This document is a service manual for the Crossfire 600GT, an off-road utility vehicle (UTV). The manual provides detailed information for maintenance and repair procedures, covering various aspects of the vehicle's engine, chassis, final drive, brakes, and electrical system.
General Device Description:
The Crossfire 600GT is a UTV designed for various terrains. It has been upgraded with a Canadian CVTech Invance Variators clutch system and a 39hp motor, which may slightly impact some information provided in the manual. The manual emphasizes the importance of proper maintenance and repair procedures for the safety and reliability of the vehicle. It is primarily intended for qualified mechanics and Linhai dealers, assuming a basic understanding of mechanical principles.
Important Technical Specifications (Engine):
- Type: Single Cylinder, 4-Stroke, Liquid-cooled, 4 Valve, SOHC
- Bore and Stroke: 87.5mm × 82.0mm
- Displacement: 493ml
- Compression Ratio: 10.2:1
- Lowest Continuous Idle Speed with Load: 1400r/min ± 100r/min
- Starting Type: Electrical starting
- Ignition/Ignition Timing: EFI ECU Magneto ignition/BTDC10°1500r/min
- Spark Plug: NGK DPR7EA-9
- Spark Plug Gap: 0.8mm - 0.9mm
- Magneto: Permanent Magnet AC Type
- Combustion Chamber: Triangle Combustion Chamber
- Air Filter: Sponge Element Filter
- Gasoline: RQ-87 (unleaded gasoline with octane number over 87)
- Valve Type: SOHC/Chain Drive
- Lubrication Type: Pressure & Splash
- Oil Pump: Trochoid
- Filter Type: Full Flow Filter Screen
- Oil Type: SAE15W-40/SG (or alternative according to viscosity chart)
- Cooling Type: Closed Coolant Circulation
- Coolant Type: -35℃ Rust-resistant antifreeze, high boiling point coolant
- Clutch Type: Wet, Auto-centrifugal
- Operation Mode: Automatic (CVT) + Parking and Gear Shifting
- Gears: 2 Forward Gears + 1 Reverse Gear
- Shift Type/Sequence: Hand Operation/L-H-N-R
- CVT Gear Ratio: 2.88-0.70
- Final Ratio: 1.333 (24/18, bevel gear)
- Secondary Ratio: 1.952 (41/21)
- Gears (Low/High/Reverse): Low Gear: 2.25 (36/16), High Gear: 1.35 (27/20), Reverse Gear: 1.471 (25/17)
- Total Gear (Low/High/Reverse): Low Gear: 5.857, High Gear: 3.514, Reverse Gear: 3.828
- Overall Dimension: 610 × 568 × 519mm
- Net Weight: 70kg
- Output Type: Front and rear shaft output
- Rotational Direction of Engine Output: Clockwise (from behind engine at forward gear)
Important Technical Specifications (Brakes):
- Brake Pad Friction Material Thickness (Front/Rear): Standard 0.157" / 5.5mm, Service Limit 0.04" / 1mm
- Brake Disc Thickness (Front): Standard 0.150-0.164" / 3.810-4.166mm, Service Limit 0.140" / 3.556mm
- Brake Disc Thickness (Rear): Standard 0.177-0.187" / 4.496-4.750mm, Service Limit 0.167" / 4.242mm
- Brake Disc Thickness Variance (Front/Rear): Service Limit 0.002" / 0.051mm
- Brake Disc Runout (Front/Rear): Service Limit 0.005" / 0.127mm
- Brake Fluid: DOT 3
Usage Features:
- Safe Operation: Always start engines outdoors due to carbon monoxide exhaust. Gasoline is flammable and explosive, and battery electrolyte is poisonous. Wear protection and keep alert.
- Throttle Freeplay: Should be 1.5 – 3 mm. Adjust by loosening the adjuster locknut and turning the adjuster.
- Choke Adjustment: If the choke knob doesn't stay out, tighten the choke cable boot clockwise until the choke slider moves freely but stays out.
- Fuel System: Check fuel lines for wear, damage, or leakage every two years. Ensure vent lines are routed properly and not kinked or pinched.
- Toe Alignment: Ensure steering wheel is straight. Rear rim measurement (A) should be 1/8" to 1/4" (3 to 6 mm) more than front rim measurement (B).
- Braking System: Maintain fluid level in the master cylinder reservoir. Use DOT 3 brake fluid. Check for leaks, excessive travel, spongy feel, and pad/disc condition.
- Parking Brake Adjustment: Free play should allow the vehicle to not roll after 2-4 clicks of lever travel. Adjust using the jam nut and adjustment bolt on the rear caliper.
- Suspension Spring Preload: Adjust both shock absorber spring preloads to the same setting using a shock spanner wrench. Standard position is 3, minimum (soft) is 1, maximum (hard) is 5.
- Wheels: Inspect for runout or damage. Ensure wheel nuts are tight (55 ft.lbs / 75 Nm for both front and rear).
- Tire Pressure: Maintain proper tire pressure as indicated on the decal. Replace tires when tread depth is worn to 1/8" (3mm) or less.
- Electrical 4WD Shift: Shift from 2WD to 4WD using the panel switch. When shifting 2WD/4WD or Diff Lock, the mechanics in the front gearbox may remain engaged/disengaged until the vehicle is ridden on a hard surface or in reverse. Always shift when the vehicle is stopped.
Maintenance Features:
- Periodic Maintenance Schedule: A detailed chart outlines inspection, adjustment, and lubrication intervals for various components, based on average riding conditions (16km/h or 10 mph). More frequent maintenance is recommended for severe use (wet or dusty areas).
- Service (Main) Brake System, Parking Brake, Tires, Wheels, Frame nuts, bolts fasteners: Inspect pre-ride.
- Air Filter-Pre-Cleaner: Inspect and clean daily.
- Coolant/Level: Inspect daily.
- Coolant: Replace annually (150 hours). Inspect strength seasonally (25 hours / 3 months).
- Air Box Sediment Tube: Drain daily.
- Headlamp/Tail lamp Inspection: Daily. Apply dielectric grease to connectors/sockets when replaced.
- Air Filter-Main Element: Inspect and clean weekly (2 hours). Replace if necessary.
- Transmission Oil Level: Inspect monthly (10 hours). Change annually.
- Battery Terminals: Inspect and clean monthly (10 hours).
- Gear Case Oil: Inspect monthly (10 hours). Change annually (150 hours).
- Engine Cylinder Head and Base Fasteners: Inspect (re-torque required at first service only) every 3 months (25 hours).
- General Lubrication (fittings, pivots, cables): Lubricate every 3 months (25 hours).
- Engine Oil-Level: Inspect daily.
- Engine Oil Change: Replace every 3 months (30 hours). Break-in service at 1 month. More often in cold weather.
- Oil Filter: Inspect and clean every 6 months (50 hours).
- Engine Breather Hose: Inspect every 6 months (100 hours).
- Throttle Cable: Inspect pre-ride.
- Throttle Cable/Throttle Pedal: Adjust and lubricate (Grease M) every 6 months (50 hours). Replace if necessary.
- Shift Linkage: Inspect, adjust, and lubricate every 6 months (50 hours). Replace if necessary.
- Transmission Belt: Inspect and replace every 6 months (50 hours).
- Steering, Front/Rear Suspension: Inspect, lubricate, and adjust every 6 months (50 hours). Adjust if necessary.
- Spark Plug: Inspect every 12 months (100 hours). Replace every 6000km.
- Ignition Timing: Inspect and adjust as needed every 12 months (100 hours).
- Fuel System: Check for leaks at tank, cap, lines, fuel valve, and filter every 12 months (100 hours). Replace lines every 2 years.
- Fuel Filter: Replace every 12 months (100 hours).
- Radiator: Inspect and replace every 12 months (100 hours).
- Cooling System Hoses: Inspect and replace every 6 months (50 hours).
- Spark Arrestor: Clean and replace every month (10 hours).
- Clutches (drive and Driven): Inspect and replace every 3 months (25 hours).
- Engine Mounts: Inspect and tighten every 3 months (25 hours).
- Valve Clearance: Inspect and adjust every 12 months (100 hours).
- Shift Selector Box (R/N/H/L): Change grease every two years (200 hours).
- Exhaust System: Inspect every 12 months (100 hours).
- Brake Fluid Level: Inspect pre-ride.
- Brake Fluid: Change every two years (200 hours).
- Idle Speed: Adjust as required.
- Toe Adjustment: Periodic inspection, adjust when parts.
- Lubrication Recommendations:
- Engine Oil (SAE15W/40 SG): Check level daily.
- Brake Fluid (DOT 3 Only): Maintain level, change every two years or 200 hours.
- Rear/Front Gear Case Oil (SAE GL-4 85W/90): Change annually or at 100 hours.
- Steering System (Grease): Lubricate pivoting and sliding parts every 3 months or 50 hours.
- Tie Rods (Grease): Grease semi-annually.
- Shift Linkages (Grease): Locate fittings and grease semi-annually.
- Front/Rear Wheel Bearings: Inspect and replace if necessary semi-annually.
- Ball Joints (Grease): Inspect, locate fittings and grease, or replace if necessary semi-annually.
- Prop Shaft & Shaft Yoke, Spline Joint (Grease): Locate fitting and grease semi-annually.
- Front/Rear A-arm Pivot Shaft (Grease): Locate fitting on pivot shaft and grease with grease gun every 3 months or 50 hours.
- Throttle Cable (Grease M): Grease, inspect and replace if necessary monthly or 20 hours.
- Accelerator Pedal and Brake Pedal (Grease): Grease, inspect monthly or 20 hours.
- Engine Overhaul Information: Includes detailed procedures for removal, installation, inspection, and adjustment of various engine components (valves, spark plug, air filter, fuel hose, drive belt, lubrication system, cooling system, cylinder pressure, oil pressure, clutch engagement).
- Chassis Maintenance: Procedures for front and rear A-arm replacement, rear stabilizer bar removal/installation, box removal/installation, and steering assembly removal/installation.
- Final Drive Maintenance: Detailed instructions for front and rear hub removal/inspection/installation, bearing replacement, drive axle disassembly/inspection/assembly, and gearcase disassembly/assembly.
- Brake System Maintenance: Comprehensive guide for brake pad inspection/replacement, disc inspection/replacement, caliper removal/inspection/installation, and brake bleeding/fluid change.
- Electrical System Troubleshooting: Provides diagnostic procedures for ignition system failures, fan motor issues, heat alarm unit malfunctions, and checks for fuel gauge/level sensor. Includes wiring diagrams and a list of MT05 ECU Malf Codes for diagnosis.
- Special Tools: A list of specialized tools required for various maintenance and repair tasks, such as spark plug wrench, clutch holder, oil filter wrench, piston pin puller, flywheel puller, crankshaft separator, valve spring compressor, ring nut wrench, sheave holder, bearing driver, oil seal remover, and universal joint holder.
- Materials for Operation and Fixing: Specifies types of engine oil (10W-50 SN), molybdenum lubrication oil, lubricating grease (#3 MoS2 Lithium Base Grease), coolant (-35℃ antifreeze), joint face sealant, and thread locker.
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