Cfmoto Uforce 800 XL (2025-2026) - Workshop Manual - Electrical Circuits

CFMOTO UFORCE 800 XL (2025-2026) - SERVICE MANUAL - WIRING DIAGRAMS

- English Service Manual / Repair Manual and Wiring Diagrams for vehicles Cfmoto Uforce 800 XL (2025-2026).


CONTENTS:


2025 MODEL

01 Safety Information
- 1.1 Service Manual
- 1.2 Safety Instructions
- 1.3 Hazard Levels and Symbols
- 1.4 Operation Notice
- 1.5 General Precautions
- 1.5.1 Avoid Carbon Monoxide Poisoning
- 1.5.2 Avoid Corrosion Injury by Electrolyte
- 1.5.3 Avoid Injuries
- 1.5.4 Avoid Burns on High-temperature Parts
- 1.5.5 Avoid Toxic Liquid Coolants
- 1.5.6 Avoid Explosions or Fires
- 1.5.7 Operation Safety
- 1.6 Precautions for Disassembly and Assembly
- 1.7 Engine Break-in
- 1.8 Warranty
- 1.9 Fuel and Fluid Recommendations
- 1.10 Captions and Illustrations

02 General Information
- 2.1 Unit Conversion Table and Symbols
- 2.2 Identification Number Locations
- 2.3 Main Specification Chart
- 2.4 Specifications for Service
- 2.5 Torque Table - Vehicle
- 2.6 Torque Table - Engine
- 2.7 Grease and Sealant
- 2.8 Engine Service Products
- 2.9 Engine Service Tools

03 Maintenance Information
- 3.1 Maintenance Information
- 3.1.1 Pre-Ride Maintenance Checklist
- 3.1.2 Break-In Maintenance Checklist
- 3.1.3 Periodic Maintenance Schedule

04 CVT and Transmission
- 4.1 CVT System
- 4.1.1 System Description
- 4.1.2 Special Tools
- 4.1.3 Drive Pulley Exploded View
- 4.1.4 Driven Pulley Exploded View
- 4.1.5 CVT Air Duct Exploded View
- 4.1.6 How to Avoid CVT Failure / Overheating and Diagnosis
- 4.1.7 CVT Draining and Drying Procedure (Water Ingress)
- 4.1.8 Drive Belt – Removal/Inspection/Replacement
- 4.2 CVT Removal/Overhaul/Installation
- 4.2.1 Removal
- 4.2.2 Drive Pulley Overhaul
- 4.2.2.1 Disassembly
- 4.2.2.2 Inspection
- 4.2.2.3 Reassembly
- 4.2.3 Driven Pulley Overhaul
- 4.2.3.1 Disassembly
- 4.2.3.2 Inspection
- 4.2.3.3 Reassembly
- 4.2.4 Installation
- 4.2.4.1 CVT Cover Installation
- 4.3 Transmission (Engine)
- 4.3.1 Special Tools
- 4.3.2 Transmission Exploded View
- 4.3.3 Transmission Overhaul
- 4.3.3.1 Gear Shift Assembly
- 4.3.3.2 Gearshift Cover
- 4.3.3.3 Gearshift Position Swing Arm, Drum Cam and Shift Drum
- 4.3.3.4 Shift Fork Assembly
- 4.3.3.5 Transmission Output Shaft
- 4.3.3.6 Transmission Driven Shaft Assembly
- 4.3.3.7 Drive Bevel Gear
- 4.3.3.8 Driven Bevel Gear
- 4.3.3.9 Output Shaft
- 4.3.3.10 Transmission Bevel Gear Backlash Adjustment
- 4.3.4 Gear Selector
- 4.3.4.1 Gear Selector Inspection
- 4.3.4.2 Shift Cable Adjustment
- 4.3.4.3 Gear Selector Removal
- 4.3.4.4 Shift Lever Inspection
- 4.3.4.5 Gear Selector Installation

05 Engine
- 5.1 Special Tools
- 5.2 Engine Removal
- 5.3 Engine Disassembly
- 5.3.1 Engine and Transmission Oil Drain
- 5.3.2 CVT Case
- 5.3.3 Thermostat, Housing and Seat
- 5.3.4 Cylinder Head Covers
- 5.3.5 Spark Plug
- 5.3.6 Magneto Cover and Crankshaft Position Sensor
- 5.3.7 Setting Cylinder 2 TDC (Repair)
- 5.3.8 Cylinder 2 Tensioner
- 5.3.9 Cylinder 2 Head
- 5.3.10 Setting Cylinder 1 TDC (Repair)
- 5.3.11 Cylinder 1 Tensioner
- 5.3.12 Cylinder 1 Head
- 5.3.13 Oil Filter
- 5.3.14 Water Pump Cover
- 5.3.15 Starter Motor
- 5.3.16 Oil Cooler
- 5.3.17 PTO Crankcase Cover
- 5.3.18 Magneto Crankcase Cover
- 5.3.19 Starter Dual Gear
- 5.3.20 Magneto Rotor
- 5.3.21 Crankcase Breather
- 5.3.22 Oil pump
- 5.3.23 Cylinder 1 Timing Chain
- 5.3.24 Cylinder 2 Timing Chain
- 5.3.25 Gearshift Assembly
- 5.3.26 Cylinder and Piston 1
- 5.3.27 Cylinder and Piston 2
- 5.3.28 MAG and PTO Crankcase Disassembly
- 5.3.29 Crankshaft and Connecting Rod
- 5.3.30 Transmission Disassembly
- 5.4 Engine Parts Inspection
- 5.4.1 Cylinder Head Cover and Seal
- 5.4.2 Cylinder Head
- 5.4.2.1 Disassembly
- 5.4.2.2 Parts Inspection
- 5.4.2.3 Reassembly
- 5.4.3 Cylinder Body
- 5.4.4 Timing Chain Tensioner
- 5.4.5 Piston
- 5.4.6 Timing Sprocket
- 5.4.7 Timing Chain
- 5.4.8 Tension Plate, Chain Guide and Chain Guard
- 5.4.9 Water Pump Assembly
- 5.4.10 Oil Filter
- 5.4.11 Overriding Clutch
- 5.4.12 Magneto Rotor
- 5.4.13 Magneto Stator
- 5.4.14 Starter Gears
- 5.4.15 Oil Pump Gears
- 5.4.16 Oil Pump
- 5.4.17 Crankcase Breather Gears
- 5.4.18 Starter Driven Gear
- 5.4.19 Crankshaft Assembly
- 5.4.20 Thermostat and Coolant Temperature Sensor
- 5.4.21 PTO Crankcase
- 5.4.22 MAG Crankcase
- 5.4.23 Crankcase Plain Bearings
- 5.4.24 Magneto Crankcase Cover
- 5.4.25 CVT Case
- 5.4.26 PTO Crankcase Cover
- 5.4.27 Oil Cooler
- 5.4.28 Thermostat Seat and Water Pipe
- 5.5 Engine Assembly
- 5.5.1 Transmission Reassembly
- 5.5.2 Crankshaft Installation
- 5.5.3 Crankcase Reassembly
- 5.5.4 Gearshift Assembly Installation
- 5.5.5 Piston and Cylinder Installation
- 5.5.6 Timing Chain Installation
- 5.5.7 Cylinder Head Installation
- 5.5.8 Oil Pump Installation
- 5.5.9 Crankcase Breather Gear Installation
- 5.5.10 Magneto Rotor Installation
- 5.5.11 Starter Gear Installation
- 5.5.12 Magneto Crankcase Cover and Water Pump Cover Installation
- 5.5.13 Setting Cylinder 2 TDC (Overhaul)
- 5.5.14 Cylinder 2 Timing Sprocket Installation
- 5.5.15 Cylinder 2 Tensioner Installation
- 5.5.16 Cylinder 2 Valve Clearance Adjustment
- 5.5.17 Setting Cylinder 1 TDC (Overhaul)
- 5.5.18 Cylinder 1 Timing Sprocket Installation
- 5.5.19 Cylinder 1 Tensioner Installation
- 5.5.20 Cylinder 1 Valve Clearance Adjustment
- 5.5.21 Spark Plug Installation
- 5.5.22 Cylinder Head Cover Installation
- 5.5.23 Crankshaft Position Sensor and Strainer Cover Installation
- 5.5.24 Oil Cooler and Oil Filter Installation
- 5.5.25 Starter Motor Installation
- 5.5.26 Thermostat and Thermostat Seat Installation
- 5.5.27 PTO Crankcase Cover Installation
- 5.5.28 CVT Case Installation
- 5.5.29 Drain Bolt Installation
- 5.5.30 Oil Dipstick Installation
- 5.6 Engine Installation
- 5.7 Engine Coolant/Oil Heat Exchanger
- 5.8 Lubrication System
- 5.8.1 Engine Oil
- 5.8.1.1 Oil Level Inspection
- 5.8.1.2 Oil Replacement
- 5.8.2 Transmission Oil
- 5.8.2.1 Oil Level Inspection
- 5.8.2.2 Oil Replacement
- 5.8.3 Engine Oil Pressure Inspection
- 5.9 Air Intake System
- 5.9.1 Air Filter Maintenance
- 5.9.2 Air Filter Housing Assembly
- 5.9.3 Air Intake Manifold
- 5.10 Exhaust System
- 5.10.1 Removal
- 5.10.2 Inspection
- 5.10.3 Reassembly

06 Vehicle Body and Body Covering Parts
- 6.1 Front Seat
- 6.1.1 Driver Seat Cushion
- 6.1.2 Passenger Seat Cushion
- 6.1.3 Passenger Seat Backrest
- 6.2 Rear Seat
- 6.2.1 Rear Seat Cushion
- 6.2.2 Rear Passenger Seat Backrest
- 6.2.3 Headrest Assembly
- 6.3 Front Panel and Headlight Assembly
- 6.3.1 Front Panel Latch
- 6.3.2 Headlight Guard
- 6.3.3 LH/RH Front Headlight
- 6.3.4 Front Headlight Panel
- 6.3.5 Front LH/RH Deco Plate
- 6.4 Front LH/RH Panels
- 6.5 Top Roof Assembly
- 6.5.1 Top Roof
- 6.5.2 Top Roof Bracket
- 6.6 Front LH/RH Upper Panels
- 6.7 Seat Protection Plate
- 6.8 Rear Seat Backplate
- 6.9 Rear LH Lower Panel
- 6.10 Rear RH Lower Panel
- 6.11 Rear LH/RH Upper Panels
- 6.12 Front LH/RH Lower Panels
- 6.13 Front Seat Backplate Assembly
- 6.13.1 Front Seat Backplate
- 6.13.2 USB/12 Volt Socket Cover
- 6.13.3 Rear Cup Holders and Accessory Sockets
- 6.14 Front Floorboard Service Cover
- 6.15 Rear Floorboard Service Cover
- 6.16 Seat Base Lower Panel
- 6.17 Rear Floorboard Section
- 6.18 Front Floorboard Section
- 6.19 Extended Floorboard
- 6.20 Front LH/RH Lower Inner Panel
- 6.21 Safety Belt Assembly
- 6.21.1 Safety Belt Buckle
- 6.21.2 Safety Belt Reel
- 6.22.3 Safety Belt Inspection
- 6.22 Cab Frame
- 6.22.1 Front Cab Assembly
- 6.22.2 Connecting Beams
- 6.22.4 Middle Cab Assembly
- 6.22.5 Rear Cab Assembly
- 6.22.6 Protection Pipe Assembly
- 6.23 Steering Wheel
- 6.24 Switch Panel Assembly
- 6.24.1 Switch Panel - With Turn Lights
- 6.24.2 Switch Panel - Without Turn Lights
- 6.25 Dashboard Upper Panel Assembly
- 6.25.1 Dashboard and Dashboard Deco Cover
- 6.25.1.1 Dashboard Replacement
- 6.25.2 Center Storage Box
- 6.25.3 Passenger Storage Box Cover
- 6.25.4 2WD/4WD Switch
- 6.25.5 Key Switch Assembly
- 6.25.6 Switch Assembly
- 6.25.7 Cup Holder
- 6.25.8 Dashboard Lower Panel Assembly
- 6.26 Coolant Reservoir Assembly
- 6.27 Brake Reservoir Assembly
- 6.28 Front Inner Lock Panel
- 6.29 Gearshift Assembly
- 6.29.1 Gearshift Mechanism Gearshift Head
- 6.30 Steering Mechanism Assembly
- 6.31 Throttle Pedal
- 6.32 Brake Pedal
- 6.33 Front Fender
- 6.34 Rear LH/RH Fender
- 6.35 Cargo Box
- 6.35.1 Gas Spring
- 6.35.2 Cargo Box
- 6.36 Skid Plate Assembly
- 6.36.1 Front Skid Plate
- 6.36.2 Rear Gear Case Skid Plate
- 6.36.3 Middle Skid Plate
- 6.36.4 Rear Middle Skid Plate
- 6.36.5 LH/RH Side Skid Plate
- 6.36.6 LH/RH Rear Side Skid Plate

07 Powertrain System
- 7.1 Maintenance and Troubleshooting
- 7.1.1 Maintenance Information
- 7.1.2 Troubleshooting
- 7.2 CV Shaft
- 7.2.1 Removal
- 7.2.2 CV Shaft Inspection and Maintenance
- 7.2.3 CV Shaft Dust Boot and Universal Joint
- 7.3 Drive Shafts
- 7.3.1 Front Drive Shaft Removal
- 7.3.2 Rear Drive Shaft Removal
- 7.3.2.1 Drive Shafts Inspection
- 7.3.3 Universal Joint Installation
- 7.3.4 Drive Shaft Assembly
- 7.3.4.1 Front Drive Shaft Installation
- 7.3.4.2 Rear Drive Shaft Installation
- 7.4 Front Gear Case
- 7.4.1 Removal
- 7.4.2 Disassembly
- 7.4.3 Front Drive Bevel Gear Disassembly
- 7.4.4 Differential Disassembly
- 7.4.4.1 Reassembly
- 7.4.5 Component Inspection
- 7.4.6 Front Drive Bevel Gear Reassembly
- 7.5 Rear Gear Case and Drive Shaft
- 7.5.1 Removal/Installation
- 7.6 Rear Gear Case (Non-Differential)
- 7.6.1 Disassembly
- 7.6.2 Driven Bevel Gear Disassembly
- 7.6.2.1 Reassembly
- 7.6.3 Drive Bevel Gear Disassembly
- 7.6.3.1 Reassembly
- 7.7 Rear Gear Case (Differential with Diff-Lock)
- 7.7.1 Disassembly
- 7.7.1.1 Differential Disassembly
- 7.7.2 Component Inspection
- 7.7.3 Reassembly
- 7.7.3.1 Differential Reassembly
- 7.7.3.2 Drive Bevel Gear Reassembly
- 7.7.4 Adjust Rear Gear Case Backlash

08 Brake System
- 8.1 Brake System View
- 8.2 Brake Noise Troubleshooting
- 8.3 Hand Brake Assembly
- 8.4 Brake System
- 8.4.1 Brake Calipers
- 8.4.2 Brake Disc and Mounting Bracket
- 8.4.3 Master Cylinder
- 8.5 Brake Fluid
- 8.6 Brake Fluid Replacement
- 8.7 Brake Pedal
- 8.8 Parking System

09 Suspension System 
- 9.1 Tire
- 9.1.1 Wheel Toe-in
- 9.2 Wheel Hubs
- 9.3 Suspension
- 9.3.1 Front Shock Absorber
- 9.3.2 Rear Shock Absorber
- 9.3.3 Steering Knuckle
- 9.3.4 Front Swing Arm
- 9.3.5 Rear Bearing Carrier
- 9.3.6 Rear Swing Arm
- 9.3.7 Rear Sway Bar

10 Steering System
- 10.1 Steering Wheel
- 10.1.1 Steering Column and Steering Wheel Inspection
- 10.1.2 Steering Wheel Height Adjustment
- 10.1.3 Upper Steering Shaft Assembly
- 10.1.4 Adjust the Initial Position of Steering Wheel
- 10.1.5 Removal and Installation of Steering Wheel
- 10.1.6 Gas Spring Assembly
- 10.1.7 Upper Steering Universal Shaft Assemy
- 10.2 EPS Drive Removal and Installation
- 10.3 Steering Motor
- 10.4 Removal and Installation of Steering Rod
- 10.5 Gearshift Assembly
- 10.6 Shift Lever Position Inspection
- 10.7 Gearshift Cable Adjustment

11 Cooling System
- 11.1 Coolant Specification
- 11.2 Cooling System View
- 11.3 Cooling System
- 11.4 Cooling System Pipes
- 11.5 Fan Motor
- 11.6 Fan Troubleshooting
- 11.7 Water Pump Maintenance
- 11.8 Cooling System Sealing Inspection
- 11.9 Coolant Replacement and Venting
- 11.9.1 Coolant Replacement
- 11.9.2 Air Bleeding

12 Electrical System
- 12.1 Service Tool
- 12.2 Lights
- 12.2.1 Lights View
- 12.2.2 Headlight Inspection
- 12.2.3 Tail Light Inspection
- 12.2.4 Brake Light Inspection
- 12.2.5 Turn Light Inspection (If equipped)
- 12.3 Fuse and Relay Box
- 12.3.1 Fuse and Relay Box Guide
- 12.3.2 Fuse and Relay Box
- 12.4 Switch Inspections and Testing
- 12.4.1 Switch Function Diagrams
- 12.5 Charging System and Battery
- 12.5.1 Charging Wire Diagram
- 12.5.2 Battery
- 12.5.3 Battery Leakage Test
- 12.5.4 Regulator
- 12.5.5 Magneto Stator
- 12.5.5.1 Magneto Coil Inspection
- 12.6 Electric Horn
- 12.7 Starting System
- 12.7.1 Starter Relay
- 12.7.1.1 Starter Relay Path Inspection
- 12.7.1.2 Starter Relay Operation Inspection
- 12.7.2 Starter Motor
- 12.7.2.1 Appearance Inspection of Starter Motor
- 12.7.2.2 Starter Motor Work Inspection
- 12.7.3 Trigger
- 12.7.3.1 Trigger Peak Voltage Inspection
- 12.7.3.2 Trigger Resistance Inspection
- 12.8 EVAP/Fuel Pump
- 12.8.1 EVAP System Guide
- 12.8.2 Carbon Tank Test
- 12.8.3 Canister Magnetic Valve Test
- 12.8.4 Fuel Pump
- 12.8.4.1 Fuel Pump Pressure Test
- 12.8.4.2 Fuel Pump Removal
- 12.8.4.3 Fuel Level Sensor Detection
- 12.9 EFI System
- 12.9.1 EFI Structure
- 12.9.2 Sensors
- 12.9.3 ECM
- 12.9.4 Actuators
- 12.9.5 EFI System Maintenance Notice
- 12.9.6 Throttle Body Assembly
- 12.9.7 Ignition Coil
- 12.9.8 Water Temperature Sensor
- 12.9.9 Oxygen Sensor
- 12.9.10 Injector
- 12.9.10.1 Injector Resistance Detection
- 12.9.10.2 Injector Input Voltage Detection
- 12.9.11 Air Intake Pressure Temperature Sensor
- 12.9.12 ECU
- 12.10 T-BOX
- 12.10.1 T-BOX Pin
- 12.10.2 T-BOX Troubleshooting:
- 12.11 Fault Code Table
- 12.11.1 ECU Fault Code Table
- 12.11.2 Trouble Diagnosis In Accordance With Engine Error 

Wire Diagram


2026 MODEL

01 Safety Information
- 1.1 Service Manual
- 1.2 Safety Instructions
- 1.3 Hazard Levels and Symbols
- 1.4 Operation Notice
- 1.5 General Precautions
- 1.5.1 Avoid Carbon Monoxide Poisoning
- 1.5.2 Avoid Corrosion Injury by Electrolyte
- 1.5.3 Avoid Injuries
- 1.5.4 Avoid Burns on High-temperature Parts
- 1.5.5 Avoid Toxic Liquid Coolants
- 1.5.6 Avoid Explosions or Fires
- 1.5.7 Operation Safety
- 1.6 Precautions for Disassembly and Assembly
- 1.7 Engine Break-in
- 1.8 Warranty
- 1.9 Fuel and Fluid Recommendations
- 1.10 Captions and Illustrations

02 General Information
- 2.1 Unit Conversion Table and Symbols
- 2.2 Identification Number Locations
- 2.3 Main Specification Chart
- 2.4 Specifications for Service
- 2.5 Torque Table - Vehicle
- 2.6 Torque Table - Engine
- 2.7 Grease and Sealant
- 2.8 Engine Service Products
- 2.9 Engine Service Tools

03 Maintenance Information
- 3.1 Maintenance Information
- 3.1.1 Pre-Ride Maintenance Checklist
- 3.1.2 Break-In Maintenance Checklist
- 3.1.3 Periodic Maintenance Schedule

04 CVT and Transmission
- 4.1 CVT System
- 4.1.1 System Description
- 4.1.2 Special Tools
- 4.1.3 Drive Pulley Exploded View
- 4.1.4 Driven Pulley Exploded View
- 4.1.5 CVT Air Duct Exploded View
- 4.1.6 How to Avoid CVT Failure / Overheating and Diagnosis
- 4.1.7 CVT Draining and Drying Procedure (Water Ingress)
- 4.1.8 Drive Belt – Removal/Inspection/Replacement
- 4.2 CVT Removal/Overhaul/Installation
- 4.2.1 Removal
- 4.2.2 Drive Pulley Overhaul
- 4.2.2.1 Disassembly
- 4.2.2.2 Inspection
- 4.2.2.3 Reassembly
- 4.2.3 Driven Pulley Overhaul
- 4.2.3.1 Disassembly
- 4.2.3.2 Inspection
- 4.2.3.3 Reassembly
- 4.2.4 Installation
- 4.2.4.1 CVT Cover Installation
- 4.3 Transmission (Engine)
- 4.3.1 Special Tools
- 4.3.2 Transmission Exploded View
- 4.3.3 Transmission Overhaul
- 4.3.3.1 Gear Shift Assembly
- 4.3.3.2 Gearshift Cover
- 4.3.3.3 Gearshift Position Swing Arm, Drum Cam and Shift Drum
- 4.3.3.4 Shift Fork Assembly
- 4.3.3.5 Transmission Output Shaft
- 4.3.3.6 Transmission Driven Shaft Assembly
- 4.3.3.7 Drive Bevel Gear
- 4.3.3.8 Driven Bevel Gear
- 4.3.3.9 Output Shaft
- 4.3.3.10 Transmission Bevel Gear Backlash Adjustment
- 4.3.4 Gear Selector
- 4.3.4.1 Gear Selector Inspection
- 4.3.4.2 Shift Cable Adjustment
- 4.3.4.3 Gear Selector Removal
- 4.3.4.4 Shift Lever Inspection
- 4.3.4.5 Gear Selector Installation

05 Engine
- 5.1 Special Tools
- 5.2 Engine Removal
- 5.3 Engine Disassembly
- 5.3.1 Engine and Transmission Oil Drain
- 5.3.2 CVT Case
- 5.3.3 Thermostat, Housing and Seat
- 5.3.4 Cylinder Head Covers
- 5.3.5 Spark Plug
- 5.3.6 Magneto Cover and Crankshaft Position Sensor
- 5.3.7 Setting Cylinder 2 TDC (Repair)
- 5.3.8 Cylinder 2 Tensioner
- 5.3.9 Cylinder 2 Head
- 5.3.10 Setting Cylinder 1 TDC (Repair)
- 5.3.11 Cylinder 1 Tensioner
- 5.3.12 Cylinder 1 Head
- 5.3.13 Oil Filter
- 5.3.14 Water Pump Cover
- 5.3.15 Starter Motor
- 5.3.16 Oil Cooler
- 5.3.17 PTO Crankcase Cover
- 5.3.18 Magneto Crankcase Cover
- 5.3.19 Starter Dual Gear
- 5.3.20 Magneto Rotor
- 5.3.21 Crankcase Breather
- 5.3.22 Oil pump
- 5.3.23 Cylinder 1 Timing Chain
- 5.3.24 Cylinder 2 Timing Chain
- 5.3.25 Gearshift Assembly
- 5.3.26 Cylinder and Piston 1
- 5.3.27 Cylinder and Piston 2
- 5.3.28 MAG and PTO Crankcase Disassembly
- 5.3.29 Crankshaft and Connecting Rod
- 5.3.30 Transmission Disassembly
- 5.4 Engine Parts Inspection
- 5.4.1 Cylinder Head Cover and Seal
- 5.4.2 Cylinder Head
- 5.4.2.1 Disassembly
- 5.4.2.2 Parts Inspection
- 5.4.2.3 Reassembly
- 5.4.3 Cylinder Body
- 5.4.4 Timing Chain Tensioner
- 5.4.5 Piston
- 5.4.6 Timing Sprocket
- 5.4.7 Timing Chain
- 5.4.8 Tension Plate, Chain Guide and Chain Guard
- 5.4.9 Water Pump Assembly
- 5.4.10 Oil Filter
- 5.4.11 Overriding Clutch
- 5.4.12 Magneto Rotor
- 5.4.13 Magneto Stator
- 5.4.14 Starter Gears
- 5.4.15 Oil Pump Gears
- 5.4.16 Oil Pump
- 5.4.17 Crankcase Breather Gears
- 5.4.18 Starter Driven Gear
- 5.4.19 Crankshaft Assembly
- 5.4.20 Thermostat and Coolant Temperature Sensor
- 5.4.21 PTO Crankcase
- 5.4.22 MAG Crankcase
- 5.4.23 Crankcase Plain Bearings
- 5.4.24 Magneto Crankcase Cover
- 5.4.25 CVT Case
- 5.4.26 PTO Crankcase Cover
- 5.4.27 Oil Cooler
- 5.4.28 Thermostat Seat and Water Pipe
- 5.5 Engine Assembly
- 5.5.1 Transmission Reassembly
- 5.5.2 Crankshaft Installation
- 5.5.3 Crankcase Reassembly
- 5.5.4 Gearshift Assembly Installation
- 5.5.5 Piston and Cylinder Installation
- 5.5.6 Timing Chain Installation
- 5.5.7 Cylinder Head Installation
- 5.5.8 Oil Pump Installation
- 5.5.9 Crankcase Breather Gear Installation
- 5.5.10 Magneto Rotor Installation
- 5.5.11 Starter Gear Installation
- 5.5.12 Magneto Crankcase Cover and Water Pump Cover Installation
- 5.5.13 Setting Cylinder 2 TDC (Overhaul)
- 5.5.14 Cylinder 2 Timing Sprocket Installation
- 5.5.15 Cylinder 2 Tensioner Installation
- 5.5.16 Cylinder 2 Valve Clearance Adjustment
- 5.5.17 Setting Cylinder 1 TDC (Overhaul)
- 5.5.18 Cylinder 1 Timing Sprocket Installation
- 5.5.19 Cylinder 1 Tensioner Installation
- 5.5.20 Cylinder 1 Valve Clearance Adjustment
- 5.5.21 Spark Plug Installation
- 5.5.22 Cylinder Head Cover Installation
- 5.5.23 Crankshaft Position Sensor and Strainer Cover Installation
- 5.5.24 Oil Cooler and Oil Filter Installation
- 5.5.25 Starter Motor Installation
- 5.5.26 Thermostat and Thermostat Seat Installation
- 5.5.27 PTO Crankcase Cover Installation
- 5.5.28 CVT Case Installation
- 5.5.29 Drain Bolt Installation
- 5.5.30 Oil Dipstick Installation
- 5.6 Engine Installation
- 5.7 Engine Coolant/Oil Heat Exchanger
- 5.8 Lubrication System
- 5.8.1 Engine Oil
- 5.8.1.1 Oil Level Inspection
- 5.8.1.2 Oil Replacement
- 5.8.2 Transmission Oil
- 5.8.2.1 Oil Level Inspection
- 5.8.2.2 Oil Replacement
- 5.8.3 Engine Oil Pressure Inspection
- 5.9 Air Intake System
- 5.9.1 Air Filter Maintenance
- 5.9.2 Air Filter Housing Assembly
- 5.9.3 Air Intake Manifold
- 5.10 Exhaust System
- 5.10.1 Removal
- 5.10.2 Inspection
- 5.10.3 Reassembly

06 Vehicle Body and Body Covering Parts
- 6.1 Front Seat
- 6.1.1 Driver Seat Cushion
- 6.1.2 Passenger Seat Cushion
- 6.1.3 Passenger Seat Backrest
- 6.2 Rear Seat
- 6.2.1 Rear Seat Cushion
- 6.2.2 Rear Passenger Seat Backrest
- 6.2.3 Headrest Assembly
- 6.3 Front Panel and Headlight Assembly
- 6.3.1 Front Panel Latch
- 6.3.2 Headlight Guard
- 6.3.3 LH/RH Front Headlight
- 6.3.4 Front Headlight Panel
- 6.3.5 Front LH/RH Deco Plate
- 6.4 Front LH/RH Panels
- 6.5 Top Roof Assembly
- 6.5.1 Top Roof
- 6.5.2 Top Roof Bracket
- 6.6 Front LH/RH Upper Panels
- 6.7 Seat Protection Plate
- 6.8 Rear Seat Backplate
- 6.9 Rear LH Lower Panel
- 6.10 Rear RH Lower Panel
- 6.11 Rear LH/RH Upper Panels
- 6.12 Front LH/RH Lower Panels
- 6.13 Front Seat Backplate Assembly
- 6.13.1 Front Seat Backplate
- 6.13.2 USB/12 Volt Socket Cover
- 6.13.3 Rear Cup Holders and Accessory Sockets
- 6.14 Front Floorboard Service Cover
- 6.15 Rear Floorboard Service Cover
- 6.16 Seat Base Lower Panel
- 6.17 Rear Floorboard Section
- 6.18 Front Floorboard Section
- 6.19 Extended Floorboard
- 6.20 Front LH/RH Lower Inner Panel
- 6.21 Safety Belt Assembly
- 6.21.1 Safety Belt Buckle
- 6.21.2 Safety Belt Reel
- 6.22.3 Safety Belt Inspection
- 6.22 Cab Frame
- 6.22.1 Front Cab Assembly
- 6.22.2 Connecting Beams
- 6.22.4 Middle Cab Assembly
- 6.22.5 Rear Cab Assembly
- 6.22.6 Protection Pipe Assembly
- 6.23 Steering Wheel
- 6.24 Switch Panel Assembly
- 6.24.1 Switch Panel - With Turn Lights
- 6.24.2 Switch Panel - Without Turn Lights
- 6.25 Dashboard Upper Panel Assembly
- 6.25.1 Dashboard and Dashboard Deco Cover
- 6.25.1.1 Dashboard Replacement
- 6.25.2 Center Storage Box
- 6.25.3 Passenger Storage Box Cover
- 6.25.4 2WD/4WD Switch
- 6.25.5 Key Switch Assembly
- 6.25.6 Switch Assembly
- 6.25.7 Cup Holder
- 6.25.8 Dashboard Lower Panel Assembly
- 6.26 Coolant Reservoir Assembly
- 6.27 Brake Reservoir Assembly
- 6.28 Front Inner Lock Panel
- 6.29 Gearshift Assembly
- 6.29.1 Gearshift Mechanism Gearshift Head
- 6.30 Steering Mechanism Assembly
- 6.31 Throttle Pedal
- 6.32 Brake Pedal
- 6.33 Front Fender
- 6.34 Rear LH/RH Fender
- 6.35 Cargo Box
- 6.35.1 Gas Spring
- 6.35.2 Cargo Box
- 6.36 Skid Plate Assembly
- 6.36.1 Front Skid Plate
- 6.36.2 Rear Gear Case Skid Plate
- 6.36.3 Middle Skid Plate
- 6.36.4 Rear Middle Skid Plate
- 6.36.5 LH/RH Side Skid Plate
- 6.36.6 LH/RH Rear Side Skid Plate

07 Powertrain System
- 7.1 Maintenance and Troubleshooting
- 7.1.1 Maintenance Information
- 7.1.2 Troubleshooting
- 7.2 CV Shaft
- 7.2.1 Removal
- 7.2.2 CV Shaft Inspection and Maintenance
- 7.2.3 CV Shaft Dust Boot and Universal Joint
- 7.3 Drive Shafts
- 7.3.1 Front Drive Shaft Removal
- 7.3.2 Rear Drive Shaft Removal
- 7.3.2.1 Drive Shafts Inspection
- 7.3.3 Universal Joint Installation
- 7.3.4 Drive Shaft Assembly
- 7.3.4.1 Front Drive Shaft Installation
- 7.3.4.2 Rear Drive Shaft Installation
- 7.4 Front Gear Case
- 7.4.1 Removal
- 7.4.2 Disassembly
- 7.4.3 Front Drive Bevel Gear Disassembly
- 7.4.4 Differential Disassembly
- 7.4.4.1 Reassembly
- 7.4.5 Component Inspection
- 7.4.6 Front Drive Bevel Gear Reassembly
- 7.5 Rear Gear Case and Drive Shaft
- 7.5.1 Removal/Installation
- 7.6 Rear Gear Case (Non-Differential)
- 7.6.1 Disassembly
- 7.6.2 Driven Bevel Gear Disassembly
- 7.6.2.1 Reassembly
- 7.6.3 Drive Bevel Gear Disassembly
- 7.6.3.1 Reassembly
- 7.7 Rear Gear Case (Differential with Diff-Lock)
- 7.7.1 Disassembly
- 7.7.1.1 Differential Disassembly
- 7.7.2 Component Inspection
- 7.7.3 Reassembly
- 7.7.3.1 Differential Reassembly
- 7.7.3.2 Drive Bevel Gear Reassembly
- 7.7.4 Adjust Rear Gear Case Backlash

08 Brake System
- 8.1 Brake System View
- 8.2 Brake Noise Troubleshooting
- 8.3 Brake System
- 8.3.1 Brake Calipers
- 8.3.2 Brake Disc and Wheel Hub
- 8.3.3 Master Cylinder
- 8.4 Brake Fluid
- 8.5 Brake Fluid Replacement
- 8.6 Brake Pedal
- 8.7 Parking System
- 8.7.1 Parking Cable
- 8.7.2 Hand Brake Assembly

09 Suspension System 
- 9.1 Tire
- 9.1.1 Wheel Toe-in
- 9.2 Wheel Hubs
- 9.3 Suspension
- 9.3.1 Front Shock Absorber
- 9.3.2 Rear Shock Absorber
- 9.3.3 Steering Knuckle
- 9.3.4 Front Swing Arm
- 9.3.5 Rear Bearing Carrier
- 9.3.6 Rear Swing Arm
- 9.3.7 Rear Sway Bar

10 Steering System
- 10.1 Steering Wheel
- 10.1.1 Steering Column and Steering Wheel Inspection
- 10.1.2 Steering Wheel Height Adjustment
- 10.1.3 Upper Steering Shaft Assembly
- 10.1.4 Adjust the Initial Position of Steering Wheel
- 10.1.5 Removal and Installation of Steering Wheel
- 10.1.6 Gas Spring Assembly
- 10.1.7 Steering Universal Shaft Assembly
- 10.2 Electric Power Steering (EPS) 
- 10.2.1 EPS Pin Function
- 10.2.2 EPS System Fault Diagnosis Code Table
- 10.2.3 EPS System Fault Analysis and Troubleshooting
- 10.3 Steering Gear Assembly
- 10.4 Steering Tie Rods
- 10.5 Gearshift Assembly
- 10.5.1 Shift Lever Position Inspection
- 10.5.2 Gearshift Cable Adjustment

11 Cooling System
- 11.1 Coolant Specification
- 11.2 Cooling System View
- 11.3 Cooling System
- 11.4 Cooling System Pipes
- 11.5 Fan Motor
- 11.6 Fan Troubleshooting
- 11.7 Water Pump Maintenance
- 11.8 Cooling System Sealing Inspection
- 11.9 Coolant Replacement and Venting
- 11.9.1 Coolant Replacement
- 11.9.2 Air Bleeding

12 Electrical System
- 12.1 Service Tool
- 12.2 Lights
- 12.2.1 Lights View
- 12.2.2 Headlight Inspection
- 12.2.3 Tail Light Inspection
- 12.2.4 Brake Light Inspection
- 12.2.5 Turn Light Inspection (If equipped)
- 12.3 Fuse and Relay Box
- 12.3.1 Fuse and Relay Box Guide
- 12.3.2 Fuse and Relay Box
- 12.4 Switch Inspections and Testing
- 12.4.1 Switch Function Diagrams
- 12.5 Charging System and Battery
- 12.5.1 Charging Wire Diagram
- 12.5.2 Battery
- 12.5.3 Battery Leakage Test
- 12.5.4 Regulator
- 12.5.5 Magneto Stator
- 12.5.5.1 Magneto Coil Inspection
- 12.6 Electric Horn
- 12.7 Starting System
- 12.7.1 Starter Relay
- 12.7.1.1 Starter Relay Path Inspection
- 12.7.1.2 Starter Relay Operation Inspection
- 12.7.2 Starter Motor
- 12.7.2.1 Appearance Inspection of Starter Motor
- 12.7.2.2 Starter Motor Work Inspection
- 12.7.3 Trigger
- 12.7.3.1 Trigger Peak Voltage Inspection
- 12.7.3.2 Trigger Resistance Inspection
- 12.8 EVAP/Fuel Pump
- 12.8.1 EVAP System Guide
- 12.8.2 Carbon Tank Test
- 12.8.3 Canister Magnetic Valve Test
- 12.8.4 Fuel Pump
- 12.8.4.1 Fuel Pump Pressure Test
- 12.8.4.2 Fuel Pump Removal
- 12.8.4.3 Fuel Level Sensor Detection
- 12.9 EFI System
- 12.9.1 EFI Structure
- 12.9.2 Sensors
- 12.9.3 ECM
- 12.9.4 Actuators
- 12.9.5 EFI System Maintenance Notice
- 12.9.6 Throttle Body Assembly
- 12.9.7 Electric Throttle Pedal
- 12.9.8 Ignition Coil
- 12.9.9 Water Temperature Sensor
- 12.9.10 Oxygen Sensor
- 12.9.11 Injector
- 12.9.11.1 Injector Resistance Detection
- 12.9.11.2 Injector Input Voltage Detection
- 12.9.12 Air Intake Pressure Temperature Sensor
- 12.9.13 ECU
- 12.10 T-BOX
- 12.10.1 T-BOX Pin
- 12.10.2 T-BOX Troubleshooting:
- 12.11 Fault Code Table
- 12.11.1 ECU Fault Code Table
- 12.11.2 Trouble Diagnosis In Accordance With Engine Error 

Wire Diagram