environments transmission components will wear out faster.
64
Specifications
show steering rod specs
bushing specs
Torque Values
Special Tools
 pin-type face spanner wrench (35mm span. 6mm pin)
65
Removal: Transmission
1. Remove left side Subframe (see Left Side
Subframe Removal section)
5. Remove outer belt
2. Remove transmission case intake duct
and Track Guard
6. Remove crank bolt and outer shaft
collar.
3. Remove left side-cover
- You will need a pin-type face spanner wrench
(6mm pin - 35mm span or adjustable)
4. Remove outer transmission case
assembly. Be careful not to damage the
gasket if you don’t have a replacement.
Be sure to pull the case off straight. Tap
case lightly with a mallet to break the
seal.
7. Remove transmission driver sheave
assembly
66
8. Remove inner fixed sheave and spacer
disc
12. Remove transmission steering sheave
assembly
9. Remove right side Subframe (see Right
Side Subframe Removal section)
13. Remove 4 transmission mounting
screws
10. Remove 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
11. Remove right Side Cover
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 not try 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:


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.
Check belts for excessive wear or
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 wear 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
faster


Check wear on 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
1. Remove Spring Holder Cap and
Spring
2. Slide Moveable Sheave Assembly to
one end of Main Shaft
71
3. remove the 3 exposed Moveable
Sheave Keys
5. Slide Moveable Sheave assembly off
Main Shaft, and remove Spring
Holders
6. Pull apart Moveable Sheaves
To Disassemble Roller Weight Guide
Assembly:
4. Slide Moveable Sheave Assembly
back the other way and remove
remaining 3 Moveable Sheave Keys
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:






Clean all parts and inspect for wear and damage
Replace any broken, worn or damaged parts
Ensure all Sliders have smooth action, but not excessive play, on Inner Plate after Roller
Weight Guide Assembly is reassembled
Check that all roll pins are present and fully engaged
Check ramp surfaces of Moveable Sheaves for excessive wear or rutting from Roller
Weights. If excessive wear or rutting is visible replace Moveable Sheaves
Ensure alignment marks (dimples) on inside of each Moveable Sheave are facing each
other, as shown
Alignment Mark (dimple)
Alignment Mark (dimple)
Cross-section view of Driver Assembly
73
1. Reassemble Moveable Sheave
Assembly ensuring the alignment
marks are facing each other, as
shown
2. 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
Alignment mark
3. 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
Male Moveable Sheave engagement with
Roller Weight Guide Assembly:
4. 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
Female Moveable Sheave engagement with
Roller Weight Guide Assembly
74
flush with the conical sheave face
6. Slide Moveable Sheave Assembly
carefully back into centre of Main
Shaft ensuring all Keys are properly
seated and flush with the belt
contact surface
7. Insert Spring into centre of Driver
Assembly, compress and install
Spring Holder Cap
5. Place remaining 3 Moveable Sheave
Keys around other end of Main Shaft
engaging with other Spring Holder,
as shown
75
3.6 Steering System
Assembly Drawing
#
1
2
3
4
5
6
7
8
9
10
11
12
Name
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
Rear Deck Pivot
Steering Adjustment Wheel Bolt
Steering Adjustment Wheel Set Screw
Steering Adjustment Wheel
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 function.
Disconnecting: Steering System
NOTE: disconnection of the steering system is necessary in order to remove the right side
Subframe assembly.
1. Remove Deck
2. Remove 4 Rear Deck Pivot mounting
screws
3. Remove right side Track Guard
4. Loosen Upper and Lower Jam Nuts
5. Turn Steering Tie Rod counterclockwise (if standing on right side of
machine) until it pulls out of both
Upper and Lower Ball Joints
Reconnection: Steering System
Reconnection is in reverse order of disconnection. Follow “Steering Alignment” instructions in
the “Troubleshooting Guide” section to realign the steering.
77
3.7.
Engine
Assembly Drawings
#
1
2
5
Name
Frame
Engine
Engine Damper Pad
78
Removal – Engine
1. Remove the deck (8 screws)
2. Remove the subframes from both
sides (see subframe section in
Service chapter).
3. Remove Side Covers
4. Remove Engine intake duct
5. Remove transmission intake duct
6. Remove transmission (see
transmission section of Service
chapter)
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
Installation – 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 steering
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.








Place Engine on Engine cradle in frame with 4 mount bolts loose
Reinstall transmission (see transmission section of Service Chapter) leaving the
transmission Axle Housing Clamp Bolt on the Transmission Support Bracket loose
Reinstall Subframes and secure to frame
Adjust Engine position so that Steering Rod lines up with Steering Knuckle and fasten
securely.
Tighten Transmission Axle Housing Clamp Bolt on the Transmission Support Bracket
Tighten Engine mount bolts (4)
Reconnect ignition wire, starter motor wires, throttle cable and fuel line
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:
1. Remove Deck
2. 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
5. Check the valve clearance with a
feeler gauge between the rocker
and the lash cap on top of the valve
stem
Setting Valve 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)
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
3. Tighten the rocker Arm Pivot Lock
Nut while holding the Rocker Arm
Pivot
80
3.7.2.
Ignition Pickup Sensor Gap
To access the Pickup Sensor:
1. Remove the right side Subframe assembly
2. Remove the Engine Intake Duct and
Carburetor rubber Intake Elbow
3. Remove the Engine Side Cover
4. Remove the Engine Recoil Cover assembly
(4 screws).
5. Loosen the Ignition Pickup Sensor mounting
screws very slightly
6. 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
7. Push the sensor firmly but gently against
the feeler gauge and tighten the Pickup
Sensor mounting screws
8. Recheck gap after tightening screws to
ensure Pickup Sensor did not shift
9. Readjust if necessary
10. Reinstall Recoil Cover assembly
11. Reinstall Engine Side Cover
12. Reinstall Carburetor rubber Intake Elbow
13. 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
The ignition Pickup Sensor gap should be set to 0.5 mm (0.020 in).
0.5 mm (0.020 in) gap
81
3.7.3.
Carburetor
Components
1
2
3
11
10
4
5
6
7
12
8
13
15
9
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
14
Name
Throttle Cable Rubber Guide
Throttle Cable Adjuster
Throttle Cable Adjuster Locknut
Mixing Chamber Top
Throttle Valve Slide Spring
Needle Jet Retaining Spring
Needle Jet Clip
Needle Jet
Throttle Valve Slide
Choke Cable
Mixing Chamber Top
Idle Adjustment Knob
Float Bowl
Float Bowl Overflow Tube
Float Bowl Drain
82
Removal - Carburetor
1.
2.
3.
4.
Remove right Subframe
Remove Engine intake duct
Remove right Side Cover
Remove right Brake Rotor
5. Disconnect Throttle Cable from top
of Carburetor
6. Remove Carburetor (2 nuts)
Replacing/Changing Jets
1. Remove Float Bowl screws (4)
2. Unscrew Pilot Jet and replace
3. Unscrew Main Jet and replace
4. Reinstall Float Bowl
Adjusting Needle Jet
5. Unscrew the Mixing Chamber Top
and pull out the Throttle Valve Slide
assembly
6. Compress the Throttle Valve Slide
Spring and disconnect Throttle Cable
end from the Throttle Valve Slide
through the groove
7. Remove Needle Jet Retaining Spring
from inside the Throttle Valve Slide
8. Remove the Needle Jet
9. Move Needle Jet Clip up or down
depending on desired performance
change.
NOTE: The Needle Jet affects fuel
delivery in the ¼ to ¾ throttle range
Standard Factory
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
84
4. Troubleshooting Guide
4.1 Steering Alignment
If steering seems to be biased to one side more than the other, it can be brought back into
alignment by adjusting the length of the steering tie rod.
#
1
2
3
4
5
6
7
8
9
10
11
12
Name
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
Rear Deck Pivot
Steering Adjustment
Wheel Bolt
Steering Adjustment
Wheel Set Screw
Steering Adjustment
Wheel
IMPORTANT: 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 function.
85
Setting Steering Alignment:
1. Remove deck
2. Remove right side track guard
3. Loosen upper and lower ball joint jam
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.
4.
5.
6.
7.
8.
- If steering is biased to the left,
lengthen linkage to centre it.
- If steering is biased to the right,
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 riding one. Even
at low speeds the steering will only work while also applying some throttle. It can be counterintuitive 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
block the action of the deck, or the
rotation of the tracks
2. Make sure the Steering Tie-Rod ball
joints are not loose or broken
3. Ensure the Steering Adjustment
Wheel is secure
4. Ensure the Rear Deck Pivot
Assembly is not loose (bushings not
worn, pivot bolt not loose)
5. Ensure the Steering Knuckle cavity
end caps are securely fastened
6. Ensure Steering Knuckle cavity is
filled with grease and Steering
Knuckle action is smooth
* When vehicle is not moving, the
knuckle should have approximately
4-6mm of total travel
4.3 Tracks Coming Off
1. Ensure track tension is adjusted
correctly
2. Ensure Track Drive Sprockets are not
worn out or damaged
3. Ensure Tracks are not damaged
4. Ensure bogie wheels are not
damaged or missing
5. Ensure Upper Bogie Wheel Axles are
not loose
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
air intake system are tight, and the
rubber Carburetor elbow is securely
attached to the Carburetor and not
kinked
2. Ensure Air Filter is not blocked
3. Ensure there is sufficient fuel. Fuel
Petcock may get blocked with debris
if it is on “reserve”. Pull fuel line
momentarily off petcock to
determine if fuel is flowing freely.
Always switch petcock back after
refueling, never operate on
‘RESERVE’ for longer than necessary
4. Ensure the Throttle Cable is
operating properly and opens/closes
fully
5. Ensure spark plug is not fouled
6. Ensure Carburetor Jets are sized
correctly for the particular climate
(temperature and altitude)
88
4.5 Engine Hard to Start
NOTE: Electric Start should only be used after the Engine has been warmed up. Use pull-start
when Engine is cold.
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:
1. Pull the 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 KillSwitch 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. If the 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)
7. Ensure Carburetor Jets are sized
correctly for the particular climate
(temperature and altitude)
8. 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
9. If all of the above are ok take your
DTV to an authorized dealer or
service centre
4.6 Engine idle too high/low
Engine suddenly starts revving high
1. Ensure choke knob has been pushed
back to ‘off’ position
2. Throttle cable is not stuck open
3. Adjust idle with remote manual
adjustment knob
89