Cub Cadet Challenger Series Manual de usuario

SERVICE MANUAL

Challenger 500

Challenger 700

Foreword

Brief Introduction to the Service and MaintenanceHandbook

500/700 Challenger Utility Vehicles

This manual gives methods to check, maintain and repair the Cub Cadet 500 &700

utility vehicles (UV’s), and supplies some relevant techniques and performance

data.

Please read the handbook through and fully understand it; otherwise, any

improper repairing could cause problems, and/or an accident mayoccur.

Proper use and maintenance will reduce malfunctions, and help the vehicle

remain at its best performance level.

The standards, procedures and specifications mentioned in this manual are basedon

the sample in design, and they are subject to changes according to theproduct’s

improvement without prior notice.

INDEX

Chapter

Troubl

eshooti

agram

Chapter

ectri

cal

Chapte

Engi

Management

stem

Chapte

Engi

Chapte

Chassi

Chapter

Speci

ficati

ons

Chapter

Peri

odi

Mai

ntenance

and

Adj

ustments

ndex

Chapter

General

INDEX

General Information

Chapter 1

Warning, Caution, Note

Description

Vehicle Identification Code, Engine

Number

Safety

Handling Gasoline, Cleaning Parts

Warning Labels, Serial Numbers,

Fasteners

Self-Locking Fasteners, Washers,

Cotter Pins, Snap Rings and E-

clips

Shop Supplies

Lubricants and Fluids,

Engine Oils, Greases, Brake Fluid

Coolant, Cleaners, Degreasers,

and solvents

Gasket Sealant, Gasket Remover,

Thread Locking Compound

Basic Tools

Screwdrivers

Wrenches

Adjustable Wrenches, Sockets,

Ratchets, and Handles

Impact Drivers

Allen Wrenches

Torque Wrenches, Torque

Adapters

Pliers, Snap Ring Pliers

Ignition Grounding Tool

Precision Measuring Tools

Feeler Gauge, Calipers

Micrometers

Adjustment and Care

Metric Micrometer

Standard Micrometer

Telescoping and Small Bore

Gauges

Dial Indicator, Compression Gauge

Multimeter

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

1-11

1-12

1-13

1-14

1-15

1-16

1-17

1-18

1-19

1-20

1-21

1-22

1-23

1-24

Electrical System Fundamentals

Voltage

Resistance, Amperage

Basic Service Methods

Removing Frozen Fasteners

Removing Broken Fastener

Stud Removal, Removing Hoses

Bearings

Removal

Installation

Interference Fit

Seal Replacement

Storage

Area Selection

Preparing the UV for storage

Returning the UV to Service

Specifications

Chapter 2

General Specifications

Engine Torque Specifications

Chassis Torque Specifications

General Torque Specifications

Chassis Lubrication points

Periodic Maintenance

Chapter 3

Periodic Maintenance Table

Periodic Maintenance

Engine

Valve Clearance

Spark Plug

Compression Test

Engine oil

Oil Change

Air Filter cleaning

Coolant Change

V-Belt Inspection

Replacement

Cleaning the Spark Arrester

Adjustment of the Parking Brake

Brake Fluid Level check

1-24

1-25

1-27

1-28

1-29

1-30

1-31

1-32

1-33

2-1

2-13

2-16

2-18

2-19

3-1

3-3

3-4

3-6

3-7

3-8

3-9

3-11

3-12

3-15

3-16

3-17

3-18

INDEX

Brake lines, Bleeding the Brake

Select Lever Shift Rod adjustment

Brake light switch adjustment

Final Gear oil Change

Tow In adjustment

CV Boot inspection

Steering system Inspection

Rear Shock adjustment

Tire inspection

Headlight Bulb replacement

Tail Light Bulb replacement

Engine

Chapter 4

Special Notes

Engine removal

Cylinder Head and Cover

Inspection, installation

Rocker Arm and Camshaft

3-19

3-20

3-21

3-22

3-23

3-24

3-25

4-1

4-2

4-3

4-4

4-6

Crankcase, Starter Motor and Oil

Filter

Crankcase

Bearings

Inspection

Assembly

Crankshaft and Oil Pump

Oil Pump

Inspection

Installation

Transmission

Drive Axle Assembly

Inspection

Installation

Middle Gear, Middle Drive Shaft

Middle Driven Shaft

Inspection

Installation

Chassis

4-30

4-31

4-32

4-33

4-34

4-35

4-36

4-37

4-38

4-39

4-40

4-41

4-42

4-43

4-44

4-45

4-46

Inspection 4-7

Chapte

Installation 4-8

Val

es and Valve springs 4-9 Inspection 5-1

Inspection 4-10 Steering S

stem 5-4

Installation 4-11 Steering Wheel

ssembly 5-5

linde

and Piston 4-12 Disassembl

, Inspection 5-6

Inspection 4-13 Installation 5-8

Installation 4-14 B

ake S

stem Inspection 5-8

Engine Cooling Fan and

.C. 4-15 B

ake Line Removal 5-10

Magneto B

ake Disc Removal 5-11

Inspection 4-16 Inspection 5-12

Installation 4-17 B

ake Pad Removal 5-13

Balance

Gea

s and Oil Pump 4-18 Installation 5-14

Gea

ont B

eCalipe

Remo

al 5-15

Inspection 4-19 B

ake Calipe

Disassembly 5-16

Installation 4-19 Installation 5-17

Prima

y and Seconda

y Sheaves 4-20 Rea

ake Disc Remo

al 5-19

Prima

y Shea

e4-21 Inspection 5-20

Seconda

y Shea

e4-22 Rea

ake Calipe

and Pads 5-21

Inspection 4-23 Rea

ake Pad Replacement, 5-23

Installation 4-24 Inspection 5-23

Clutch 4-26

ssembly and Installation 5-24

Disassembly 4-27 B

ake Mas

linde

5-26

Inspection 4-28 Inspection, Ins

allation 5-27

Installation 4-29 Foot

est

ssembly 5-28

INDEX

Front Wheel and Tire

Rear Wheel

Inspection, Installation

Transmission Front Bridge

Front Bridge Removal

Disassembly

CV Joint Inspection

Differential Gear and Gear Motor

Operation

U-Joint Assembly

Differential Gear Motor Adjustment

Front Bridge Installation

Rear Bridge

Rear Differential Removal

Gear Shift Mechanism

Adjustment

Front Suspension and A-Arm

Inspection, Installation

Rear Suspension

Rear A-Arm

Inspection, Installation

Cooling System

Inspection, Coolant replacement

Water Pump Assembly

Disassembly, Inspection

Assembly

Seat Assembly

Fuel System

Fuel Pump Inspection

Electrical

Chapter 6

Components

Battery

Lead Acid Battery Charging

Maintenance Free Battery

Charging

Checking Fuses

Switch Inspection

Switch Locations

Bulbs and Sockets

Ignition Circuit Diagram

Ignition Troubleshoot

Starting Circuit Diagram

5-30

5-31

5-32

5-33

5-34

5-37

5-38

5-39

5-40

5-41

5-42

5-45

5-46

5-47

5-49

5-50

5-51

5-52

5-53

5-55

5-56

5-58

5-59

5-60

5-62

5-66

6-1

6-3

6-4

6-6

6-7

6-8

6-9

6-10

6-11

6-12

6-15

Brake Master Cylinder

Inspection, Installation

Footrest Assembly

Starter Motor Troubleshoot

Starter Motor Removal

Charging Circuit Diagram

Charging System Troubleshoot

Lighting Circuit Diagram

Signaling Circuit Diagram

Cooling Circuit Diagram

2WD / 4WD Select Circuit Diagram

Engine Management

System Chapter 7

Components

E.C.U.

Fuel Injectors

Installation Guidelines

Replacement

Cleaning Procedure

Throttle Body

Engine Coolant Temperature

Sensor

Oxygen Sensor

Fuel Pump Module

Inspection

Removal, Installation

Fuel Leak Check

E.M.S.

Fault Codes

Troubleshooting

Chapter 8

Spark Test

Fuel System Check

Compression Test

Engine Overheating

Engine Noises

Cylinder Leak Down

Electrical checks

Intermittent Problems

E.C.U.

5-26

5-27

5-28

6-16

6-17

6-18

6-19

6-20

6-21

6-22

6-23

7-1

7-2

7-3

7-5

7-6

7-7

7-8

7-9

7-10

7-11

8-1

8-2

8-3

8-4

8-5

8-7

8-8

8-9

Vehicle Identification Number

LWG

MD SZ 44

E B

123456

LWG

Manufacturer

UV below 750 cc

UV above 750 cc

TZ 500cc

700cc

44 DOT Check Digits

2010 Model Year

2011 Model year

2012 Model Year

2013 Model Year

2014 Model Year

Manufacturing Plant A

Manufacturing Plant B

123456 Sequential Serial

Number

General

Information

1‐1

This manual provides complete information on maintenance, tune-up, repairand

overhaul. Hundreds of photographs and illustrations created during the complete

disassembly of Utility Vehicles (UV) guide the reader through every job. All

procedures are in step by step format and designed for the reader who maybe

working on the UV for the first time.

Warnings, Cautions and Notes

The terms Warning, Caution and Note have specific meanings in thismanual.

Warning

Emphasizes areas where injury or even death could resultfrom

negligence.

Caution

Emphasizes areas where equipment damage could result.

Disregarding a Caution could cause permanent

mechanical damage, although injury isunlikely.

Note

Provides additional information to make a step or procedureeasier

or clearer. Disregarding a Note could cause inconvenience, but

would not cause equipment damage orinjury.

General

Information

1‐2

Description

Note

The vehicle you have purchased may

differ slightly from those in the

figures of this manual.

1. Headlights

2. Frontshockabsorberadjustingring

3. Brakefluidreservoir

4. Airfilterelement(insideairintakeduct)

5. V‐beltcase

6. Driverseat

7. Driverseatbelt

8. Sparkplug

9. Cargobed

10. Tail/brakelights

11. Rearshockabsorberadjustingring

12. Cargobedreleaselever

13. Sparkarrester

14. Passengerseatbelt

15. Passengerseat

16. Oilfilter

17. Engineoildipstick

18. Battery

19. Fuses

20. Coolantreservoir

21. Radiatorcap

22. Fuelcap

23. Lightswitch

24. Steeringwheel

25. Choke

26. Ignitionswitch

27. On‐commandfour‐wheeldriveand

Differentiallockswitches

28. Multi‐functiondisplayunit

29. AuxiliaryDCoutlet

30. Driveselectlever

31. Parkingbrakelever

32. Acceleratorpedal

33. Brakepedal

General

Information

1‐3

Identification Code

Vehicle Identification Number

Vehicle Identification number is

stamped in the lower right side of

the frame.

Engine Number

Engine number is printed on a

white tag on top of the clutch

cover.

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