cvt enclosure kit assembly instructions treker 4200st …cvt pulley and belt installation refer to...
TRANSCRIPT
1© Copyright 2005 Printed 4/07/05 Manual No. 701-097M
Before You Start
These optional assembly instructions contain onlyinformation required to assemble the CVT Enclosure tothe ST Series Treker. A detailed Operator’s Manual wassupplied with the Treker. Refer to the Operator’s Manualfor additional specific information especially informationrelating to safety concerns. Also included in the Operator’sManual is important information on operation, adjustment,troubleshooting, and maintenance for this attachment(some manual sections do not apply to all options).A separate Parts Manual for replacement parts can bepurchased from your dealer or available free of charge atwww.landpride.com. Have model and serial numbershandy when placing an order.
Manual Part Numbers:• Treker Operator’s Manual . . . . . . . . . . . . 700-108M• Treker Parts Manual. . . . . . . . . . . . . . . . . 700-108P
General InformationThese assembly instructions apply to the following CVTEnclosure kit options listed below:701-095A Treker ST Series (S/N 44720+)701-105A Treker ST Series (S/N 437154 to 440719)701-107A Treker ST Series (S/N 437153-)
Assembly InstructionsA detailed listing of parts for kit no’s 701-095A, 701-105Aand 701-107A are provided on pages 9, 10 and 11. Usethe list that is for your ST Treker as a checklist to inventoryparts received.
When you see this symbol, the subsequentinstructions and warnings are serious - followwithout exception. Your life and the lives ofothers depend on it!
!Initial Preparations
! CAUTION!Securely support cargo box in the up position to preventinjury when working under the cargo box.
1. Park vehicle on a flat surface, move gear shift lever toneutral, set park brake, and chock front and back ofthe right rear wheel to prevent the vehicle from rolling.
2. Raise cargo box fully up and securely support it in theup position to prevent injury while working around theengine.
3. Turn off engine and remove ignition key.
Left Side Panel DetachmentThe fuse box on the left side panel can interfere withremoving and assembling the CVT enclosure. It is simplerto detach the side panel from the frame than to detach thefuse box.Refer to Figure 1:1. Remove five 1/4" hex flange lock nuts (#3) and 1/4"
Phillip head machine screws (#2) and let the sidepanel hang from the wiring harness along side theTreker frame.
2. Lift side panel (#1) with fuse box and wiring harnessout of the way when removing and installing drivelinecomponents that interfere with the fuse box.
Side Panel RemovalFigure 1
22416
Treker 4200/4400 ST Series Manual No. 701-097M
CVT Enclosure KitAssembly Instructions
2 Manual No. 701-097M 4/07/05
Land Pride
Assembly Instructions
■
Exhaust Modification (S/N 440719-)All Trekers with S/N 440719 and below will need theexhaust system replaced when installing the CVT SealedKit. There are two mufflers used on Trekers built beforeS/N 440719. See Figure 2 to determine which muffler yourTreker is equipped with.
Refer to Figure 21. Remove 5/16" lock nut (#3), 5/16" flat washer (#5) and
5/16" x 3/4" hex head cap screws (#2). Save forreattaching the new muffler.
2. Disconnect extension springs (#6) and remove muffler(#7), exhaust sock (#10) and exhaust sock clamps(#11) together as one unit.
3. (For S/N 421412- only) Remove muffler support stand(#1) from Treker frame.
4. Unscrew M8 flanged hex nuts (#4) and remove enginemanifold (#8).
5. Remove exhaust gaskets (#9). Make certain thegaskets are completely scraped from engine exhaustports before reinstalling new exhaust gaskets.
Exhaust Removal (For Trekers With S/N 440719-)Figure 2
34/07/05 Manual No. 701-097M
Assembly Instructions
Land Pride
■
Refer to Figure 3:6. Position two new exhaust manifold gaskets (#7) over
the engine exhaust ports and install exhaust manifold(#9). Secure with four new M8 hex flange nuts (#4).Tighten nuts to 12 ft. lbs of torque.
7. Install new muffler (#8) to Treker frame with twoexisting 5/16" x 3/4" hex head bolts (#2), 5/16" flatwashers (#5) and 5/16" hex lock nuts (#3). Tightenlock nuts to 17 ft. lbs. of torque.
8. Install two new extension springs (#6) to exhaustmanifold (#7) and muffler (#8) as shown.
9. Exhaust heat shield (#10) and self-tapping hex headscrews (#1) will be installed later.
Exhaust Modification (S/N 440720+)All Trekers with S/N 440720 and above do not require anew exhaust system. The heat shield will require removalbefore the existing CVT shield can be removed.Refer to Figure 4:1. Remove two #8 x 1/2" hex screws (#1) from the
exhaust heat shield (#2). Remove exhaust heat shieldand store for reattachment.
Exhaust Heat Shield RemovalFigure 4
22401
New Exhaust Installation (For Trekers With S/N 440719-)Figure 3
4 Manual No. 701-097M 4/07/05
Land Pride
Assembly Instructions
■
CVT Shield RemovalRefer to Figure 5 on page 4:1. Remove two M8 x 1.25 x20 hex bolts (#4), 5/16" lock
washer (#11) and 5/16" flat washers (#10). Removeone M8 x 1.25 x 10 hex bolt (#6) and oneTrans-axle bolt (#13) from existing CVT cover (#16).
2. Remove CVT cover (#16).
3. Replace trans-axle bolt (#13) and tighten to 25-35 ft.lbs. of torque.
4. Remove 3/8" x 3 1/2" hex bolt (#7), lock washer (#8)and CVT adapter (#17) from CVT drive pulley (#14).
5. Remove 1/2" x 2" hex bolt (#5) and flat washer (#9)from CVT driven pulley.
IMPORTANT: Pulley flanges will bend and nick easilyif handled roughly. Always handle pulleys gently toprevent damage.
6. Carefully remove CVT pulleys (#14 & #15) and CVTbelt (#12). Gently place pulleys on a flat protectedsurface such as cardboard or plywood.
7. Make certain the CVT spacer (#1) and all shims (#18)remain on the engine output shaft.
8. Remove 3/16" x 1/4" x 2 1/2" long key (#3) from enginedrive shaft.
9. Remove 3/16" sq. x 3" long key (#2) from trans-axledriven shaft.
IMPORTANT: Keep pulleys for reinstallation if Trekerserial number is 437154+. Do not reuse existingpulleys if the Treker serial number is 437153-.
CVT Drive RemovalFigure 5
22403
54/07/05 Manual No. 701-097M
Assembly Instructions
Land Pride
■
Fan Installation (S/N 437154+)All Trekers with S/N 437154 and above will require theexisting drive pulley modification to include a fan.
Refer to Figure 6:
1. Bend locking tabs on locking ring (#4) down.
2. Remove three existing 1/4" x 3/4" hex head screws(#1), locking ring (#5) and 1/4" flat washers (#2).
3. Discard flat washers and locking ring. Keep 1/4" boltsfor reuse.
Refer to Figure 7:4. Install new Fan (#3) with fins pointing out away from
pulley (#2) as shown.
5. Install new locking ring (#4) with bent-up locking tabspointing away from the pulley as shown.
6. Secure fan to pulley with existing 1/4" x 3/4" hex headbolts (#1). Tighten bolts to 8 ft. lbs. of torque.
7. Bend locking tabs on locking ring (#4) up around hexhead bolts to prevent bolts from backing out.
IMPORTANT: Pulley flanges will bend and nick easilyif handled roughly. Handle clutch assembly pulleygently to prevent damage.
Lock Ring Removal (For Trekers With S/N 437154+)Figure 6
Fan Assembly to Clutch (For Trekers With S/N 437154+)Figure 7
22418a
22418
6 Manual No. 701-097M 4/07/05
Land Pride
Assembly Instructions
■
CVT Inner Shield InstallationRefer to Figure 8:1. Remove two trans-axle nuts (#1) and save for step 2.
Engine Drive Shaft and Trans-Axle Driven ShaftFigure 8
22407
Inner CVT Shield InstallationFigure 9
22415
Refer to Figure 9:2. Install trans-axle inner shield mounting bracket (#4) to
trans-axle as shown. Secure with existing 1/4" hexnuts (#9) and tighten to 5.6 ft.lbs. of torque.
3. Be careful not to remove spacer (#1) and shims (#12)from the engine output shaft. Keys (#5) & (#6) will beinstalled later.
4. Install gasket (#13) over engine output shaft asshown.
5. Place CVT inner shield (#2) over trans-axle input shaftand engine output shaft as shown.
6. Secure CVT inner shield to engine block with sealplate (#3) and four 5/16" x 3/4" hex socket screws (#7).Do not tighten bolts.
7. Secure CVT inner shield to trans-axle shaft with four5/16" x 1" hex bolts (#8), neoprene plated washers(#11) and flanged nylock nuts (#10) as shown. Do nottighten nuts.
8. Center CVT inner shield over trans-axle input shaftand tighten the four flanged nylock nuts (#10) to17 ft.lbs. of torque. Tighten all four hex socket screws(#7) to 13 ft. lbs. of torque.
IMPORTANT: Neoprene on washer (#11) in step 6 isplaced against the inner shield.
74/07/05 Manual No. 701-097M
Assembly Instructions
Land Pride
■
CVT Pulley and Belt InstallationRefer to Figure 10:1. Make certain the CVT spacer (#1) and shims (#12)
are still on the shaft. (Spacer and shims are formaintaining drive and driven pulley alignment.)
2. Install 3/16" x 1/4" x 2 1/2" long key (#3) to engineoutput shaft.
3. Install CVT Drive pulley (#10) to engine output shaftas shown.
4. Insert CVT adapter (#13) into drive pulley (#10).Secure pulley to engine shaft with 3/8" x 3 1/2" hexbolt (#5) and 3/8" lock washer (#6). Torque hex bolt to35 ft. lbs.
5. Install 3/16" sq. x 3" long key (#2) to trans-axle inputshaft.
6. Install CVT driven pulley (#11) to the trans-axle inputshaft as shown.
IMPORTANT: Use existing pulleys and belt if Trekerserial number is 437154+. Use pulleys and beltprovided with the installation kit if Treker serialnumber is 437153-.
7. Secure driven pulley (#11) to trans-axle input shaftwith 1/2" x 2" hex bolt (#4), 1/2" lock washer (#7) and1/2" flat washer (#8). Torque hex bolt to 85 ft. lbs.
8. Make certain the front and back of the back rightwheel is chocked, ignition key is removed and clutch isin neutral. Release park brake and spin driven pulley(#11) by hand to verify that it does not catch on anyobjects while rotating.
! DANGER!Ignition key should be turned off and removed beforeturning belt onto pulley or engine could start and causebodily injury.
! WARNING!Keep hands, fingers and clothing away from pinch pointareas such as where the belt contacts the pulley. Seriousbodily injury can result from getting caught in the belt.
9. Install CVT belt (#9) over drive pulley (#10) and thenover driven pulley (#11). Turn driven pulley by hand towalk belt onto pulley.
Pulley and belt InstallationFigure 10
22415a
8 Manual No. 701-097M 4/07/05
Land Pride
Assembly Instructions
■
CVT Outer Shield InstallationRefer to Figure 11:1. Being careful not to scratch the gasket edge of the
new outer shield (#2), mate outer shield to innershield. Secure in place with twelve 1/4" x 3/4" screws(#1). Do not tighten until all screws are installed.Tighten each screw to 5.6 ft. lbs. of torque.
Outer Shield InstallationFigure 11
CVT Venting InstallationRefer to Figure 12:1. Press air inlet duct (#9) over CVT outer shield (#8)
opening as shown.
2. Slip two worm drive hose clamps (#3) over the inletduct (#9). Do not tighten.
3. Insert air intake filter (#12) into air intake snorkel(#11).
4. Install air intake snorkel (#11) into the open end of airinlet duct (#9) and position air intake snorkel on top ofTreker firewall panel (#1) as shown.
5. Secure air intake snorkel (#11) to the treker firewallpanel (#1) by driving two 1/4" x 3/4" hex head self-tapping drive screws (#4) into the panel’s flange asshown.
6. Tighten worm drive hose clamps (#3) to secure airinlet duct (#9) to outer shield (#8) and to intake snorkel(#11).
7. Press air outlet duct (#10) over CVT outer shield (#8)opening with hose opening pointing down as shown.
22415b
8. Slip worm drive hose clamp (#3) over air outlet duct(#10) and tighten.
9. Press drain cap (#6) over 7/8" drain opening andsecure with 1" hose spring clamp (#2).
CVT Venting InstallationFigure 12
Final AssemblyRefer to Figure 12:1. Install exhaust heat shield (#7) to exhaust pipe as
shown. Secure with two existing #8 x 1/2" hex screws(#5) and tighten.
Refer to Figure 1 on page 1:2. Reattach side panel (#1) with five 1/4" Phillip head
machine screws (#2) and 1/4" hex flange lock nuts(#3). Tighten lock nuts to 6 ft. lbs. of torque.
3. Remove blocking supporting the Treker bed in the upposition and lower the bed.
4. Set the Treker park brake, place Treker in gear andremove blocking on both sides of the Treker back rightwheel.
22407
94/07/05 Manual No. 701-097M
Listing of Parts
Land Pride
Listing of PartsKit No. 701-095A ENCLOSURE, CVT ST (S/N 440720+)
1 700-228S ASSEMBLY, CVT INNER COVER1 700-285D PLATE, ENGINE SEAL1 700-286D BRACKET, CVT COVER TO TRANS.1 701-097M ST MANUAL, CVT ENCLOSURE KIT1 800-235C SPRING CLAMP 1" OD HOSE3 800-259C CLAMP WORM DRIVE #36SS (1.81-2.75)2 801-174C HEX HEAD DRILL SCREW 1/4" x 3/4" LG12 801-180C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE4 801-197C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK4 802-159C HEX HEAD CAP SCREW 5/16"-18 x 1" GR54 803-177C NUT HEX LOCK 5/16" -18 FLANGE4 804-135C WASHER FLAT 5/16" NEOPRENE PLATE1 817-621C CAP, DRAIN 7/8" OD PORT1 826-475C CVT COOLING FAN1 826-483C RING, LOCKING TAB1 840-218C COVER, CVT ENCLOSURE OUTER1 840-239C DUCT, CVT AIR INLET1 840-240C DUCT, CVT AIR OUTLET1 840-266C SNORKEL AIR INTAKE1 840-268C FILTER, AIR INTAKE
Qty. Part No. Part Description
■
10 Manual No. 701-097M 4/07/05
Land Pride
Listing of Parts
■
Kit No. 701-105A ENCLOSURE, CVT ST (S/N 437154 to 440719)
1 700-228S ASSEMBLY, CVT INNER COVER1 700-285D PLATE, ENGINE SEAL1 700-286D BRACKET, CVT COVER TO TRANS.1 701-097M ST MANUAL, CVT ENCLOSURE KIT1 800-235C SPRING CLAMP 1" OD HOSE3 800-259C CLAMP WORM DRIVE #36SS (1.81-2.75)2 801-174C HEX HEAD DRILL SCREW 1/4" x 3/4" LG12 801-180C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE2 801-193C SCREW HEX #8 X 1/2 SELF TAP4 801-197C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK4 802-159C HEX HEAD CAP SCREW 5/16"-18 x 1" GR54 803-177C NUT HEX LOCK 5/16" -18 FLANGE4 803-220C NUT HEX FLANGE M8 x 1.25" PLT4 804-135C WASHER FLAT 5/16" NEOPRENE PLATE2 807-219C SPRING EXTENSION .5" OD x 1.68" LG x .08" W1 817-621C CAP, DRAIN 7/8" OD PORT1 826-475C CVT COOLING FAN1 826-483C RING, LOCKING TAB2 839-383C GASKET MUFFLER HONDA 20HP1 839-401C HONDA 20 HP ENGINE MUFFLER1 839-402C HONDA 20 HP ENGINE MANIFOLD1 839-403C EXHAUST HEAT SHEILD 20 HP1 840-218C COVER, CVT ENCLOSURE OUTER1 840-239C DUCT, CVT AIR INLET1 840-240C DUCT, CVT AIR OUTLET1 840-266C SNORKEL AIR INTAKE1 840-268C FILTER, AIR INTAKE
Qty. Part No. Part Description
114/07/05 Manual No. 701-097M
Listing of Parts
Land Pride
■
Kit No. 701-107A ENCLOSURE, CVT ST (S/N 437153-)
1 700-228S ASSEMBLY, CVT INNER COVER1 700-285D PLATE, ENGINE SEAL1 700-286D BRACKET, CVT COVER TO TRANS.1 701-097M ST MANUAL, CVT ENCLOSURE KIT1 800-235C SPRING CLAMP 1" OD HOSE3 800-259C CLAMP WORM DRIVE #36SS (1.81-2.75)2 801-174C HEX HEAD DRILL SCREW 1/4" x 3/4" LG12 801-180C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE2 801-193C SCREW HEX #8 X 1/2 SELF TAP4 801-197C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK4 802-159C HEX HEAD CAP SCREW 5/16"-18 x 1" GR54 803-177C NUT HEX LOCK 5/16" -18 FLANGE4 803-220C NUT HEX FLANGE M8 x 1.25" PLT4 804-135C WASHER FLAT 5/16" NEOPRENE PLATE2 807-219C SPRING EXTENSION .5" OD x 1.68" LG x .08" W1 816-464C BELT CVT TRUCK1 817-621C CAP, DRAIN 7/8 OD PORT1 826-445C CVT DRIVEN TRUCK 9 1/2" OD1 826-474C CVT, 780 DIVEER WITH FAN2 839-383C GASKET MUFFLER HONDA 20HP1 839-401C HONDA 20 HP ENGINE MUFFLER1 839-402C HONDA 20 HP ENGINE MANIFOLD1 839-403C EXHAUST HEAT SHEILD 20 HP1 840-P218C COVER, CVT ENCLOSURE 1vpOUTER1 840-239C DUCT, CVT AIR INLET1 840-240C DUCT, CVT AIR OUTLET1 840-266C SNORKEL AIR INTAKE1 840-268C FILTER, AIR INTAKE
Qty. Part No. Part Description
Corporate Office: P.O. Box 5060Salina, Kansas 67402-5060 USA
www.landpride.com
1© Copyright 2005 Printed 4/07/05 Manual No. 701-097M
Before You Start
These optional assembly instructions contain onlyinformation required to assemble the CVT Enclosure tothe ST Series Treker. A detailed Operator’s Manual wassupplied with the Treker. Refer to the Operator’s Manualfor additional specific information especially informationrelating to safety concerns. Also included in the Operator’sManual is important information on operation, adjustment,troubleshooting, and maintenance for this attachment(some manual sections do not apply to all options).A separate Parts Manual for replacement parts can bepurchased from your dealer or available free of charge atwww.landpride.com. Have model and serial numbershandy when placing an order.
Manual Part Numbers:• Treker Operator’s Manual . . . . . . . . . . . . 700-108M• Treker Parts Manual. . . . . . . . . . . . . . . . . 700-108P
General InformationThese assembly instructions apply to the following CVTEnclosure kit options listed below:701-095A Treker ST Series (S/N 44720+)701-105A Treker ST Series (S/N 437154 to 440719)701-107A Treker ST Series (S/N 437153-)
Assembly InstructionsA detailed listing of parts for kit no’s 701-095A, 701-105Aand 701-107A are provided on pages 9, 10 and 11. Usethe list that is for your ST Treker as a checklist to inventoryparts received.
When you see this symbol, the subsequentinstructions and warnings are serious - followwithout exception. Your life and the lives ofothers depend on it!
!Initial Preparations
! CAUTION!Securely support cargo box in the up position to preventinjury when working under the cargo box.
1. Park vehicle on a flat surface, move gear shift lever toneutral, set park brake, and chock front and back ofthe right rear wheel to prevent the vehicle from rolling.
2. Raise cargo box fully up and securely support it in theup position to prevent injury while working around theengine.
3. Turn off engine and remove ignition key.
Left Side Panel DetachmentThe fuse box on the left side panel can interfere withremoving and assembling the CVT enclosure. It is simplerto detach the side panel from the frame than to detach thefuse box.Refer to Figure 1:1. Remove five 1/4" hex flange lock nuts (#3) and 1/4"
Phillip head machine screws (#2) and let the sidepanel hang from the wiring harness along side theTreker frame.
2. Lift side panel (#1) with fuse box and wiring harnessout of the way when removing and installing drivelinecomponents that interfere with the fuse box.
Side Panel RemovalFigure 1
22416
Treker 4200/4400 ST Series Manual No. 701-097M
CVT Enclosure KitAssembly Instructions
2 Manual No. 701-097M 4/07/05
Land Pride
Assembly Instructions
■
Exhaust Modification (S/N 440719-)All Trekers with S/N 440719 and below will need theexhaust system replaced when installing the CVT SealedKit. There are two mufflers used on Trekers built beforeS/N 440719. See Figure 2 to determine which muffler yourTreker is equipped with.
Refer to Figure 21. Remove 5/16" lock nut (#3), 5/16" flat washer (#5) and
5/16" x 3/4" hex head cap screws (#2). Save forreattaching the new muffler.
2. Disconnect extension springs (#6) and remove muffler(#7), exhaust sock (#10) and exhaust sock clamps(#11) together as one unit.
3. (For S/N 421412- only) Remove muffler support stand(#1) from Treker frame.
4. Unscrew M8 flanged hex nuts (#4) and remove enginemanifold (#8).
5. Remove exhaust gaskets (#9). Make certain thegaskets are completely scraped from engine exhaustports before reinstalling new exhaust gaskets.
Exhaust Removal (For Trekers With S/N 440719-)Figure 2
34/07/05 Manual No. 701-097M
Assembly Instructions
Land Pride
■
Refer to Figure 3:6. Position two new exhaust manifold gaskets (#7) over
the engine exhaust ports and install exhaust manifold(#9). Secure with four new M8 hex flange nuts (#4).Tighten nuts to 12 ft. lbs of torque.
7. Install new muffler (#8) to Treker frame with twoexisting 5/16" x 3/4" hex head bolts (#2), 5/16" flatwashers (#5) and 5/16" hex lock nuts (#3). Tightenlock nuts to 17 ft. lbs. of torque.
8. Install two new extension springs (#6) to exhaustmanifold (#7) and muffler (#8) as shown.
9. Exhaust heat shield (#10) and self-tapping hex headscrews (#1) will be installed later.
Exhaust Modification (S/N 440720+)All Trekers with S/N 440720 and above do not require anew exhaust system. The heat shield will require removalbefore the existing CVT shield can be removed.Refer to Figure 4:1. Remove two #8 x 1/2" hex screws (#1) from the
exhaust heat shield (#2). Remove exhaust heat shieldand store for reattachment.
Exhaust Heat Shield RemovalFigure 4
22401
New Exhaust Installation (For Trekers With S/N 440719-)Figure 3
4 Manual No. 701-097M 4/07/05
Land Pride
Assembly Instructions
■
CVT Shield RemovalRefer to Figure 5 on page 4:1. Remove two M8 x 1.25 x20 hex bolts (#4), 5/16" lock
washer (#11) and 5/16" flat washers (#10). Removeone M8 x 1.25 x 10 hex bolt (#6) and oneTrans-axle bolt (#13) from existing CVT cover (#16).
2. Remove CVT cover (#16).
3. Replace trans-axle bolt (#13) and tighten to 25-35 ft.lbs. of torque.
4. Remove 3/8" x 3 1/2" hex bolt (#7), lock washer (#8)and CVT adapter (#17) from CVT drive pulley (#14).
5. Remove 1/2" x 2" hex bolt (#5) and flat washer (#9)from CVT driven pulley.
IMPORTANT: Pulley flanges will bend and nick easilyif handled roughly. Always handle pulleys gently toprevent damage.
6. Carefully remove CVT pulleys (#14 & #15) and CVTbelt (#12). Gently place pulleys on a flat protectedsurface such as cardboard or plywood.
7. Make certain the CVT spacer (#1) and all shims (#18)remain on the engine output shaft.
8. Remove 3/16" x 1/4" x 2 1/2" long key (#3) from enginedrive shaft.
9. Remove 3/16" sq. x 3" long key (#2) from trans-axledriven shaft.
IMPORTANT: Keep pulleys for reinstallation if Trekerserial number is 437154+. Do not reuse existingpulleys if the Treker serial number is 437153-.
CVT Drive RemovalFigure 5
22403
54/07/05 Manual No. 701-097M
Assembly Instructions
Land Pride
■
Fan Installation (S/N 437154+)All Trekers with S/N 437154 and above will require theexisting drive pulley modification to include a fan.
Refer to Figure 6:
1. Bend locking tabs on locking ring (#4) down.
2. Remove three existing 1/4" x 3/4" hex head screws(#1), locking ring (#5) and 1/4" flat washers (#2).
3. Discard flat washers and locking ring. Keep 1/4" boltsfor reuse.
Refer to Figure 7:4. Install new Fan (#3) with fins pointing out away from
pulley (#2) as shown.
5. Install new locking ring (#4) with bent-up locking tabspointing away from the pulley as shown.
6. Secure fan to pulley with existing 1/4" x 3/4" hex headbolts (#1). Tighten bolts to 8 ft. lbs. of torque.
7. Bend locking tabs on locking ring (#4) up around hexhead bolts to prevent bolts from backing out.
IMPORTANT: Pulley flanges will bend and nick easilyif handled roughly. Handle clutch assembly pulleygently to prevent damage.
Lock Ring Removal (For Trekers With S/N 437154+)Figure 6
Fan Assembly to Clutch (For Trekers With S/N 437154+)Figure 7
22418a
22418
6 Manual No. 701-097M 4/07/05
Land Pride
Assembly Instructions
■
CVT Inner Shield InstallationRefer to Figure 8:1. Remove two trans-axle nuts (#1) and save for step 2.
Engine Drive Shaft and Trans-Axle Driven ShaftFigure 8
22407
Inner CVT Shield InstallationFigure 9
22415
Refer to Figure 9:2. Install trans-axle inner shield mounting bracket (#4) to
trans-axle as shown. Secure with existing 1/4" hexnuts (#9) and tighten to 5.6 ft.lbs. of torque.
3. Be careful not to remove spacer (#1) and shims (#12)from the engine output shaft. Keys (#5) & (#6) will beinstalled later.
4. Install gasket (#13) over engine output shaft asshown.
5. Place CVT inner shield (#2) over trans-axle input shaftand engine output shaft as shown.
6. Secure CVT inner shield to engine block with sealplate (#3) and four 5/16" x 3/4" hex socket screws (#7).Do not tighten bolts.
7. Secure CVT inner shield to trans-axle shaft with four5/16" x 1" hex bolts (#8), neoprene plated washers(#11) and flanged nylock nuts (#10) as shown. Do nottighten nuts.
8. Center CVT inner shield over trans-axle input shaftand tighten the four flanged nylock nuts (#10) to17 ft.lbs. of torque. Tighten all four hex socket screws(#7) to 13 ft. lbs. of torque.
IMPORTANT: Neoprene on washer (#11) in step 6 isplaced against the inner shield.
74/07/05 Manual No. 701-097M
Assembly Instructions
Land Pride
■
CVT Pulley and Belt InstallationRefer to Figure 10:1. Make certain the CVT spacer (#1) and shims (#12)
are still on the shaft. (Spacer and shims are formaintaining drive and driven pulley alignment.)
2. Install 3/16" x 1/4" x 2 1/2" long key (#3) to engineoutput shaft.
3. Install CVT Drive pulley (#10) to engine output shaftas shown.
4. Insert CVT adapter (#13) into drive pulley (#10).Secure pulley to engine shaft with 3/8" x 3 1/2" hexbolt (#5) and 3/8" lock washer (#6). Torque hex bolt to35 ft. lbs.
5. Install 3/16" sq. x 3" long key (#2) to trans-axle inputshaft.
6. Install CVT driven pulley (#11) to the trans-axle inputshaft as shown.
IMPORTANT: Use existing pulleys and belt if Trekerserial number is 437154+. Use pulleys and beltprovided with the installation kit if Treker serialnumber is 437153-.
7. Secure driven pulley (#11) to trans-axle input shaftwith 1/2" x 2" hex bolt (#4), 1/2" lock washer (#7) and1/2" flat washer (#8). Torque hex bolt to 85 ft. lbs.
8. Make certain the front and back of the back rightwheel is chocked, ignition key is removed and clutch isin neutral. Release park brake and spin driven pulley(#11) by hand to verify that it does not catch on anyobjects while rotating.
! DANGER!Ignition key should be turned off and removed beforeturning belt onto pulley or engine could start and causebodily injury.
! WARNING!Keep hands, fingers and clothing away from pinch pointareas such as where the belt contacts the pulley. Seriousbodily injury can result from getting caught in the belt.
9. Install CVT belt (#9) over drive pulley (#10) and thenover driven pulley (#11). Turn driven pulley by hand towalk belt onto pulley.
Pulley and belt InstallationFigure 10
22415a
8 Manual No. 701-097M 4/07/05
Land Pride
Assembly Instructions
■
CVT Outer Shield InstallationRefer to Figure 11:1. Being careful not to scratch the gasket edge of the
new outer shield (#2), mate outer shield to innershield. Secure in place with twelve 1/4" x 3/4" screws(#1). Do not tighten until all screws are installed.Tighten each screw to 5.6 ft. lbs. of torque.
Outer Shield InstallationFigure 11
CVT Venting InstallationRefer to Figure 12:1. Press air inlet duct (#9) over CVT outer shield (#8)
opening as shown.
2. Slip two worm drive hose clamps (#3) over the inletduct (#9). Do not tighten.
3. Insert air intake filter (#12) into air intake snorkel(#11).
4. Install air intake snorkel (#11) into the open end of airinlet duct (#9) and position air intake snorkel on top ofTreker firewall panel (#1) as shown.
5. Secure air intake snorkel (#11) to the treker firewallpanel (#1) by driving two 1/4" x 3/4" hex head self-tapping drive screws (#4) into the panel’s flange asshown.
6. Tighten worm drive hose clamps (#3) to secure airinlet duct (#9) to outer shield (#8) and to intake snorkel(#11).
7. Press air outlet duct (#10) over CVT outer shield (#8)opening with hose opening pointing down as shown.
22415b
8. Slip worm drive hose clamp (#3) over air outlet duct(#10) and tighten.
9. Press drain cap (#6) over 7/8" drain opening andsecure with 1" hose spring clamp (#2).
CVT Venting InstallationFigure 12
Final AssemblyRefer to Figure 12:1. Install exhaust heat shield (#7) to exhaust pipe as
shown. Secure with two existing #8 x 1/2" hex screws(#5) and tighten.
Refer to Figure 1 on page 1:2. Reattach side panel (#1) with five 1/4" Phillip head
machine screws (#2) and 1/4" hex flange lock nuts(#3). Tighten lock nuts to 6 ft. lbs. of torque.
3. Remove blocking supporting the Treker bed in the upposition and lower the bed.
4. Set the Treker park brake, place Treker in gear andremove blocking on both sides of the Treker back rightwheel.
22407
94/07/05 Manual No. 701-097M
Listing of Parts
Land Pride
Listing of PartsKit No. 701-095A ENCLOSURE, CVT ST (S/N 440720+)
1 700-228S ASSEMBLY, CVT INNER COVER1 700-285D PLATE, ENGINE SEAL1 700-286D BRACKET, CVT COVER TO TRANS.1 701-097M ST MANUAL, CVT ENCLOSURE KIT1 800-235C SPRING CLAMP 1" OD HOSE3 800-259C CLAMP WORM DRIVE #36SS (1.81-2.75)2 801-174C HEX HEAD DRILL SCREW 1/4" x 3/4" LG12 801-180C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE4 801-197C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK4 802-159C HEX HEAD CAP SCREW 5/16"-18 x 1" GR54 803-177C NUT HEX LOCK 5/16" -18 FLANGE4 804-135C WASHER FLAT 5/16" NEOPRENE PLATE1 817-621C CAP, DRAIN 7/8" OD PORT1 826-475C CVT COOLING FAN1 826-483C RING, LOCKING TAB1 840-218C COVER, CVT ENCLOSURE OUTER1 840-239C DUCT, CVT AIR INLET1 840-240C DUCT, CVT AIR OUTLET1 840-266C SNORKEL AIR INTAKE1 840-268C FILTER, AIR INTAKE
Qty. Part No. Part Description
■
10 Manual No. 701-097M 4/07/05
Land Pride
Listing of Parts
■
Kit No. 701-105A ENCLOSURE, CVT ST (S/N 437154 to 440719)
1 700-228S ASSEMBLY, CVT INNER COVER1 700-285D PLATE, ENGINE SEAL1 700-286D BRACKET, CVT COVER TO TRANS.1 701-097M ST MANUAL, CVT ENCLOSURE KIT1 800-235C SPRING CLAMP 1" OD HOSE3 800-259C CLAMP WORM DRIVE #36SS (1.81-2.75)2 801-174C HEX HEAD DRILL SCREW 1/4" x 3/4" LG12 801-180C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE2 801-193C SCREW HEX #8 X 1/2 SELF TAP4 801-197C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK4 802-159C HEX HEAD CAP SCREW 5/16"-18 x 1" GR54 803-177C NUT HEX LOCK 5/16" -18 FLANGE4 803-220C NUT HEX FLANGE M8 x 1.25" PLT4 804-135C WASHER FLAT 5/16" NEOPRENE PLATE2 807-219C SPRING EXTENSION .5" OD x 1.68" LG x .08" W1 817-621C CAP, DRAIN 7/8" OD PORT1 826-475C CVT COOLING FAN1 826-483C RING, LOCKING TAB2 839-383C GASKET MUFFLER HONDA 20HP1 839-401C HONDA 20 HP ENGINE MUFFLER1 839-402C HONDA 20 HP ENGINE MANIFOLD1 839-403C EXHAUST HEAT SHEILD 20 HP1 840-218C COVER, CVT ENCLOSURE OUTER1 840-239C DUCT, CVT AIR INLET1 840-240C DUCT, CVT AIR OUTLET1 840-266C SNORKEL AIR INTAKE1 840-268C FILTER, AIR INTAKE
Qty. Part No. Part Description
114/07/05 Manual No. 701-097M
Listing of Parts
Land Pride
■
Kit No. 701-107A ENCLOSURE, CVT ST (S/N 437153-)
1 700-228S ASSEMBLY, CVT INNER COVER1 700-285D PLATE, ENGINE SEAL1 700-286D BRACKET, CVT COVER TO TRANS.1 701-097M ST MANUAL, CVT ENCLOSURE KIT1 800-235C SPRING CLAMP 1" OD HOSE3 800-259C CLAMP WORM DRIVE #36SS (1.81-2.75)2 801-174C HEX HEAD DRILL SCREW 1/4" x 3/4" LG12 801-180C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE2 801-193C SCREW HEX #8 X 1/2 SELF TAP4 801-197C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK4 802-159C HEX HEAD CAP SCREW 5/16"-18 x 1" GR54 803-177C NUT HEX LOCK 5/16" -18 FLANGE4 803-220C NUT HEX FLANGE M8 x 1.25" PLT4 804-135C WASHER FLAT 5/16" NEOPRENE PLATE2 807-219C SPRING EXTENSION .5" OD x 1.68" LG x .08" W1 816-464C BELT CVT TRUCK1 817-621C CAP, DRAIN 7/8 OD PORT1 826-445C CVT DRIVEN TRUCK 9 1/2" OD1 826-474C CVT, 780 DIVEER WITH FAN2 839-383C GASKET MUFFLER HONDA 20HP1 839-401C HONDA 20 HP ENGINE MUFFLER1 839-402C HONDA 20 HP ENGINE MANIFOLD1 839-403C EXHAUST HEAT SHEILD 20 HP1 840-P218C COVER, CVT ENCLOSURE 1vpOUTER1 840-239C DUCT, CVT AIR INLET1 840-240C DUCT, CVT AIR OUTLET1 840-266C SNORKEL AIR INTAKE1 840-268C FILTER, AIR INTAKE
Qty. Part No. Part Description
Corporate Office: P.O. Box 5060Salina, Kansas 67402-5060 USA
www.landpride.com