Cub Cadet Challenger 550 - Front Disc Brakes

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Chassis

5‐11

Front Disc Brakes

No.

Part Name

Removing the brake discs

Brake Caliper assembly

Qty

Remarks

Brake Disc

Bolt

Axle housing

Bolt

Brake disc guard

Main Page

Index3
Vehicle Identification Number7
General Information8
Warnings, Cautions, and Notes8
Description9
Engine Identification Number10
Feature Code II10
Year Code10
Identification Code11
Safety12
Handling Gasoline13
Cleaning Parts13
Warning Labels14
Serial Numbers14
Fasteners14
Torque Specifications14
Self-Locking Fasteners15
Washers15
Snap Rings and E-Clips15
Cotter Pins15
Shop Supplies16
Lubricants and Fluids16
Engine Oils17
Greases17
Brake Fluid17
Coolant18
Cleaners, Degreasers and Solvents18
Gasket Sealant18
Gasket Remover18
Thread Locking Compound19
Basic Tools19
Screwdrivers19
Wrenches20
Adjustable Wrenches21
Socket Wrenches, Ratchets and Handles21
Impact Drivers22
Allen Wrenches23
Torque Wrenches23
Torque Adapters23
Snap Ring Pliers24
Hammers25
Ignition Grounding Tool25
Precision Measuring Tools25
Feeler Gauge26
Calipers26
Micrometers27
Decimal Placevalues27
Adjustment28
Care28
Metric Micrometer28
Standard Inch Micrometer29
Telescoping and Small Bore Gauges30
Dial Indicator31
Compression Gauge31
Multi Meter32
Electrical System Fundamentals32
Voltage32
Resistance33
Amperage33
Basic Service Methods33
Removing Frozen Fasteners35
Removing Broken Fasteners35
Stud36
Bearings36
Removing Hoses36
Removing Bearings37
Installation38
Interference Fit39
Seal Replacement40
Storage Area Selection40
Preparing the UV for Storage41
Returning the UV to Service41
General Specifications42
Air Filter42
Specifications43
750 UV Engine Specifications44
Engine Specifications50
Engine Tightening Torques59
Chassis Tightening Torques62
Chassis Tightening Torques64
General Tightening Torque Specs64
Chassis65
Periodic Maintenance66
Maintenance and Adjustments of the UV69
Valve Adjustment70
Rotate the Crankshaft70
Remove the Cooling Fan70
Reassembly Is in Reverse Order71
Checking the Spark Plug71
Measuring the Compression Pressure72
Normal Color Should be72
Standard Compression Pressure73
Checking the Engine Oil Level73
Changing the Engine Oil74
Oil Quantity74
Cleaning the Air Filter75
Checking the Coolant Level76
Changing the Coolant77
Bleeding the Cooling System79
Checking the Coolant Temperature Warning Light80
Coolant Temperature Indicator Light80
Checking the V-Belt81
Replacing the V-Belt82
Cleaning the Spark Arrester82
Adjusting the Brake Pedal83
Adjusting the Parking Brake Free Play83
Checking and Adjusting the Parking Brake84
Checking the Brake Fluid Level85
Checking the Front Brake Pads85
Checking the Rear Brake Pads85
Checking the Brake Hoses and Brake Lines86
Bleeding the Hydraulic Brake System87
Adjusting the Select Lever Shift Rod90
Checking the Final Gear Oil Level91
Drain Bolt Torque91
Filler Plug Torque91
Changing the Final Gear Oil91
Adjusting the Toe-In92
Locknut (Rod End)92
Adjusting the Shock Absorbers93
Damping Rate Adjuster (C)93
Rebound Adjuster (A)93
Pre-Load Spring Adjuster (B)93
Checking the Constant Velocity Joint Dust Boots95
Check the Tie-Rod Ends95
Check the Ball Joints95
Checking the Steering System95
Checking the Tires96
Changing the Tail/Brake Light Assembly96
Special Notes97
Engine Removal98
Cylinder Head and Cylinder Head Cover99
Check the Valve Clearance100
Installation100
Checking Condition of Cam Drive Assembly101
Rocker Arms and Camshaft102
Inspect the Rocker Arms103
Clearance Limit 0.05Mm103
Inspect the Camshaft103
Inspect the Decompression System103
Valves and Valve Springs105
Measure Valve Stem Run out106
Valve Spring Free Length Intake106
Measure the Compressed Spring Force106
Remove the Valve Guide107
Cylinder and Piston108
Measure the Cylinder Bore109
Measure Piston Ring Side Clearance109
Measure the Piston Rings End Gap109
Piston to Cylinder Clearance109
Piston Rings110
Piston110
Cylinder110
Engine Cooling Fan and A.C. Magneto111
Inspect the A.C. Magneto112
Inspect the Starter Clutch112
Installing Rotor to Crankshaft113
Engine Cooling Fan114
Inspect the Engine Cooling Fan114
Balancer Gears and Oil Pump Gears115
Primary and Secondary Sheaves117
Primary Sheave118
Secondary Sheave119
Check Outside Diameter Wear Limit120
Inspect the Secondary Sheave120
Assembling the Primary Sheave121
Assembling the Secondary Sheave121
Clutch123
Inspect the Clutch125
Inspection of the One Way Clutch Bearing125
Crankcase127
Starter Motor and Oil Filter127
Assembling the Crankcase130
Left Crankcase131
Right Crankcase131
Installing the Shift Levers131
Crankshaft and Oil Pump132
Oil Pump133
Inspect the Oil Pump134
Measure the Oil Pump134
Measure the Crankshaft134
Transmission136
Drive Axle Assembly137
Inspect the Shift Forks138
Springs138
Shift Drum138
Inspect the Secondary Shaft and Driven Sprocket139
Measure the Shaft Run out139
Installing the Transmission139
Middle Gear140
Middle Drive Shaft140
Middle Driven Shaft141
Inspect the Pinion Gears142
Measure Gear Lash142
Selecting the Middle Drive and Driven Gear Shims142
Universal Joint143
Inspection145
Appearance Inspection145
Plastic Body Panels Damaged145
Bumper Damaged145
Front Wheel Turns Excessive146
Front Wheel Sway During Driving146
Wheel Hop During Driving146
Shock Absorber Became Soft146
Abnormal Noise from Front or Rear Axle Area147
Steering System148
Steering Wheel Assembly149
Disassembly of the Steering Wheel Assembly150
Disassembly of the Steering Column Assembly150
Disassembling the Steering Shaft Assembly151
Inspect the Steering Knuckle151
Inspect the Dust Boots151
Inspect the Tie Rod Ends151
Inspect the Tie Rods152
Inspect the Steering Joint152
Inspect the Rack and Pinion Gear152
Attach the Steering Wheel and Cover152
The Brake System153
Front Disc Brake Components154
Front Disc Brakes155
Inspect the Front Brake Discs156
Front Brake Pads157
Replacing the Front Brake Pads158
Brake Caliper Bleed Screw158
Front Brake Caliper159
Brake Caliper Disassembly160
Disassembling the Front Brake Calipers161
Installation161
Installing the Front Brake Calipers162
Rear Brake Disc163
Inspecting the Rear Brake Disc164
Rear Brake Caliper and Brake Pads165
Replacing the Rear Brake Pads167
Disassembling the Rear Brake Caliper167
Assembling the Rear Brake Caliper168
Caliper169
Brake Master Cylinder170
Removing the Brake Master Cylinder170
Inspecting the Brake Master Cylinder171
Installing the Brake Master Cylinder171
Footrest Assembly172
Front Wheel and Tire174
Rear Wheel175
Removing the Rear Wheel175
Inspect the Rim176
Installing the Wheel Hub176
Installing the Wheel Assembly176
Inspect the Wheel Hub176
Transmission System Front Bridge177
Front Bridge178
Removing the Front Bridge178
Disassembling the Front Bridge182
Disassembling the Universal Joint182
Removing the Differential Gear Assembly182
Checking the CV Joints182
Inspecting the Differential Gear183
Checking the Operation of the Gear Motor183
Assembling the Universal Joint184
Assembly of the Differential Gear184
Installing the Front Bridge185
Rear Bridge186
Removing the Rear Bridge187
Gear Shift Mechanism191
Removing Mechanism191
Adjusting the Gearshift Mechanism192
Suspension193
Front Suspension and a Arm193
Removing Front Suspension and Arm193
Front Suspension Components195
Front Shock Absorbers195
Installing the Front a Arms and Shock Absorbers195
Rear Suspension and a Arm196
Removing the Rear Suspension196
Checking the Components of the Rear Suspension198
Installing the Rear a Arms and Shock Absorbers198
Cooling System199
Removing the Radiator 1199
Checking the Radiator201
Replacing the Coolant201
Recommended Antifreeze201
Oil Cooler201
Water Pump202
Water Pump Assembly202
Disassembling the Water Pump204
Inspecting the Water Pump204
Assembling the Water Pump205
Seat206
Fuel Tank207
Removing the Fuel Tank207
Checking the Fuel Pump Operation209
Electrical Components210
Lead Acid Battery212
Maintenance Free Battery212
First Aid in Case of Bodily Contact213
Charging a Lead Acid Battery213
Warnings213
Using a Constant Voltage Charger (Lead Acid Battery)214
Charging a Maintenance Free Battery215
Using a Variable Rate Charger (Maintenance Free Batteries)215
Checking the Fuses216
Checking the Switch217
Checking the Switch Continuity218
Checking the Bulbs and Bulb Sockets219
Ignition System220
Circuit Diagram220
Troubleshooting221
No Continuity221
Electric Starting System224
Troubleshooting a Starter Motor Failure225
Starter Motor226
Removing the Starter Motor226
Disassembling the Starter Motor226
Charging System227
Troubleshooting the Charging System228
Condition: Battery Is Not Charging228
Lighting System229
Signaling System230
2WD / 4WD Selecting System232
EMS (Engine Management System)233
Typical Components of EMS233
Layout of EMS Components234
Components of Ems234
Electronic Control Unit234
Handling234
Multec 3.5 Fuel Injectors235
Installation Guidelines235
Replacement of the Injector237
Plugging237
Cleaning Procedure238
Throttle Body Assembly (with Stepper Motor)238
Throttle Body Removal239
Throttle Body Installation239
Engine Coolant Temperature Sensor239
Oxygen Sensor240
Ignition Coil240
Installation Requirements240
Fuel Pump Module240
Fuel Module Diagnosis241
Fuel Module Removal242
Fuel Leakage Check Procedure242
Ems Fault Codes243
Fault Code List243
Spark Test244
Troubleshooting244
Compression Test245
Valves245
Cylinder Head246
Engine Overheating246
Pre-Ignition247
Detonation247
Engine Noises247
Cylinder Leak down Test248
Electrical Testing250
Preliminary Checks and Precautions250
Intermittent Problems251
Electrical Component Replacement252
ECU Unit252
Wiring253
MY 2019 Forward Wiring254

Cub Cadet Challenger 550 - Front Disc Brakes

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