CVT Enclosure Kit. Assembly Instructions ! CAUTION! Before You Start. General Information. Assembly Instructions

Transcription

1 CVT Enclosure Kit Assembly Instructions Treker 4200/4400 ST Series Manual No M Before You Start! When you see this symbol, the subsequent instructions and warnings are serious - follow without exception. Your life and the lives of others depend on it! These optional assembly instructions contain only information required to assemble the CVT Enclosure to the ST Series Treker. A detailed Operator s Manual was supplied with the Treker. Refer to the Operator s Manual for additional specific information especially information relating to safety concerns. Also included in the Operator s Manual 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 be purchased from your dealer or available free of charge at Have model and serial numbers handy when placing an order. Manual Part Numbers: Treker Operator s Manual M Treker Parts Manual P General Information These assembly instructions apply to the following CVT Enclosure kit options listed below: A Treker ST Series (S/N ) A Treker ST Series (S/N to ) A Treker ST Series (S/N ) Assembly Instructions A detailed listing of parts for kit no s A, A and A are provided on pages 9, 10 and 11. Use the list that is for your ST Treker as a checklist to inventory parts received. Initial Preparations! CAUTION! Securely support cargo box in the up position to prevent injury when working under the cargo box. 1. Park vehicle on a flat surface, move gear shift lever to neutral, set park brake, and chock front and back of the right rear wheel to prevent the vehicle from rolling. 2. Raise cargo box fully up and securely support it in the up position to prevent injury while working around the engine. 3. Turn off engine and remove ignition key. Left Side Panel Detachment The fuse box on the left side panel can interfere with removing and assembling the CVT enclosure. It is simpler to detach the side panel from the frame than to detach the fuse 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 side panel hang from the wiring harness along side the Treker frame. 2. Lift side panel (#1) with fuse box and wiring harness out of the way when removing and installing driveline components that interfere with the fuse box Side Panel Removal Figure 1 Copyright 2005 Printed 4/07/05 Manual No M 1

2 Exhaust Modification (S/N ) All Trekers with S/N and below will need the exhaust system replaced when installing the CVT Sealed Kit. There are two mufflers used on Trekers built before S/N See Figure 2 to determine which muffler your Treker is equipped with. Refer to Figure 2 1. Remove 5/16" lock nut (#3), 5/16" flat washer (#5) and 5/16" x 3/4" hex head cap screws (#2). Save for reattaching 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 only) Remove muffler support stand (#1) from Treker frame. 4. Unscrew M8 flanged hex nuts (#4) and remove engine manifold (#8). 5. Remove exhaust gaskets (#9). Make certain the gaskets are completely scraped from engine exhaust ports before reinstalling new exhaust gaskets. Exhaust Removal (For Trekers With S/N ) Figure 2 2 Manual No M 4/07/05

3 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 two existing 5/16" x 3/4" hex head bolts (#2), 5/16" flat washers (#5) and 5/16" hex lock nuts (#3). Tighten lock nuts to 17 ft. lbs. of torque. 8. Install two new extension springs (#6) to exhaust manifold (#7) and muffler (#8) as shown. 9. Exhaust heat shield (#10) and self-tapping hex head screws (#1) will be installed later. Exhaust Modification (S/N ) All Trekers with S/N and above do not require a new exhaust system. The heat shield will require removal before 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 shield and store for reattachment. Exhaust Heat Shield Removal Figure New Exhaust Installation (For Trekers With S/N ) Figure 3 4/07/05 Manual No M 3

4 CVT Shield Removal Refer 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). Remove one M8 x 1.25 x 10 hex bolt (#6) and one Trans-axle bolt (#13) from existing CVT cover (#16). 2. Remove CVT cover (#16). 3. Replace trans-axle bolt (#13) and tighten to 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. 6. Carefully remove CVT pulleys (#14 & #15) and CVT belt (#12). Gently place pulleys on a flat protected surface such as cardboard or plywood. IMPORTANT: Keep pulleys for reinstallation if Treker serial number is Do not reuse existing pulleys if the Treker serial number is 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 engine drive shaft. 9. Remove 3/16" sq. x 3" long key (#2) from trans-axle driven shaft. IMPORTANT: Pulley flanges will bend and nick easily if handled roughly. Always handle pulleys gently to prevent damage CVT Drive Removal Figure 5 4 Manual No M 4/07/05

5 Fan Installation (S/N ) All Trekers with S/N and above will require the existing drive pulley modification to include a fan. Refer to Figure 6: IMPORTANT: Pulley flanges will bend and nick easily if handled roughly. Handle clutch assembly pulley gently to prevent damage. 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" bolts for reuse a Lock Ring Removal (For Trekers With S/N ) Figure 6 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 tabs pointing away from the pulley as shown. 6. Secure fan to pulley with existing 1/4" x 3/4" hex head bolts (#1). Tighten bolts to 8 ft. lbs. of torque. 7. Bend locking tabs on locking ring (#4) up around hex head bolts to prevent bolts from backing out Fan Assembly to Clutch (For Trekers With S/N ) Figure 7 4/07/05 Manual No M 5

6 CVT Inner Shield Installation Refer to Figure 8: 1. Remove two trans-axle nuts (#1) and save for step 2. Refer to Figure 9: 2. Install trans-axle inner shield mounting bracket (#4) to trans-axle as shown. Secure with existing 1/4" hex nuts (#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 be installed later. 4. Install gasket (#13) over engine output shaft as shown. 5. Place CVT inner shield (#2) over trans-axle input shaft and engine output shaft as shown. 6. Secure CVT inner shield to engine block with seal plate (#3) and four 5/16" x 3/4" hex socket screws (#7). Do not tighten bolts. IMPORTANT: Neoprene on washer (#11) in step 6 is placed against the inner shield. Engine Drive Shaft and Trans-Axle Driven Shaft Figure Secure CVT inner shield to trans-axle shaft with four 5/16" x 1" hex bolts (#8), neoprene plated washers (#11) and flanged nylock nuts (#10) as shown. Do not tighten nuts. 8. Center CVT inner shield over trans-axle input shaft and tighten the four flanged nylock nuts (#10) to 17 ft.lbs. of torque. Tighten all four hex socket screws (#7) to 13 ft. lbs. of torque Inner CVT Shield Installation Figure 9 6 Manual No M 4/07/05

7 CVT Pulley and Belt Installation Refer to Figure 10: 1. Make certain the CVT spacer (#1) and shims (#12) are still on the shaft. (Spacer and shims are for maintaining drive and driven pulley alignment.) 2. Install 3/16" x 1/4" x 2 1/2" long key (#3) to engine output shaft. IMPORTANT: Use existing pulleys and belt if Treker serial number is Use pulleys and belt provided with the installation kit if Treker serial number is Install CVT Drive pulley (#10) to engine output shaft as shown. 4. Insert CVT adapter (#13) into drive pulley (#10). Secure pulley to engine shaft with 3/8" x 3 1/2" hex bolt (#5) and 3/8" lock washer (#6). Torque hex bolt to 35 ft. lbs. 5. Install 3/16" sq. x 3" long key (#2) to trans-axle input shaft. 6. Install CVT driven pulley (#11) to the trans-axle input shaft as shown. 7. Secure driven pulley (#11) to trans-axle input shaft with 1/2" x 2" hex bolt (#4), 1/2" lock washer (#7) and 1/2" flat washer (#8). Torque hex bolt to 85 ft. lbs. 8. Make certain the front and back of the back right wheel is chocked, ignition key is removed and clutch is in neutral. Release park brake and spin driven pulley (#11) by hand to verify that it does not catch on any objects while rotating.! DANGER! Ignition key should be turned off and removed before turning belt onto pulley or engine could start and cause bodily injury.! WARNING! Keep hands, fingers and clothing away from pinch point areas such as where the belt contacts the pulley. Serious bodily injury can result from getting caught in the belt. 9. Install CVT belt (#9) over drive pulley (#10) and then over driven pulley (#11). Turn driven pulley by hand to walk belt onto pulley a Pulley and belt Installation Figure 10 4/07/05 Manual No M 7

8 CVT Outer Shield Installation Refer to Figure 11: 1. Being careful not to scratch the gasket edge of the new outer shield (#2), mate outer shield to inner shield. 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. 8. Slip worm drive hose clamp (#3) over air outlet duct (#10) and tighten. 9. Press drain cap (#6) over 7/8" drain opening and secure with 1" hose spring clamp (#2) b Outer Shield Installation Figure 11 CVT Venting Installation Refer 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 inlet duct (#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 air inlet duct (#9) and position air intake snorkel on top of Treker firewall panel (#1) as shown. 5. Secure air intake snorkel (#11) to the treker firewall panel (#1) by driving two 1/4" x 3/4" hex head selftapping drive screws (#4) into the panel s flange as shown. 6. Tighten worm drive hose clamps (#3) to secure air inlet 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. CVT Venting Installation Figure Final Assembly Refer 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 up position and lower the bed. 4. Set the Treker park brake, place Treker in gear and remove blocking on both sides of the Treker back right wheel. 8 Manual No M 4/07/05

9 Listing of Parts Listing of Parts Kit No A ENCLOSURE, CVT ST (S/N ) Qty. Part No. Part Description S ASSEMBLY, CVT INNER COVER D PLATE, ENGINE SEAL D BRACKET, CVT COVER TO TRANS M ST MANUAL, CVT ENCLOSURE KIT C SPRING CLAMP 1" OD HOSE C CLAMP WORM DRIVE #36SS ( ) C HEX HEAD DRILL SCREW 1/4" x 3/4" LG C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK C HEX HEAD CAP SCREW 5/16"-18 x 1" GR C NUT HEX LOCK 5/16" -18 FLANGE C WASHER FLAT 5/16" NEOPRENE PLATE C CAP, DRAIN 7/8" OD PORT C CVT COOLING FAN C RING, LOCKING TAB C COVER, CVT ENCLOSURE OUTER C DUCT, CVT AIR INLET C DUCT, CVT AIR OUTLET C SNORKEL AIR INTAKE C FILTER, AIR INTAKE 4/07/05 Manual No M 9

10 Listing of Parts Kit No A ENCLOSURE, CVT ST (S/N to ) Qty. Part No. Part Description S ASSEMBLY, CVT INNER COVER D PLATE, ENGINE SEAL D BRACKET, CVT COVER TO TRANS M ST MANUAL, CVT ENCLOSURE KIT C SPRING CLAMP 1" OD HOSE C CLAMP WORM DRIVE #36SS ( ) C HEX HEAD DRILL SCREW 1/4" x 3/4" LG C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE C SCREW HEX #8 X 1/2 SELF TAP C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK C HEX HEAD CAP SCREW 5/16"-18 x 1" GR C NUT HEX LOCK 5/16" -18 FLANGE C NUT HEX FLANGE M8 x 1.25" PLT C WASHER FLAT 5/16" NEOPRENE PLATE C SPRING EXTENSION.5" OD x 1.68" LG x.08" W C CAP, DRAIN 7/8" OD PORT C CVT COOLING FAN C RING, LOCKING TAB C GASKET MUFFLER HONDA 20HP C HONDA 20 HP ENGINE MUFFLER C HONDA 20 HP ENGINE MANIFOLD C EXHAUST HEAT SHEILD 20 HP C COVER, CVT ENCLOSURE OUTER C DUCT, CVT AIR INLET C DUCT, CVT AIR OUTLET C SNORKEL AIR INTAKE C FILTER, AIR INTAKE 10 Manual No M 4/07/05

11 Listing of Parts Kit No A ENCLOSURE, CVT ST (S/N ) Qty. Part No. Part Description S ASSEMBLY, CVT INNER COVER D PLATE, ENGINE SEAL D BRACKET, CVT COVER TO TRANS M ST MANUAL, CVT ENCLOSURE KIT C SPRING CLAMP 1" OD HOSE C CLAMP WORM DRIVE #36SS ( ) C HEX HEAD DRILL SCREW 1/4" x 3/4" LG C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE C SCREW HEX #8 X 1/2 SELF TAP C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK C HEX HEAD CAP SCREW 5/16"-18 x 1" GR C NUT HEX LOCK 5/16" -18 FLANGE C NUT HEX FLANGE M8 x 1.25" PLT C WASHER FLAT 5/16" NEOPRENE PLATE C SPRING EXTENSION.5" OD x 1.68" LG x.08" W C BELT CVT TRUCK C CAP, DRAIN 7/8 OD PORT C CVT DRIVEN TRUCK 9 1/2" OD C CVT, 780 DIVEER WITH FAN C GASKET MUFFLER HONDA 20HP C HONDA 20 HP ENGINE MUFFLER C HONDA 20 HP ENGINE MANIFOLD C EXHAUST HEAT SHEILD 20 HP P218C COVER, CVT ENCLOSURE 1vpOUTER C DUCT, CVT AIR INLET C DUCT, CVT AIR OUTLET C SNORKEL AIR INTAKE C FILTER, AIR INTAKE 4/07/05 Manual No M 11

12 Corporate Office: P.O. Box 5060 Salina, Kansas USA

13 CVT Enclosure Kit Assembly Instructions Treker 4200/4400 ST Series Manual No M Before You Start! When you see this symbol, the subsequent instructions and warnings are serious - follow without exception. Your life and the lives of others depend on it! These optional assembly instructions contain only information required to assemble the CVT Enclosure to the ST Series Treker. A detailed Operator s Manual was supplied with the Treker. Refer to the Operator s Manual for additional specific information especially information relating to safety concerns. Also included in the Operator s Manual 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 be purchased from your dealer or available free of charge at Have model and serial numbers handy when placing an order. Manual Part Numbers: Treker Operator s Manual M Treker Parts Manual P General Information These assembly instructions apply to the following CVT Enclosure kit options listed below: A Treker ST Series (S/N ) A Treker ST Series (S/N to ) A Treker ST Series (S/N ) Assembly Instructions A detailed listing of parts for kit no s A, A and A are provided on pages 9, 10 and 11. Use the list that is for your ST Treker as a checklist to inventory parts received. Initial Preparations! CAUTION! Securely support cargo box in the up position to prevent injury when working under the cargo box. 1. Park vehicle on a flat surface, move gear shift lever to neutral, set park brake, and chock front and back of the right rear wheel to prevent the vehicle from rolling. 2. Raise cargo box fully up and securely support it in the up position to prevent injury while working around the engine. 3. Turn off engine and remove ignition key. Left Side Panel Detachment The fuse box on the left side panel can interfere with removing and assembling the CVT enclosure. It is simpler to detach the side panel from the frame than to detach the fuse 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 side panel hang from the wiring harness along side the Treker frame. 2. Lift side panel (#1) with fuse box and wiring harness out of the way when removing and installing driveline components that interfere with the fuse box Side Panel Removal Figure 1 Copyright 2005 Printed 4/07/05 Manual No M 1

14 Exhaust Modification (S/N ) All Trekers with S/N and below will need the exhaust system replaced when installing the CVT Sealed Kit. There are two mufflers used on Trekers built before S/N See Figure 2 to determine which muffler your Treker is equipped with. Refer to Figure 2 1. Remove 5/16" lock nut (#3), 5/16" flat washer (#5) and 5/16" x 3/4" hex head cap screws (#2). Save for reattaching 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 only) Remove muffler support stand (#1) from Treker frame. 4. Unscrew M8 flanged hex nuts (#4) and remove engine manifold (#8). 5. Remove exhaust gaskets (#9). Make certain the gaskets are completely scraped from engine exhaust ports before reinstalling new exhaust gaskets. Exhaust Removal (For Trekers With S/N ) Figure 2 2 Manual No M 4/07/05

15 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 two existing 5/16" x 3/4" hex head bolts (#2), 5/16" flat washers (#5) and 5/16" hex lock nuts (#3). Tighten lock nuts to 17 ft. lbs. of torque. 8. Install two new extension springs (#6) to exhaust manifold (#7) and muffler (#8) as shown. 9. Exhaust heat shield (#10) and self-tapping hex head screws (#1) will be installed later. Exhaust Modification (S/N ) All Trekers with S/N and above do not require a new exhaust system. The heat shield will require removal before 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 shield and store for reattachment. Exhaust Heat Shield Removal Figure New Exhaust Installation (For Trekers With S/N ) Figure 3 4/07/05 Manual No M 3

16 CVT Shield Removal Refer 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). Remove one M8 x 1.25 x 10 hex bolt (#6) and one Trans-axle bolt (#13) from existing CVT cover (#16). 2. Remove CVT cover (#16). 3. Replace trans-axle bolt (#13) and tighten to 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. 6. Carefully remove CVT pulleys (#14 & #15) and CVT belt (#12). Gently place pulleys on a flat protected surface such as cardboard or plywood. IMPORTANT: Keep pulleys for reinstallation if Treker serial number is Do not reuse existing pulleys if the Treker serial number is 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 engine drive shaft. 9. Remove 3/16" sq. x 3" long key (#2) from trans-axle driven shaft. IMPORTANT: Pulley flanges will bend and nick easily if handled roughly. Always handle pulleys gently to prevent damage CVT Drive Removal Figure 5 4 Manual No M 4/07/05

17 Fan Installation (S/N ) All Trekers with S/N and above will require the existing drive pulley modification to include a fan. Refer to Figure 6: IMPORTANT: Pulley flanges will bend and nick easily if handled roughly. Handle clutch assembly pulley gently to prevent damage. 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" bolts for reuse a Lock Ring Removal (For Trekers With S/N ) Figure 6 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 tabs pointing away from the pulley as shown. 6. Secure fan to pulley with existing 1/4" x 3/4" hex head bolts (#1). Tighten bolts to 8 ft. lbs. of torque. 7. Bend locking tabs on locking ring (#4) up around hex head bolts to prevent bolts from backing out Fan Assembly to Clutch (For Trekers With S/N ) Figure 7 4/07/05 Manual No M 5

18 CVT Inner Shield Installation Refer to Figure 8: 1. Remove two trans-axle nuts (#1) and save for step 2. Refer to Figure 9: 2. Install trans-axle inner shield mounting bracket (#4) to trans-axle as shown. Secure with existing 1/4" hex nuts (#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 be installed later. 4. Install gasket (#13) over engine output shaft as shown. 5. Place CVT inner shield (#2) over trans-axle input shaft and engine output shaft as shown. 6. Secure CVT inner shield to engine block with seal plate (#3) and four 5/16" x 3/4" hex socket screws (#7). Do not tighten bolts. IMPORTANT: Neoprene on washer (#11) in step 6 is placed against the inner shield. Engine Drive Shaft and Trans-Axle Driven Shaft Figure Secure CVT inner shield to trans-axle shaft with four 5/16" x 1" hex bolts (#8), neoprene plated washers (#11) and flanged nylock nuts (#10) as shown. Do not tighten nuts. 8. Center CVT inner shield over trans-axle input shaft and tighten the four flanged nylock nuts (#10) to 17 ft.lbs. of torque. Tighten all four hex socket screws (#7) to 13 ft. lbs. of torque Inner CVT Shield Installation Figure 9 6 Manual No M 4/07/05

19 CVT Pulley and Belt Installation Refer to Figure 10: 1. Make certain the CVT spacer (#1) and shims (#12) are still on the shaft. (Spacer and shims are for maintaining drive and driven pulley alignment.) 2. Install 3/16" x 1/4" x 2 1/2" long key (#3) to engine output shaft. IMPORTANT: Use existing pulleys and belt if Treker serial number is Use pulleys and belt provided with the installation kit if Treker serial number is Install CVT Drive pulley (#10) to engine output shaft as shown. 4. Insert CVT adapter (#13) into drive pulley (#10). Secure pulley to engine shaft with 3/8" x 3 1/2" hex bolt (#5) and 3/8" lock washer (#6). Torque hex bolt to 35 ft. lbs. 5. Install 3/16" sq. x 3" long key (#2) to trans-axle input shaft. 6. Install CVT driven pulley (#11) to the trans-axle input shaft as shown. 7. Secure driven pulley (#11) to trans-axle input shaft with 1/2" x 2" hex bolt (#4), 1/2" lock washer (#7) and 1/2" flat washer (#8). Torque hex bolt to 85 ft. lbs. 8. Make certain the front and back of the back right wheel is chocked, ignition key is removed and clutch is in neutral. Release park brake and spin driven pulley (#11) by hand to verify that it does not catch on any objects while rotating.! DANGER! Ignition key should be turned off and removed before turning belt onto pulley or engine could start and cause bodily injury.! WARNING! Keep hands, fingers and clothing away from pinch point areas such as where the belt contacts the pulley. Serious bodily injury can result from getting caught in the belt. 9. Install CVT belt (#9) over drive pulley (#10) and then over driven pulley (#11). Turn driven pulley by hand to walk belt onto pulley a Pulley and belt Installation Figure 10 4/07/05 Manual No M 7

20 CVT Outer Shield Installation Refer to Figure 11: 1. Being careful not to scratch the gasket edge of the new outer shield (#2), mate outer shield to inner shield. 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. 8. Slip worm drive hose clamp (#3) over air outlet duct (#10) and tighten. 9. Press drain cap (#6) over 7/8" drain opening and secure with 1" hose spring clamp (#2) b Outer Shield Installation Figure 11 CVT Venting Installation Refer 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 inlet duct (#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 air inlet duct (#9) and position air intake snorkel on top of Treker firewall panel (#1) as shown. 5. Secure air intake snorkel (#11) to the treker firewall panel (#1) by driving two 1/4" x 3/4" hex head selftapping drive screws (#4) into the panel s flange as shown. 6. Tighten worm drive hose clamps (#3) to secure air inlet 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. CVT Venting Installation Figure Final Assembly Refer 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 up position and lower the bed. 4. Set the Treker park brake, place Treker in gear and remove blocking on both sides of the Treker back right wheel. 8 Manual No M 4/07/05

21 Listing of Parts Listing of Parts Kit No A ENCLOSURE, CVT ST (S/N ) Qty. Part No. Part Description S ASSEMBLY, CVT INNER COVER D PLATE, ENGINE SEAL D BRACKET, CVT COVER TO TRANS M ST MANUAL, CVT ENCLOSURE KIT C SPRING CLAMP 1" OD HOSE C CLAMP WORM DRIVE #36SS ( ) C HEX HEAD DRILL SCREW 1/4" x 3/4" LG C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK C HEX HEAD CAP SCREW 5/16"-18 x 1" GR C NUT HEX LOCK 5/16" -18 FLANGE C WASHER FLAT 5/16" NEOPRENE PLATE C CAP, DRAIN 7/8" OD PORT C CVT COOLING FAN C RING, LOCKING TAB C COVER, CVT ENCLOSURE OUTER C DUCT, CVT AIR INLET C DUCT, CVT AIR OUTLET C SNORKEL AIR INTAKE C FILTER, AIR INTAKE 4/07/05 Manual No M 9

22 Listing of Parts Kit No A ENCLOSURE, CVT ST (S/N to ) Qty. Part No. Part Description S ASSEMBLY, CVT INNER COVER D PLATE, ENGINE SEAL D BRACKET, CVT COVER TO TRANS M ST MANUAL, CVT ENCLOSURE KIT C SPRING CLAMP 1" OD HOSE C CLAMP WORM DRIVE #36SS ( ) C HEX HEAD DRILL SCREW 1/4" x 3/4" LG C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE C SCREW HEX #8 X 1/2 SELF TAP C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK C HEX HEAD CAP SCREW 5/16"-18 x 1" GR C NUT HEX LOCK 5/16" -18 FLANGE C NUT HEX FLANGE M8 x 1.25" PLT C WASHER FLAT 5/16" NEOPRENE PLATE C SPRING EXTENSION.5" OD x 1.68" LG x.08" W C CAP, DRAIN 7/8" OD PORT C CVT COOLING FAN C RING, LOCKING TAB C GASKET MUFFLER HONDA 20HP C HONDA 20 HP ENGINE MUFFLER C HONDA 20 HP ENGINE MANIFOLD C EXHAUST HEAT SHEILD 20 HP C COVER, CVT ENCLOSURE OUTER C DUCT, CVT AIR INLET C DUCT, CVT AIR OUTLET C SNORKEL AIR INTAKE C FILTER, AIR INTAKE 10 Manual No M 4/07/05

23 Listing of Parts Kit No A ENCLOSURE, CVT ST (S/N ) Qty. Part No. Part Description S ASSEMBLY, CVT INNER COVER D PLATE, ENGINE SEAL D BRACKET, CVT COVER TO TRANS M ST MANUAL, CVT ENCLOSURE KIT C SPRING CLAMP 1" OD HOSE C CLAMP WORM DRIVE #36SS ( ) C HEX HEAD DRILL SCREW 1/4" x 3/4" LG C TRUSS PHILIPS HEAD MACHINE SCREW Y 1/4"-20 x 3/4" YELLOW DIE C SCREW HEX #8 X 1/2 SELF TAP C HEX SOCKET FLAT HEAD CAP SCREWS 5/16"-24 x 3/4", BLK C HEX HEAD CAP SCREW 5/16"-18 x 1" GR C NUT HEX LOCK 5/16" -18 FLANGE C NUT HEX FLANGE M8 x 1.25" PLT C WASHER FLAT 5/16" NEOPRENE PLATE C SPRING EXTENSION.5" OD x 1.68" LG x.08" W C BELT CVT TRUCK C CAP, DRAIN 7/8 OD PORT C CVT DRIVEN TRUCK 9 1/2" OD C CVT, 780 DIVEER WITH FAN C GASKET MUFFLER HONDA 20HP C HONDA 20 HP ENGINE MUFFLER C HONDA 20 HP ENGINE MANIFOLD C EXHAUST HEAT SHEILD 20 HP P218C COVER, CVT ENCLOSURE 1vpOUTER C DUCT, CVT AIR INLET C DUCT, CVT AIR OUTLET C SNORKEL AIR INTAKE C FILTER, AIR INTAKE 4/07/05 Manual No M 11

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