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Challenger 550
Cub Cadet Challenger 550 User Manual
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Electrical
6‐
2
Electri
cal
Components
1.
Fuse/Relay Box
2.
Starter relay
3.
Battery
4.
Rectifier/regulator
5.
Speedometer
6.
On
-
Command four
-
wheel drive s
w
itch
and
differential
gear lock switch
7.
Ignition switch
components
210
212
Table of Contents
Index
3
Vehicle Identification Number
7
General Information
8
Warnings, Cautions, and Notes
8
Description
9
Engine Identification Number
10
Feature Code II
10
Year Code
10
Identification Code
11
Safety
12
Handling Gasoline
13
Cleaning Parts
13
Warning Labels
14
Serial Numbers
14
Fasteners
14
Torque Specifications
14
Self-Locking Fasteners
15
Washers
15
Snap Rings and E-Clips
15
Cotter Pins
15
Shop Supplies
16
Lubricants and Fluids
16
Engine Oils
17
Greases
17
Brake Fluid
17
Coolant
18
Cleaners, Degreasers and Solvents
18
Gasket Sealant
18
Gasket Remover
18
Thread Locking Compound
19
Basic Tools
19
Screwdrivers
19
Wrenches
20
Adjustable Wrenches
21
Socket Wrenches, Ratchets and Handles
21
Impact Drivers
22
Allen Wrenches
23
Torque Wrenches
23
Torque Adapters
23
Snap Ring Pliers
24
Hammers
25
Ignition Grounding Tool
25
Precision Measuring Tools
25
Feeler Gauge
26
Calipers
26
Micrometers
27
Decimal Placevalues
27
Adjustment
28
Care
28
Metric Micrometer
28
Standard Inch Micrometer
29
Telescoping and Small Bore Gauges
30
Dial Indicator
31
Compression Gauge
31
Multi Meter
32
Electrical System Fundamentals
32
Voltage
32
Resistance
33
Amperage
33
Basic Service Methods
33
Removing Frozen Fasteners
35
Removing Broken Fasteners
35
Stud
36
Bearings
36
Removing Hoses
36
Removing Bearings
37
Installation
38
Interference Fit
39
Seal Replacement
40
Storage Area Selection
40
Preparing the UV for Storage
41
Returning the UV to Service
41
General Specifications
42
Air Filter
42
Specifications
43
750 UV Engine Specifications
44
Engine Specifications
50
Engine Tightening Torques
59
Chassis Tightening Torques
62
Chassis Tightening Torques
64
General Tightening Torque Specs
64
Chassis
65
Periodic Maintenance
66
Maintenance and Adjustments of the UV
69
Valve Adjustment
70
Rotate the Crankshaft
70
Remove the Cooling Fan
70
Reassembly Is in Reverse Order
71
Checking the Spark Plug
71
Measuring the Compression Pressure
72
Normal Color Should be
72
Standard Compression Pressure
73
Checking the Engine Oil Level
73
Changing the Engine Oil
74
Oil Quantity
74
Cleaning the Air Filter
75
Checking the Coolant Level
76
Changing the Coolant
77
Bleeding the Cooling System
79
Checking the Coolant Temperature Warning Light
80
Coolant Temperature Indicator Light
80
Checking the V-Belt
81
Replacing the V-Belt
82
Cleaning the Spark Arrester
82
Adjusting the Brake Pedal
83
Adjusting the Parking Brake Free Play
83
Checking and Adjusting the Parking Brake
84
Checking the Brake Fluid Level
85
Checking the Front Brake Pads
85
Checking the Rear Brake Pads
85
Checking the Brake Hoses and Brake Lines
86
Bleeding the Hydraulic Brake System
87
Adjusting the Select Lever Shift Rod
90
Checking the Final Gear Oil Level
91
Drain Bolt Torque
91
Filler Plug Torque
91
Changing the Final Gear Oil
91
Adjusting the Toe-In
92
Locknut (Rod End)
92
Adjusting the Shock Absorbers
93
Damping Rate Adjuster (C)
93
Rebound Adjuster (A)
93
Pre-Load Spring Adjuster (B)
93
Checking the Constant Velocity Joint Dust Boots
95
Check the Tie-Rod Ends
95
Check the Ball Joints
95
Checking the Steering System
95
Checking the Tires
96
Changing the Tail/Brake Light Assembly
96
Special Notes
97
Engine Removal
98
Cylinder Head and Cylinder Head Cover
99
Check the Valve Clearance
100
Installation
100
Checking Condition of Cam Drive Assembly
101
Rocker Arms and Camshaft
102
Inspect the Rocker Arms
103
Clearance Limit 0.05Mm
103
Inspect the Camshaft
103
Inspect the Decompression System
103
Valves and Valve Springs
105
Measure Valve Stem Run out
106
Valve Spring Free Length Intake
106
Measure the Compressed Spring Force
106
Remove the Valve Guide
107
Cylinder and Piston
108
Measure the Cylinder Bore
109
Measure Piston Ring Side Clearance
109
Measure the Piston Rings End Gap
109
Piston to Cylinder Clearance
109
Piston Rings
110
Piston
110
Cylinder
110
Engine Cooling Fan and A.C. Magneto
111
Inspect the A.C. Magneto
112
Inspect the Starter Clutch
112
Installing Rotor to Crankshaft
113
Engine Cooling Fan
114
Inspect the Engine Cooling Fan
114
Balancer Gears and Oil Pump Gears
115
Primary and Secondary Sheaves
117
Primary Sheave
118
Secondary Sheave
119
Check Outside Diameter Wear Limit
120
Inspect the Secondary Sheave
120
Assembling the Primary Sheave
121
Assembling the Secondary Sheave
121
Clutch
123
Inspect the Clutch
125
Inspection of the One Way Clutch Bearing
125
Crankcase
127
Starter Motor and Oil Filter
127
Assembling the Crankcase
130
Left Crankcase
131
Right Crankcase
131
Installing the Shift Levers
131
Crankshaft and Oil Pump
132
Oil Pump
133
Inspect the Oil Pump
134
Measure the Oil Pump
134
Measure the Crankshaft
134
Transmission
136
Drive Axle Assembly
137
Inspect the Shift Forks
138
Springs
138
Shift Drum
138
Inspect the Secondary Shaft and Driven Sprocket
139
Measure the Shaft Run out
139
Installing the Transmission
139
Middle Gear
140
Middle Drive Shaft
140
Middle Driven Shaft
141
Inspect the Pinion Gears
142
Measure Gear Lash
142
Selecting the Middle Drive and Driven Gear Shims
142
Universal Joint
143
Inspection
145
Appearance Inspection
145
Plastic Body Panels Damaged
145
Bumper Damaged
145
Front Wheel Turns Excessive
146
Front Wheel Sway During Driving
146
Wheel Hop During Driving
146
Shock Absorber Became Soft
146
Abnormal Noise from Front or Rear Axle Area
147
Steering System
148
Steering Wheel Assembly
149
Disassembly of the Steering Wheel Assembly
150
Disassembly of the Steering Column Assembly
150
Disassembling the Steering Shaft Assembly
151
Inspect the Steering Knuckle
151
Inspect the Dust Boots
151
Inspect the Tie Rod Ends
151
Inspect the Tie Rods
152
Inspect the Steering Joint
152
Inspect the Rack and Pinion Gear
152
Attach the Steering Wheel and Cover
152
The Brake System
153
Front Disc Brake Components
154
Front Disc Brakes
155
Inspect the Front Brake Discs
156
Front Brake Pads
157
Replacing the Front Brake Pads
158
Brake Caliper Bleed Screw
158
Front Brake Caliper
159
Brake Caliper Disassembly
160
Disassembling the Front Brake Calipers
161
Installation
161
Installing the Front Brake Calipers
162
Rear Brake Disc
163
Inspecting the Rear Brake Disc
164
Rear Brake Caliper and Brake Pads
165
Replacing the Rear Brake Pads
167
Disassembling the Rear Brake Caliper
167
Assembling the Rear Brake Caliper
168
Caliper
169
Brake Master Cylinder
170
Removing the Brake Master Cylinder
170
Inspecting the Brake Master Cylinder
171
Installing the Brake Master Cylinder
171
Footrest Assembly
172
Front Wheel and Tire
174
Rear Wheel
175
Removing the Rear Wheel
175
Inspect the Rim
176
Installing the Wheel Hub
176
Installing the Wheel Assembly
176
Inspect the Wheel Hub
176
Transmission System Front Bridge
177
Front Bridge
178
Removing the Front Bridge
178
Disassembling the Front Bridge
182
Disassembling the Universal Joint
182
Removing the Differential Gear Assembly
182
Checking the CV Joints
182
Inspecting the Differential Gear
183
Checking the Operation of the Gear Motor
183
Assembling the Universal Joint
184
Assembly of the Differential Gear
184
Installing the Front Bridge
185
Rear Bridge
186
Removing the Rear Bridge
187
Gear Shift Mechanism
191
Removing Mechanism
191
Adjusting the Gearshift Mechanism
192
Suspension
193
Front Suspension and a Arm
193
Removing Front Suspension and Arm
193
Front Suspension Components
195
Front Shock Absorbers
195
Installing the Front a Arms and Shock Absorbers
195
Rear Suspension and a Arm
196
Removing the Rear Suspension
196
Checking the Components of the Rear Suspension
198
Installing the Rear a Arms and Shock Absorbers
198
Cooling System
199
Removing the Radiator 1
199
Checking the Radiator
201
Replacing the Coolant
201
Recommended Antifreeze
201
Oil Cooler
201
Water Pump
202
Water Pump Assembly
202
Disassembling the Water Pump
204
Inspecting the Water Pump
204
Assembling the Water Pump
205
Seat
206
Fuel Tank
207
Removing the Fuel Tank
207
Checking the Fuel Pump Operation
209
Electrical Components
210
Lead Acid Battery
212
Maintenance Free Battery
212
First Aid in Case of Bodily Contact
213
Charging a Lead Acid Battery
213
Warnings
213
Using a Constant Voltage Charger (Lead Acid Battery)
214
Charging a Maintenance Free Battery
215
Using a Variable Rate Charger (Maintenance Free Batteries)
215
Checking the Fuses
216
Checking the Switch
217
Checking the Switch Continuity
218
Checking the Bulbs and Bulb Sockets
219
Ignition System
220
Circuit Diagram
220
Troubleshooting
221
No Continuity
221
Electric Starting System
224
Troubleshooting a Starter Motor Failure
225
Starter Motor
226
Removing the Starter Motor
226
Disassembling the Starter Motor
226
Charging System
227
Troubleshooting the Charging System
228
Condition: Battery Is Not Charging
228
Lighting System
229
Signaling System
230
2WD / 4WD Selecting System
232
EMS (Engine Management System)
233
Typical Components of EMS
233
Layout of EMS Components
234
Components of Ems
234
Electronic Control Unit
234
Handling
234
Multec 3.5 Fuel Injectors
235
Installation Guidelines
235
Replacement of the Injector
237
Plugging
237
Cleaning Procedure
238
Throttle Body Assembly (with Stepper Motor)
238
Throttle Body Removal
239
Throttle Body Installation
239
Engine Coolant Temperature Sensor
239
Oxygen Sensor
240
Ignition Coil
240
Installation Requirements
240
Fuel Pump Module
240
Fuel Module Diagnosis
241
Fuel Module Removal
242
Fuel Leakage Check Procedure
242
Ems Fault Codes
243
Fault Code List
243
Spark Test
244
Troubleshooting
244
Compression Test
245
Valves
245
Cylinder Head
246
Engine Overheating
246
Pre-Ignition
247
Detonation
247
Engine Noises
247
Cylinder Leak down Test
248
Electrical Testing
250
Preliminary Checks and Precautions
250
Intermittent Problems
251
Electrical Component Replacement
252
ECU Unit
252
Wiring
253
MY 2019 Forward Wiring
254
4
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Cub Cadet Challenger 550 Specifications
General
Brand
Cub Cadet
Model
Challenger 550
Category
Utility Vehicle
Language
English
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