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General| Brand | TOMCAR |
|---|---|
| Model | Utility Vehicle |
| Category | Utility Vehicle |
| Language | English |
Check wheels for dents, cracks, leaks, and inspect tires for wear or damage.
Check for free play in wheel bearings; replace if excessive.
Inspect a-arm hinge points for free play after lifting wheels.
Inspect steering tie rods for damage, dry rubber boots, and ensure tight lock nuts.
Check shock mounts for free play (2-3mm max) and inspect shocks for leaks.
Inspect front brake pads for wear, clean caliper piston, check for leaks.
Check upper final drive bearings for free play; replace if necessary.
Check rear shock mounts for free play (2-3mm max) and inspect shocks for leaks.
Replace fuel filters, paying attention to flow direction. Check rear fuel filter.
Clean around spark plug, check and adjust gap (1.0-1.1mm).
Replace primary fuel filter every 5000 Km. Bleed and prime the fuel system.
Procedure to bleed and prime the fuel system after filter replacement.
Inspect radiator hoses, cap, and coolant level. Check overflow bottle for leaks.
Drain, clean, and refill transmission with 2.5 qrt of 80w90 gear oil.
Steps to install the brake caliper assembly onto the rotor and connect lines.
Steps for disassembling and inspecting the upper ball joint.
Procedure for greasing and reassembling the ball joint.
Steps for removing the upper A-arm, including noting thread counts.
Steps for removing the lower A-arm, including disconnecting the shock mount.
Safety precautions before removing the CVT belt.
Steps for sliding the CVT belt off the transmission CVT plate.
Tools needed and preparation steps for CVT installation.
Steps for aligning and installing the transmission CVT onto the shaft.
Tools and preparation steps for CVT inspection and reconditioning.
Steps for disassembling the transmission CVT, including o-ring inspection.
Inspect the outer guide for straightness and smoothness.
Inspect inner guide and guide keys for damage; replace if necessary.
Inspect the move plate for smoothness, deformation, abrasion, or grooves.
Examine spring stem and fix-plate for damage or abrasion.
Inspect the fix-plate and main shaft for smoothness and deformation.
Apply anti-seize to shafts and install transmission CVT spacer.
Screw on fix-plate, install wear strips into the groove.
Slide move plate into place, insert spring leg into inner spin guide.
Screw on inner guide, grease generously.
Slide outer spin guide into place, install o-ring into housing.
Procedure to preload the CVT spring by rotating the move plate.
Install bolts after aligning holes for spring preload.
Rotate move plate, check o-ring visibility and smooth movement.
Tools needed and exploded view for engine CVT inspection.
Steps for internal inspection and reconditioning of the engine CVT.
Carefully remove spring housing, inspect nuts and bolts.
Inspect roller plate and rollers for damage; ensure free spinning.
Apply anti-seize to shafts and install transmission CVT spacer.
Screw on fix-plate, install wear strips into the groove.
Slide move plate into place, insert spring leg into inner spin guide.
Screw on inner guide, grease generously.
Slide outer spin guide into place, install o-ring into housing.
Procedure to preload the CVT spring by rotating the move plate.
Install bolts after aligning holes for spring preload.
Rotate move plate, check o-ring visibility and smooth movement.
List of usual parts to be changed during shock absorber renovation.
Steps for disassembling shock absorbers TM4370, TM4380.
Loosen spring nut and shock cap, ensuring no air pressure remains.
Unscrew spring nut and shock cap carefully.
Take off springs and plastic spacer, loosen shock seal housing.
Carefully remove shock rod, drain oil, remove shock piston.
Install new O-ring on seal housing, install oil retainer and wiper.
Secure shock rod, place shock spring support on rod.
Place rubber support on rod, apply oil to seal housing, place on rod.
Install rebound washer, O-ring, and nylon bushing onto piston.
Install oil piston, tighten nut, check rebound washer free play.
Install O-ring onto the shock gas piston.
Apply oil to piston, insert piston into cylinder, prepare vice with spacer.
Place cylinder on spacer, tighten vice securely.
Set air piston to a depth of 33mm from the end of the cylinder.
Fill cylinder with oil, insert piston to push out excess air.
Apply anti-seize to threads, screw in housing seal.
Push piston to expel air, slowly tighten housing.
Place cylinder upside-down, fit shock spring over cylinder.
Install the shock spacer.
Apply anti-seize to cylinder threads, install second shock spring.
Install shock spring nut until it touches the spring.
Prepare shock cap, insert O-ring.
Apply anti-seize to air valve, screw in valve and tighten.
Screw on the shock cap.
Turn spring nut to set spring preload, check thread length.
Inflate the shock with pressurized air to 100psi.
Check for air leaks from the valve or shock cap.
Remove piston and o-ring, loosen and remove accumulator cylinder cap.
Install piston, push down, install new cap o-ring, apply anti-seize.
Set piston depth to 61mm, fill with 10w hydraulic oil.
Install copper washer on banjo hose fitting and tighten.
Ensure shock is filled, install banjo fitting with washers.
Position accumulator based on vehicle side (right or left).
Tighten banjo fitting, apply anti-seize to valve.
Install air valve, pressurize accumulator briefly to bleed air.
Loosen hose banjo fitting to bleed air, then retighten.
Pressurize the accumulator to 100psi.
Remove rear wheel, disconnect brake caliper and hose.
Disconnect shock absorber, remove cam wheel, grease nipple, and final drive nut.
Disconnect final drive from vehicle by removing bracket bolts.
Remove final drive spanner nut, speed ring, and axle from transmission.
Steps for draining oil and disassembling the lower axle shaft.
Remove the final drive cover and gasket after draining oil.
Remove retainer plates, final drive nut pin, and nut.
Remove brake rotor and lower drive axle.
Examine axle, keys, and sprocket for damage, wear, or deformation.
Remove the two inner axle bearings from the final drive housing.
Remove spacer, O-ring, and outer bearings. Inspect bearings and housing.
Steps for disassembling the upper axle shaft, including bearing housing.
Remove bearing housing and nut using special tools.
Remove final drive bracket, spacer, and snap ring retainer.
Remove bolt and bearing from bearing housing using hammer or press.
Remove final drive spacer and upper axle shaft nut.
Remove upper axle shaft, check for damage. Remove spacer.
Remove upper sprocket and chain, examine sprocket for damage.
Remove chain, inner housing O-ring, and center bearing plate.
Remove bearing and inner seal.
Check frame side bearing, apply anti-seize before installation.
Ensure axle o-ring is in place, place spanner nut and speed ring.
Align center axle splines with upper drive axle, push final drive into place.
Push o-ring into gap, rotate axle by turning brake rotor.
Refit cam wheel, tighten Allen bolt, refit grease nipple.
Reconnect brake hose, parking brake cable to housing and caliper.
Reconnect rear shock, bleed brakes.
Remove cam wheel, grease nipple, and final drive nut.
Disconnect final drive from vehicle, carefully pull out.
Remove gearshift and differential lock lever connection.
Remove bolts holding gear box to tray and remove gear box.
Remove gear selector sprocket and key from shift drum shaft.
Remove shift bracket from transmission case.
Remove drain plug and drain all gear oil from the transmission.
Remove remaining case bolts holding the transmission case halves.
Remove differential locking assembly using a 5mm Hex Key.
Remove short output shaft housing, noting any shims.
Remove 8mm hex head plug from left transmission case.
Use M8x30mm bolt to separate the transmission case halves.
Remove washer, high gear cog, and thin special washer from secondary shaft.
Remove spacer and reverse gear assembly from reverse shaft.
Remove shift drum, forks, CVT shaft, and selector gear as one unit.
Remove differential lock collar from long output shaft housing.
Remove all bearings, races, and seals from case halves.
Replace output shaft seal and bearing, reinstall snap ring.
Install shaft housings using correct bolt lengths, inspect gear teeth.
Set differential and secondary shaft with low gear into case bearings.
Set large steel spacer and small cog onto case top bearing.
Set shift drum with forks, install large selector gear.
Set gears and shafts into case, verify proper seating.
Install reverse gear assembly onto reverse shaft, ensure beveled teeth face each other.
Install special washer onto secondary shaft, mount high gear cog and heavy washer.
Install 8mm hex plug using loctite.
Apply silicone to mating surfaces, reassemble case halves with special bolts.
Install key onto shift drum shaft, rotate to check gear engagement.
Install shifter bracket using loctite on small bolts.
Fit gear selector sprocket onto shift drum shaft and bolt in place.
Rotate transmission gear, install shift rod through mount bracket.
Install pie gear onto shift rod, do not tighten nut yet.
Torque shift rod nut, check gear engagement for pie shaped gear.
Install differential lock lever assembly, noting bearing position.
Refit cam wheel, tighten Allen bolt, refit grease nipple.
Verify shift linkage adjustment by checking gear engagement points.
Check shift lever action and gear engagement in neutral, high, and low ranges.
Adjust shift rod as needed to correct shift points.
Disconnect battery, loosen muffler nuts.
Remove exhaust system from manifold.
Remove CVT drive belt, loosen engine mounting bolts if needed.
Drain engine coolant by removing lower radiator hose.
Loosen CVT clutch bolt, remove clutch and key.
Remove air inlet hose and air hose from intake manifold.
Remove bolts attaching air filter assembly to mounting bracket.
Remove upper radiator hose, plug open hoses.
Remove fuel supply and return lines, plug lines.
Disconnect and label wires and battery cable from engine rear.
Label and remove wire harness on front of engine.
Loosen throttle cable pinch bolt, remove cable.
Attach winching mechanism, remove engine mounting bolts.
Disconnect battery, ensure engine bay is clear of debris.
Install engine mounting bolts loosely for CVT belt tension adjustment.
Insert throttle cable, feed through liner, install dust boot, reinstall pinch bolt.
Verify action and free play at throttle pedal and lever.
Replace wire harness for alternator/temp units, replace wire bundle to engine.
Install battery cable, charging wire, and starter wire to solenoid.
Return fuel lines to fuel block, connect red fuel shut off wire.
Prime fuel system by cracking rear fitting and depressing fuel pump lever.
Replace radiator hoses, connect air filter assembly and hoses.
Slide engine CVT onto shaft, tighten CVT bolt, tighten engine mounting bolts.
Install CVT belt, tighten engine mounting bolts.
Install exhaust assembly, mount muffler studs, tighten nuts.
Drain coolant, loosen thermostat bypass hose.
Loosen alternator and remove the V-belt from pulleys.
Align pulley reference marks, fix engine rotation.
Remove crankshaft pulley center bolt and pulley.
Remove timing cover screws, note lengths.
Remove timing belt idler pulley and belt, ensure pulleys are not rotated.
Set timing belt tension using special tool, tighten idler nut.
Install timing cover and hex head screws.
Install crankshaft pulley, apply loctite to center bolt, torque to 360Nm.
Replace cooling system hoses and alternator belt, tension belt, fill system.
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