9.TROUBLESHOOTING
9-7
clutch (refer to CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)).
CVT one way clutch is worn out or damaged. Replace defective part(s)
(refer to CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)).
Check if friction washer at one way clutch is worn. Replace friction washer
(refer to CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)).
4. Check transmission lever and connecting rod.
Ball joint and/or ball joint nut is (are ) loose. Retighten or replace the ball
joint.
5. Check spring on shift shaft in gearbox.
Broken spring. Replace the spring (refer to GEARBOX).
6. Check for any mud intrusions.
CVT parts dirty. Clean all CVT parts.
COUPLING UNIT
Symptom: 4 WHEEL DRIVE INDICATION FAILS
1. Check contact screw on gear housing right side for damage and/or wear.
Shifting indicator switch pin is worn and/or damaged. Replace shifting
indicator switch.
Contact is corroded and/or contact screw for wiring harness got loose.
Clean contact surface and retighten contact screw with recommended
torque.
Wiring harness has broken cable. Replace wiring harness.
Symptom: 4 WHEEL DRIVE DOES NOT ENGAGE OR DISENGAGE
1. Check actuator and/or actuator shifting fork for wear and/or damages.
Check if selector works properly. If so, check actuator.
If selector is out of specifications, check wires, connectors and/or replace
selector.
Actuator shifting fork is worn out and/or damaged. Replace shifting fork
of actuator.
Check function of actuator. Replace if actuator is not turning, refer to
GEARBOX.
2. Check shifting sleeve splines and/or shifting fork for wear and/or damages.
Check sleeve shows damaged splines. Replace shifting sleeve (refer to
GEARBOX).
Shifting fork is worn out and/or engagement pin is damaged. Replace
shifting fork.
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