User manual

18 Section 5 — Product care
2. Remove the oil filter (a). See Figure 5-22.
(a)
Figure 5-22
3. Put a film of clean engine oil on the rubber
seal of the new filter.
4. Tighten the filter until it contacts the
mounting surface.
5. Tighten filter by hand an additional ½-turn only.
Draining the PCV Accumulator
The PCV accumulator should be drained at each
oil changed to remove oil condensation. There are
two PCV accumulators, one near the front of the air
intake box and one near the rear. To drain the PCV
accumulator, pinch the valve at the bottom of the
tube and allow the condensation to run out. See
Figure 5-23.
Figure 5-23
Replacing Mini Fuses
The mini fuses are intended to protect the
electrical system. If any of them have blown out,
be sure to pinpoint the cause.
1. Disconnect the negative battery cable.
2. Open the mini fuse box cover. See Figure 5-24.
Figure 5-24
3. Pull out the mini fuse.
4. Insert a new mini fuse into the box.
5. Close the mini fuse box cover.
6. Re-connect the negative battery cable.
Changing the Front & Rear Axle Case Oil
See your authorized service dealer to have the axle
case oil changed.
Changing the Brake Fluid
See your authorized service dealer to have the
brake fluid changed.
Replacing Radiator Hose
See your authorized service dealer to have the
radiator hose changed.
Replacing Fuel Hose
See your authorized service dealer to have the fuel
hose changed.
Replacing Brake Master Cylinder
See your authorized service dealer to have the
brake master cylinder changed.
Replacing Front Brake Seal
See your authorized service dealer to have the
front brake seal changed.
Replacing Rear Brake Cylinder Seal
See your authorized service dealer to have the rear
brake seal changed.
Replacing Intake Air Line
See your authorized service dealer to have the air
intake line changed.
Replacing Brake Hose
See your authorized service dealer to have the
brake hoses changed.
Flushing the Coolant System & Changing Coolant
CAUTION
Do not remove radiator cap while coolant is hot . When cool
slowly rotate to the first stop and allow sufficient time for
excess pressure to escape removing the cap completely.
1. Stop the engine and let it cool down.
2. To drain the coolant, open the radiator drain
plug and remove radiator cap. The radiator
cap must be removed to completely drain
the coolant.
3. After all coolant is drained, close the drain plug.
Note: Do not start engine without coolant.
4. Fill with clean water and cooling system
cleaner.
5. Follow directions of the cleaner container.
6. After flushing, fill with clean water and anti-
freeze until the coolant level is just below
the radiator cap.
Note: When the anti-freeze is mixed with
water, the antifreeze mixing ratio must be
50-50. See the Anti-Freeze section on this
page.
7. Install the radiator cap securely. If the cap is
loose or improperly fitted, water may leak
out and the engine could overheat.
8. Fill with fresh water/antifreeze up to the
“FULL” mark on the recovery tank. See
Figure 5-13.
9. Start and operate the engine for few minutes.
10. Stop the engine and let cool.
11. Check coolant level of recovery tank and
coolant if necessary.
12. Burp (remove air from) the coolant system as
instructed in the Burping (Removing Air From)
the Coolant System section on this page.
Anti-Freeze
WARNING
When using antifreeze, put on some protection such as
rubber gloves.(Antifreeze contains poison.) If you should
drink antifreeze, throw up at once and seek medical
attention. If antifreeze comes in contact with the skin or
clothing, wash it off immediately. Do not mix different types
of Antifreeze. The mixture can produce a chemical reaction
between substances. Antifreeze is extremely flammable
and explosive under certain conditions. Keep fire away
from antifreeze. Keep children away from antifreeze. When
draining fluids from the engine, place some container
underneath the engine body. Do not pour waste onto the
grounds, down a drain or into any water source. Also, observe
the relevant environmental protection regulations when
disposing of antifreeze.
If it freezes, coolant can damage the cylinders and
radiator. If the ambient temperature falls below
0°C (32°F) or before a long-term storage, let out
coolant completely, or mix fresh water with long-
life coolant and fill the radiator and recovery tank
with the mixture.
1. Long-life coolant comes in several types. Use
an ethylene glycol (EG) type for this engine.
2. Before employing long-life coolant-mixed
cooling water, fill the radiator with fresh
water and empty it again.
3. Repeat this procedure two or three times to
clean up the inside.
4. Mix the long-life coolant.
5. The procedure for the mixing of water
and antifreeze differs according to the
make of the antifreeze and the ambient
temperature. Refer to SEA J1034 standard,
more specifically also to SAE J814c.
6. Add the long-life coolant.
7. If there is a mixture leak, add the long-life
coolant of the same manufacturer and type
in the same mixture percentage.
Note: Never mix long-life coolant of
different manufacturer. (Different brands
may have different additive components,
and the engine may fail to perform as
specified.)
8. When the long-life coolant is mixed, do not
employ any radiator cleaning agent. The
long-life coolant contains anticorrosive agent.
If mixed with the cleaning agent, sludge may
build up, adversely affecting the engine parts.
9. The utility vehicle’s genuine long-life
coolant has a service life of 2 years. Be sure
to change the coolant every 2 years.
10. Burp (remove air from) the coolant system as
instructed in the Burping (Removing Air From)
the Coolant System section on this page.
Burping (Removing Air From ) the Coolant System
To “burp” the coolant system, proceed as follows:
Note: When re-filling the coolant system, this
procedure should be performed every time to
avoid an overheating risk.
1. Chock the rear wheel, engage the parking
brake place the shift lever in neutral or park
and jack up the front of the utility vehicle
approximately 6”.