TrailMaster UTV Challenger 150 PARTS MANUAL
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- Κλήμης Αλεξίου
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1 TrailMaster UTV Challenger 150 PARTS MANUAL
2 FIG. 1 ENGINE CASE COMP. ENGINE CASE COMP RIGHT CASE BODY F DAMPING BUSHING CRANKCASE GASKET F LEFT CRANKCASE BODY F COLLAR F NEUTRAL POSITION LAMP ASSY F WASHER 10.2X18X F SMALL LEFT COVER F O-RING 108X F PIN F O-RING 6X OIL SEAL 19.8X30X GB/T16674 M6X18 BOLT M6X F DOWEL PIN 10X DRAIN PLUG M12X GB WASHER F COLLAR CHAIN PULL ROD DOWEL PIN 8X DOUBLE-END BOLT M8X DOUBLE-END BOLT M8X GB WASHER 8 4
3 1-23 GB6177 M8 NUT M GB/T16674 M6X50 BOLT M6X OIL SEAL 20X32X ENGINE OIL CLAPBOARD GB/T16674 M6X12 BOLT M6X12 2
4 FIG. 2 DRIVING GEAR COMP. DRIVING GEAR COMP F GEAR BOX COVER F DRIVE SHAFT F REVERSE SHAFT ASSY F SSA SHIFTING SHAFT ASSY F OUTPUT SHAFT F SDA SHIFTING DRUM ASSY F SHIFTING FORK F DECLUTCH SHIFT SHAFT F CLUTCH SHIFT SHAFT ASSY F GEAR BOX COVER GASKET F GEAR BOX AIR PIPE F GEAR BOX AIR NOZZLE GB/T308 Φ9.5 STEEL BALL Φ9.5 1 SHIFTING DRUM POSITIONING 157F SPRING F WASHER 14.2X22X1.3 1 SHIFTING DRUM POSITIONING 157F BOLT F CASE DRAIN NOZZLE DRAIN PLUG M12X GB WASHER 12 2
5 2-20 GB/T16674 M6X12 BOLT M6X F WASHER F DOWEL PIN 10X F ADJUST WASHER GB/T BEARING GB/T BEARING GB/T BEARING GB/T894.1 Φ20 SNAP RING Φ GB/T BEARING NEEDLE ROLLER BEARING GB/T5801 RNA RNA F DAMPING BUSHING F OIL SEAL 30X40X GB/T RZ BEARING RZ F ADJUST WASHER GB/T894.1 Φ25 SNAP RING Φ GB/T893.1 Φ52 SNAP RING Φ F DRIVE SPROCKET F SPROCKET LOCKING PLATE GB/T16674 M6X12 BOLT M6X F CABLE CLAMP GB5789 M6X40 BOLT M6X40 10
6 FIG. 3 SIDE COVER COMP. SIDE COVER COMP F LEFT CRANKCASE COVER F STARTING SHAFT ASSY STARTING RETURN SPRING F STARTING SHAFT BUSHING F O-RING 13.8X WASHER GB/T894.1 Φ14 SNAP RING Φ WASHER Φ F STARTING DRIVEN GEAR ASSY FRICTION SPRING GB/T RZ BEARING RZ F A STARTING FOOT BAR GB5789 M6X25 BOLT M6X F ASPIRATION CHANNEL A F ASPIRATION CHANNEL B F ASPIRATION CHANNEL CLIP GB/T16674 M6X40 BOLT M6X F LEFT CRANKCASE COVER GASKET 1
7 FIG. 4 RIGHT COVER COMP. RIGHT COVER COMP F RIGHT CASE COVER RIGHT CASE COVER GASKET OIL SCREEN SCREW PLUG OS OIL SCREEN OIL SCREEN SPRING OIL GAGE MAGNETO WIRE CLIP OIL SEAL 19.8X30X O-RING O-RING 18X DOWEL PIN 8X GB/T16674 M6X28 BOLT M6X GB/T16674 M6X95 BOLT M6X GB/T16674 M6X100 BOLT M6X GB/T16674 M6X110 BOLT M6X GB/T16674 M6X35 BOLT M6X GB/T16674 M6X25 BOLT M6X GB5783 M5X12 BOLT M5X12 2
8 FIG. 5 FAN / WIND GUIDE COVER FAN / WIND GUIDE COVER FAN VOLUTE ASSY A FAN COVER CLAPBOARD COOLING PIPE WIND GUIDE COVER ASSY. LOWER WIND GUIDE COVER ASSY. LOWER SEAL WIND GUIDE COVER ASSY. UPPER HIGH-VOLTAGE CABLE CLIP WIND GUIDE COVER ASSY. UPPER SEAL 1 GB/T TAPPING SCREW ST4.8X ST4.8X16 4 GB/T16674 BOLT M6X M6X25 3 GB845 TAPPING SCREW ST3.8X ST3.8X11 3
9 FIG. 6 ELECTRIC START SYSTEM ELECTRIC START SYSTEM OVERRUN CLUTCH ELECTRIC STARTING GEAR SHAFT STARTING GEAR GB/T16674 M6X16 BOLT M6X STARTING MOTOR 1
10 FIG. 7 SHIFTING CONTROL SYSTEM SHIFTING CONTROL SYSTEM F SHIFTING BAR ASSY F HANDLE ASSY GB5789 M6X25 BOLT M6X GB/T819 M6X20 COUNTERSUNK HEAD SCREW M6X F SHIFT POSITIONING PLATE GB5789 M6X12 BOLT M6X F GEARS BRIDGE PLATE F TORSION SPRING F BOSS BOLT F REVERSE LAMP ASSY GB/T818 M5X16 CROSS RECESS HEAD SCREW M5X GB/T SPRING WASHER 5 2
11 FIG. 9 CYLINDER COMP. CYLINDER COMP CYLINDER CYLINDER GASKET DOWEL PIN 10X CAS CHAIN ADJUSTER SPACER CHAIN ADJUSTER ASSY CHAIN GUILDER GB/T16674 M6X20 BOLT M6X20 1
12 FIG. 10 CYLINDER HEAD COMP. CYLINDER HEAD COMP CYLINDER HEAD SPARK PLUG(C7HSA NGK) CYLINDER HEAD GASKET INSULATOR SPACER CARBURETOR INSULATOR INTAKE TUBE ASSY INTAKE TUBE CLAMP COMP. 1 CYLINDER HEAD COVER RUBBER GASKET O-RING 27X CYLINDER HEAD BREATHER PIPE DOUBLE-END BOLT M6X DOUBLE-END BOLT M6X GB/T16674 M6X25 BOLT M6X GB6177 M6 NUT M CYLINDER HEAD COVER DOWEL PIN 10X GB/T16674 M6X100 BOLT M6X INTAKE VALVE 1
13 VALVE OIL SEAL VALVE SPRING SEAT VALVE SPRING VALVE SPRING RETAINER VALVE LOCKING CLAMP EXHAUST VALVE 1
14 FIG. 11 ENGINE OIL PUMP ENGINE OIL PUMP OIL PUMP CHAIN GB6177 M6 NUT M OIL PUMP SPROCKET GB/T16674 M6X25 BOLT M6X OIL PUMP ASSY. 1
15 FIG. 12 DRIVING WHEEL COMP. DRIVING WHEEL COMP F DRIVING WHEEL COMP. 1
16 FIG. 13 MAGNETOR MAGNETOR MAGNETO STATOR ASSY MAGNETO FLYING WHEEL ASSY FAN IMPELLER GB/T16674 M6X18 BOLT M6X18 4
17 FIG. 14 DRIVEN WHEEL COMP. DRIVEN WHEEL COMP CLUTCH COAT ASSY BELT DRIVEN WHEEL COMP. 1
18 FIG. 15 CRANKSHAFT / PISTON COMP. CRANKSHAFT / PISTON COMP F CRANKSHAFT GB6187 M12X1.25 SELF-LOCKING NUT M12X LOCKING NUT M22X WASHER 22X31X F RATCHET WHEEL F WASHER 15.2X25X GB6177 M12X1.25X11 NUT M12X1.25X WOODRUFF KEY 4X PISTON PING SNAP RING PISTON PING PISTON PISTON RING 1
19 FIG. 16 TIMING SYSTEM TIMING SYSTEM VALVE ADJUSTING NUT VALVE LASH ADJUSTING SCREW VALVE ROCKET EXHAUST VALVE ROCKER SHAFT CAMSHAFT DRIVING CHAIN CAMSHAFT COMP INTAKE VALVE ROCKER SHAFT STOPPING PLATE DOWEL PIN 10X CAMSHAFT FIXING BRACKET 1
20 FIG 17. FRAME/SEAT FRAME AND SEAT FRAME ROLL CAGE N Bolt BAR RAILING BAR RIGHT RAILING BAR LEFT R-WASHER LOCKING FLANGE NUT M TUBE SEAT U SEAT SUPPORT SHELF SAFETY BELT SEAT DRIVER SEAT SLIDER PASSENGER SEAT SLIDER 1
21 FIG.18 SUSPENSION ARM ASSEMBLY SUSPENSION ARM ASSEMBLY BOLT M10X1.25X LOWER SUSPENSION ARM DUST CAP U LOWER SUSPENSION ARM COLLAR 8
22 LOWER SUSPENSION ARM BUSHING O-RING φ21.2x N000 LUBRICATING NIPPLE GB6187 M10X1.25 NUT GB6187 M U FRONT SHOCK MOUNT PLATE N CUSHION N HUB COLLAR U LEFT FRONT WHEEL SHAFT ASSY U RIGHT FRONT WHEEL SHAFT ASSY BOLT M10X1.25X FRONT SHOCK MOUNT ADJUSTING U PLATE BOLT M10X1.25X N CUSHION BUSH FRONT LOWER SUSPENSION ARM U ASSY.L FRONT UPPER SUSPENSION ARM U ASSY.L BOLT M10X1.25X REAR SHOCK ASSY FRONT LOWER SUSPENSION ARM 58750N ASSY.R FRONT UPPER SUSPENSION ARM U ASSY.R BOLT M10X1.25X55 2
23 FIG.19 REAR SWING ARM ASSY. UPPER REAR SWING ARM ASSY. UPPER LOCKING FLANGE NUT M ENGINE MOUNT LINK WASHER ENGINE MOUNT LINK CUSHION ENGINE MOUNT LINK SPACER ENGINE MOUNT LINK COLLAR FLAT WASHER NUT M ENGINE MOUNT BOLT PLATE LOCKING FLANGE NUT M BOLT M6X16 1
24 LOCKING FLANGE NUT. M BOLT M10X1.25X ENGINE MOUNT BOLT PLATE COLLAR PAN SCREW M6X SCREW CAP BATTERY BOX COVER REAR SWING ARM ASSY. UPPER FLANGE BOLT M12X1.25X LOCKING FLANGE NUT M U SWING ARM DOG BONE CON'ROD BUSH CON'ROD SPACER BOLT M8X BOLT M10X1.25X ENGINE MOUNT COLLAR PARKING BRAKE LEVER ASSY REVERSE LEVER COVER FLANGE BOLT M8X1.25X CABLE SPRING FLANGE BOLT M8X1.25X FLAT WASHER PAN SCREW M5X LOCKING FLANGE NUT M TOW BALL LOCKING WASHER BOLT M16X2X25 1
25 FIG. 20 ENGING/MUFLER/AIR CLEANER ENGING/MUFLER/AIR CLEANER U 150U SHIFT HOISE ASSY GK REVERSE CABLE FIXED PLATE LOCKING NUT M BOLT M6X GK SHIFT DISC BOLT M6x BOLT M8X AIR CLEANER CLAMP AIR CLEANER ASSY PD24J CARBURETOR XRS 150 ENGINE 1
26 XRS MUFFLER RACK SUPPORT BOLT M6X BOLT M8X MCE MUFFLER COMP XRS BOLT CLAMP XRS SIDE CASE BOLT MUFFLER JOINT NUT M EX. PIPE GASKET AIR CLEANER CASE COMP SCREW ST5X AIR FILTER ELEMENT AIR FILTER COVER XRS REAR CHAIN PROTECTOR AIR CLEANER CLIP AIR CLEANER DUCT NUT M BOLT M8X BOLT M18X GK ENGINE MOUNT PLATE FRONT AIR CLEANER MOUNT PLATE REAR AIR CLEANER MOUNT PLATE EMBRACE HOOP FOR MUFFLER N000 MUFFLER SPRING WASHER GB G000 MUFFLER RUBBER CUSHION 1
27 FIG 21 REAR SWING ARM REAR SWING ARM ASSY FLANGE BOLT M10X1.25X LOCKING FLANGE NUT M CUSHION ASSY. RR BOLT STRAP M8X1.25X FLANGE BOLT M8X1.25X FLANGE BOLT M6X LOCKING NUT M SPRING WAHSER BOLT STRAP M8X1.25X G000 SWING ARM BUSH SWING ARM COLLAR XRS CHAIN. DISC GUARD RR, LOWER SWING ARM COMP LOCKING FLANGE NUT M SWING ARM CUSHION BUSHING BOLT M12X1.25X60 2
28 FIG. 22 REAR HOUSING REAR HOUSING BOLT-WASHER M8X1.25X RR. BRAKE DISC LOCKING FLANGE NUT M XRS REAR AXLE XRS DRIVE CHAIN REAR SPROCKET BOLT-WASHER M8X1.25X DUST SEAL 50X RR. AXLE BRG HOUSING COMP RS BEARING BEARING BASE BOLT-WASHER M8X1.25X DUST SEAL 42X TIRE BOLT. M10X1.25X XRS REAR AXLE HUB GT REAR WHEEL ASSY. R GT TIRE. RR 21X RIM. RR LUG NUT CAP M RR. WHEEL SPACER. φ16 2
29 CASTLE NUT.M GB COTTER PIN φ4x HUB COVER REAR WHEEL ASSY. L CHAIN MASTER LINK TIRE VALVE 2
30 FIG. 23 FRONT WHEEL SYSTEM FRONT WHEEL SYSTEM BOLT STRAP M6X GT FR. WHEEL ASSY. R FR. DISC. BRAKE YF DUST SEAL 47* RS BEARING TIRE BOLT. M10X1.25X XRS FR. WHEEL HUB RS BEARING 6202-Z LOCKING FLANGE NUT M CASTLE NUT M GB COTTER PIN 3X HUB COVER GT FR. WHEEL ASSY. L. 1
31 FIG. 24 BRAKE ASSY. BRAKE ASSY U BRAKE ASSY N BRAKE MASTER CYLINDER FRONT BRAKE CALIPER R FRONT BRAKE CALIPER L FRONT BRAKE PAD SET 2
32 BRAKE CALIPER ASSY. RR REAR BRAKE PAD SET U LEFT FRONT BRAKE HOSE U RITHT FRONT BRAKE HOSE U REAR BRAKE HOSE BRAKE PIN SPINDLE NUT M U BRAKE LIGHT SWITCH 1
33 FIG. 25 STEERING SHAFT ASSY. STEERING SHAFT ASSY STEERING BOLT COVER BOLT M6X G000 STEERING SHAFT STEERING WHEEL BUSH STEERING SHAFT BALL JOINT DUST COVER TILT STEERING LOCKING BUSHING 2
34 25-9 GB5782 BOLT M WASHER φ U steering link JOINT BOLT M8X U STEERING ASSY U RIGHT TIE ROD k000 SSTEERING ROD END U LEFT TIE ROD N00S000 ROD END WASHER φ SPRING WASHER φ CASTLE NUT M10X GB COTTER PIN φ2.5x XRS TILT STEERING HOUSING LOCKING NUT M A ADJUSTING BOLT COLLAR BOLT M8X105 1
35 FIG. 26 FUEL TANK FUEL TANK fuel tank clamp big fuel tank clamp small fuel tank rubber strip L= fuel tank rubber strip L= U fuel tank U oil-out fuel tank cap fuel tank switch fuel oil vacuum pump petrol filter oil pipe 1 Φ6 L= oil pipe 2 Φ6 L= oil pipe 3 Φ6 L= oil pipe 4 Φ4.5 L= oil pipe 5 Φ4.5 L= oil pipe 6 Φ4.5 L= fule tank clamp big fule tank clamp small 6
36 FIG. 27 ELECTRICAL PARTS ELECTRICAL PARTS U WIRE HARENESS G000 CDI G000 IGNITION COIL G000 voltage regulator G000 starting relay G000 Flash apparatus 1
37 FIG. 28 PLASTIC PARTS PLASTIC PARTS front fender fake instrument instrument seat air window hood front guard left guard right guard footrest pedal seat baseboard left wheel arch right wheel arch back guard board tank toe-board pothook TRUNK rear fender chain wheel guard Snap 58
38 front light (with fog light) front light rear tail light left rear tail light right combination switch switch lock N light R light Plastic plug combination switch spare plate battery pull tie battery cushion battery 1
39 FIG. 29 THROTTLE AND BRAKE THROTTLE AND BRAKE CIRCLIP φ GB95 FLAT WASHER φ U THROTTLE PEDAL COMP U BRAKE PEDAL COMP N THROTTLE PEDAL RETURN SPRING N BRAKE PEDAL RETURN SPRING BOLT M6X U BRAKE PEDAL SHELF 1
- 1 - (FRAME PARTS ONLY)
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