LCE/Residential Products Side By Side Off Road Utility Vehicle 500 EFI & 700 EFI Service Manual
FOREWORD This Toro Service Manual contains service, maintenance, and troubleshooting information for the 2015 Toro UTV500/ UTV700. The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
Table of Contents General Information ........................................................ 2 Fuel/Lubrication/Cooling............................................ 118 General Specifications.........................................................2 Torque Specifications ..........................................................3 Torque Conversions (ft-lb/N-m)............................................5 Gasoline - Oil - Lubricant.....................................................5 Genuine Parts.......
General Information NOTE: Some photographs and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. General Specifications MISCELLANY (front) 26 x 10R-14 (rear) 26 x 12R-14 Tire Inflation Pressure 1.12 kg/cm² (16 psi) - 500 1.41 kg/cm² (20 psi) - 700 Spark Plug Type NGK CR7E - 500 NGK CPR8E - 700 Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.) -500 0.5-0.6 mm (0.019-0.024 in.) - 700 Gas Tank Capacity 31 L (8.2 U.S. gal.) Coolant Capacity 2.
DRIVE TRAIN COMPONENTS CRANKSHAFT (500) Connecting Rod (small end) (max) 20.021 mm Connecting Rod (big end side-to-side) 0.7 mm (max) Connecting Rod (big end width) 21.95-22.00 mm Connecting Rod (small end deflection) 3.0 mm Part (max) Crankshaft (web-to-web) Crankshaft Runout 60.9 mm (max) 0.03 mm CRANKSHAFT 700) Connecting Rod (small end inside (max) 23.021 mm (diameter) Connecting Rod (big end side-to-side)(min) 0.6 mm Connecting Rod @ 150 mm (max) 0.
ENGINE/TRANSMISSION (700) ENGINE/TRANSMISSION (500) Part Part Bolted To Clutch Shoe** Crankshaft Clutch Cover/Housing Assembly Crankcase Crankcase Half (6 mm) Crankcase Half Crankcase Half (8 mm) Crankcase Half Cylinder Nut Crankcase Half Cylinder Head (Cap Screw) Crankcase Cylinder Head Nut Cylinder Cylinder Head Cover Cylinder Head Oil Pump Drive Gear** Crankshaft Driven Pulley Nut** Driveshaft Ground Wire Engine Rotor/Flywheel Nut Crankshaft Cam Sprocket** Camshaft Valve Adju
The recommended oil to use is Toro 0W-40 All Weather synthetic engine oil, which has been specifically formulated for use in this engine. Although Toro 0W-40 All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 0W-40 synthetic oil is acceptable. Torque Conversions (ft-lb/N-m) ft-lb 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 N-m 1.4 2.7 4.1 5.4 6.8 8.2 9.5 10.9 12.2 13.6 15 16.3 17.7 19 20.4 21.8 23.1 24.5 25.8 27.2 28.6 29.
. Fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant. Genuine Parts When replacement of parts is necessary, use only genuine Toro parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description. Special Tools 9.
Periodic Maintenance This section has been organized into sub-sections which show common maintenance procedures for the Toro ROV.
Lubrication Points Air Filter It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the components using the following list as reference. CAUTION A. Accelerator Pedal Pivot/Cable Ends Failure to inspect the air filter frequently if the vehicle is used in dusty, wet, or muddy conditions can damage the engine. B. Brake Pedal Pivot NOTE: To access the air filter, raise the cargo box. C. Shift Cable 1.
8. Squeeze the element to remove excess oil. 2. Rotate the crankshaft to the TDC position on the compression stroke. CAUTION A torn air filter can cause damage to the engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn. 9. Clean any dirt or debris from inside the filter housing. 10.
3. Install the spark plug; then install the timing inspection plug. 4. Place the two tappet covers with O-rings into position. Tighten the cap screws to 8 ft-lb. Testing Engine Compression Spark Plug A light brown insulator indicates that the plug is correct. A white or dark insulator indicates that the engine may need to be serviced. To maintain a hot, strong spark, keep the plug free of carbon.
HDX238A HDX242 2. Remove the muffler by pulling it rearward out of the vehicle. NOTE: If the screen or gasket is damaged in any 3. Remove the heat shield. way, it must be replaced. 6. Install the exhaust pipe/spark arrester assembly and secure with the three cap screws. Tighten to 6.8 N-m (60 in.-lb). 7. Install the heat shield and tighten the fasteners to 8.1 N-m (72 in.-lb). 8. Install the muffler and secure it to the exhaust pipe with the two springs. Engine/Transmission Oil Filter HDX241A 4.
7. Install the engine drain plug and tighten to 22 N-m (16 ft-lb). Pour the recommended oil in the fill hole (700) or oil level stick opening (500). Install the oil fill cap (700) or the oil level stick (500). 500 8. Start the engine (while the vehicle is outside on level ground) and allow it to idle for a few minutes. 9. Turn the engine off and wait approximately one minute. Check the oil level. The engine oil level must be within the operating range but not exceeding the upper mark. HDX234A 4.
3. Drain the lubricant into a drain pan by removing the drain plug from the front differential and rear drive. Headlight/TaillightBrakelight HEADLIGHT NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing. Skin oil residue on the bulb will shorten the life of the bulb.
2. Shift the transmission into park and observe that the (P) illuminates on the LCD gauge. ADJUSTING SHIFT CABLE 1. Place the transmission in park; then tilt the cargo box. 2. Make sure the shift lever is in park; then remove the E-clip securing the cable end to the shift arm stud. 0740-647 NOTE: There should be an average operating load on the vehicle when adjusting the headlight aim. 2. Measure the distance from the floor to the mid-point of each headlight. 3.
REAR 700 Hydraulic Brake System NOTE: This ROV is equipped with hydraulic brakes at all four wheels. CHECKING/BLEEDING The hydraulic brake system has been filled and bled at the factory. 1. With the master cylinder in a level position, check the fluid level in the reservoir. If the level in the reservoir is not above the MIN, add DOT 4 brake fluid. AF637D FRONT PR377C PR095 2. Depress the brake pedal several times to check for a firm brake. If the brake is not firm, the system must be bled.
CHECKING/REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thickness of each of the brake pads as follows. 1. Remove the wheel corresponding to the brake being checked. 2. Measure the thickness of each brake pad. PR377B 5.
1. Choose an area large enough to safely accelerate the vehicle to 30 mph and to brake to a stop. 2. Accelerate to 30 mph; then depress the brake pedal to decelerate to 0-5 mph. 3. Repeat procedure 20 times until brake pads are burnished. Checking/Replacing VBelt CD966A REMOVING 1. Remove the seat, seat back, and seat base; then remove the floor and gas tank. 4. Install one of the CVT cover cap screws into the driven pulley fixed face; then turn the cap screw clockwise to spread the pulley faces.
GZ085 CF379 NOTE: The arrows on the V-belt should point in NOTE: At this point, the CVT cover cap screw can direction of engine rotation (forward). be removed. 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the front shaft. Secure the drive face with a new nut. Using an appropriate spanner wrench, tighten the nut to 147 ftlb (500) or 165 ft-lb (700). 3.
Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and fullright capability. C. Steering assembly mounting bolts tight. HDX131A D. Ball joints not worn, cracked, or damaged. E. Tie rods not bent or cracked. Tie Rods F. Knuckles not worn, cracked, or damaged. G. Cotter pins not damaged or missing.
PR784 4. While holding the rack shaft with a wrench, tighten the tie rod joint to 37 ft-lb using an appropriate crowfoot. PR785A Steering Assembly REMOVING 1. Remove the right front wheel. 2. Remove the cotter pins and nuts securing the tie rod ends to the knuckles; then remove the tie rod ends from the knuckles. PR781 NOTE: Always attach the crow-foot to the torque wrench with the open end 90° to the torque wrench handle to ensure accurate torque application. PR301 3.
PR785 PR764A 4. Check boot clamps for security. 5. Check that the steering assembly operates smoothly with no binding from full-left to full-right position. 6. Inspect for grease seepage from the steering assembly. NOTE: The steering assembly (rack and pinion) is not repairable and must be replaced as an assembly; however, the tie rods and boots are replaceable. INSTALLING 1. From the left side, install the steering assembly (rack and pinion) to the frame assembly and secure with two cap screws.
PR764B PR759B 3. Install the cap screw in the intermediate shaft coupler and tighten to 31 ft-lb. 2. Install the steering shaft housing with steering shaft connecting the steering shaft and intermediate shaft first; then slide the housing into place on the steering support. 3. Secure the steering shaft housing to the frame with four cap screws and nuts. Tighten the 6 mm nuts to 8 ft-lb and the 8 mm nuts to 20 ft-lb. PR765A Intermediate Steering Shaft Assembly AT THIS POINT PR764B 4.
2. Inspect the bearing for pits, scoring, rusting, or premature wear. Steering Knuckles 3. Inspect the knuckle for cracks, breaks, or galling of the bearing surface. REMOVING AND DISASSEMBLING 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel. ! WARNING ASSEMBLING AND INSTALLING 1. Using a suitable press and driver, press the bearing into the knuckle until firmly seated; then install the snap ring.
PR203 PR256 3. Install the tie rod end and secure with the nut (coated with red Loctite #271). Tighten to 30 ft-lb; then install a new cotter pin and spread the pin. 7. Install a new cotter pin and secure by spreading as shown. NOTE: During assembling, new cotter pins should be installed. 4. Apply a small amount of grease to the hub splines. PR260 NOTE: If the hole in the axle shaft does not align with the slots in the castle nut, tighten the nut until the hole and slots align. PR290A 5.
Accelerator Pedal REMOVING Dislodge the throttle cable holding grommet from the actuator arm; then remove two torx-head screws and nuts securing the accelerator pedal assembly to the splash panel and remove the accelerator pedal. HDX166A PR709 HDX168A INSTALLING 1. Install the shift axle supports onto the shift lever; then secure the axle supports to the frame with four cap screws and tighten to 48 in.-lb.
2. Remove the nut securing the shift cable to the shift arm stud; then loosen the upper adjuster nut on the shift cable and remove the shift cable from the shifter assembly. HDX132A INSTALLING HDX166A 1. Route the cable into position making sure there are no kinks or sharp bends. 2. Install the cable housing onto the transmission holder; then connect the cable end to the shift arm and secure with the E-clip. 3.
10. Install the steering wheel boot support. PR762A 3. Remove the six screws securing the dash panel to the frame; then remove the shifter handle and shift lever boot. 4. Slide the dash panel to the rear sufficiently to access the components. PR762A 11. Install the steering boot onto the boot support. 12. Install the steering wheel; then with a drop of red Loctite #271 on the threads of the steering shaft, install the nut and tighten to 25 ft-lb. 13. Install the lock clip and steering wheel cover.
PR087A To adjust the wheel alignment, use the following procedure. 1. Center the steering wheel; then using an open-end wrench to hold the tie rod ends, loosen the right-side and left-side jam nuts. PR086 Front Bumper Assembly REMOVING Remove four cap screws and nuts. Account for four lock washers and eight flat washers. CLEANING AND INSPECTING 1. Clean all bumper components with hot, soapy water. 2. Inspect all welds for cracking or bending.
Fenders REMOVING Remove three torx-head screws securing each fender to the frame. Account for a stiffener bracket on the front fenders. PR332A 3. Finish removing the cap screws and flange nuts (from step 2); then remove the hood assembly. CLEANING AND INSPECTING 1. Clean all hood components with soap and water. 2. Inspect the hood for cracks and/or loose fasteners. 3. Inspect for any missing decals. INSTALLING PR311A 1.
PR163 TC045A NOTE: To aid in removing, insert a small wood 3. Remove the six sheet metal and three machine screws securing the dash assembly to the frame; then remove the shift lever grip and locking nut. block to hold in position. 4. Disconnect the gauge plug, dash harness, and park/seat belt indicator light connector and remove the dash assembly. 5. Slide the dash assembly rearward and off the steering shaft and shift lever assemblies. INSTALLING 1.
Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muffler/ exhaust pipe juncture. HDX257 2. Loosen but do not remove the four shoulder cap screws securing the pivot housings to the cargo box. PR131 2. Slide the muffler assembly clear of the holder pins. INSPECTING MUFFLER 1. Inspect muffler externally for cracks, holes, and dents. 2. Inspect the muffler internally by shaking the muffler back and forth and listening for rattles or loose debris inside the muffler.
INSTALLING Taillight Assembly REMOVING 1. Remove the cap screws and lock nuts securing the taillight assembly to the ROPS tube. 2. Disconnect the wire connector; then remove the socket assembly and remove the bulb. 1. Install the new bulb in the socket and place the socket assembly into the taillight housing. Twist clockwise to lock. 2. Connect the wire connector; then install on the ROPS tube and secure with two cap screws and lock nuts. Tighten securely. Seat INSPECTING 1.
Troubleshooting Problem: Handling too heavy or stiff Condition 1. 2. 3. 4. 5. Front wheel alignment incorrect Steering shaft binding Tire inflation pressure incorrect Tie rod ends seizing U-joints seized Problem: Steering oscillation Condition 1. 2. 3. 4. 5. 6. 7. 8.
NOTE: Toro recommends the use of new gaskets, Engine/Transmission lock nuts, and seals and lubricating all internal components when servicing the engine/ transmission. NOTE: A new ROV and an overhauled ROV engine This section has been organized into sub-sections which show a progression for the complete servicing of the Toro ROV engine/transmission. To service the center crankcase halves, the engine/transmission must be removed from the frame.
Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. 2. 3. 4. 5. 6. Valve clearance out of adjustment Valve guides worn Valves mistimed Piston rings worn - broken Cylinder bore worn Starter motor cranks too slowly - does not turn 1. 2. 3. 4. 5. 6. Adjust clearance Replace guides Retime engine Replace rings Replace cylinder See Electrical System Problem: Engine will not start or is hard to start (No spark) Condition Remedy 1. 2. 3. 4. 5. 6.
Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. 2. 3. 4. 5. 6. 7. Drive - driven bevel gears damaged - worn Backlash excessive Tooth contact improper Bearing damaged Gears worn - chipped Splines worn Final driven shaft thrust clearance too large Problem: Engine idles poorly Condition 1. 2. 3. 4. 5. 6. 7. 8. 9.
Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT If the technician’s objective is to service/replace rightside cover oil seals, front output joint oil seal, rear output joint oil seal, and/or the oil strainer (from beneath the engine/transmission), the engine/transmission does not have to be removed from the frame. HDX138A 6.
8. Loosen the clamp securing the throttle body to the intake manifold boot; then remove the throttle body and set aside. 700 9. From the left side, disconnect the ECT sensor connector, speed sensor connector, and spark plug cap. HDX251 NOTE: On the 500, shifting the transmission into park will aid in accessing the shift arm cap screw. HDX135A 11. Disconnect the starter cable from the starter; then remove the cap screw securing the engine/harness ground wires to the engine case. HDX137A 10.
15. Remove the two exhaust springs at the muffler; then remove the exhaust pipe. Account for a grafoil seal in the cylinder head and a grafoil seal at the muffler. HDX147A 13. Remove the forward heat shield from the exhaust pipe; then remove the cap screws securing the exhaust pipe to the cylinder head. HDX153A 16. Remove the cap screws securing the driveshafts to the front and rear engine flanges; then disconnect the upper and lower coolant hoses. HDX152A HDX158A HDX154 14.
Top-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT HDX157A To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not need to be removed from the frame for this procedure.
FI606A FI612 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1354A 3. Remove the cap screw from the tension adjuster; then using a flat-blade screwdriver, relax the cam chain tension by rotating the adjuster screw clockwise until it locks. FI613 NOTE: Care should be taken not to drop the C-ring down into the crankcase. FI607A MD1131 6. Noting the timing marks for installing purposes, drop the sprocket off the camshaft.
FI620 FI618A FI617A FI619A 7. Remove the cam chain tensioner pivot bolt and remove the chain tensioner; then remove the two nuts securing the cylinder head to the cylinder. 8. Remove the four cylinder head cap screws and washers. Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left (spark plug) side. FI616 CD211 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins.
12. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. FI623A AT THIS POINT To service valves and cylinder head, see Servicing TopSide Components sub-section. FI624A AT THIS POINT 10. Remove the cam chain guide. To service cylinder, see Servicing Top-Side Components sub-section. AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section.
NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install a connecting rod holder. CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result. AT THIS POINT To service piston, see Servicing Top-Side Components sub-section. AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components.
3. Install the valve springs with the painted end of the spring facing away from the cylinder head. NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. CC136D NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Guide (Bore) ATV-1011A 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer. 4.
CC400D ATV-1070 2. Remove each ring by working it toward the top of the piston while rotating it out of the groove. 2. Inspect and measure the connecting rod small end inside diameter. If the measurement exceeds specifications, the connecting rod must be replaced (see Center Crankcase Components in this section). NOTE: When installing new rings, install as a complete set only. Measuring Piston-Ring End Gap (Installed) 1. Place each piston ring in the wear portion of the cylinder.
Installing Piston Rings Cleaning/Inspecting Cylinder Head 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. CAUTION The cylinder head studs must be removed for this procedure. 1.
3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained.
ATV1013A 2. The lobe heights must be greater than minimum specifications. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. NOTE: If the journals are worn, replace the camshaft. Inspecting Camshaft Spring/Drive Pin CF060A 2. If damaged, the camshaft must be replaced. Installing Top-Side Components A. Piston B. Cylinder 1.
C. Cylinder Head/Camshaft D. Cylinder Head Cover/Rocker Arms NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. MD1344 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston.
10. With the timing inspection plug removed and the cam chain held tight, rotate the crankshaft until the piston is at top-dead-center. 11. While holding the cam chain to the front, install the rear cam chain tensioner guide into the cylinder head. Install the pivot cap screw and washer. Tighten to 11 ft-lb. MD1359 14. Place the C-ring into position in its groove in the cylinder head. CD383 12.
20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed downwards. 21. Place the cam chain tensioner assembly and gasket into the cylinder. Tighten to 10 ft-lb. 22. Using a flat-blade screwdriver, turn the tensioner screw counterclockwise to apply tension to the cam chain; then install the cap screw plug and washer and tighten securely. MD1363 CAUTION Care must be taken that the tab washer is installed correctly to cover the alignment hole on the sprocket.
FI602 FI538 29. Install the spark plug and tighten securely; then install the timing inspection plug. 2. Remove the water pump housing assembly noting the location of the longer cap screw. Account for a gasket and two alignment pins. Left-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.
4. Remove the water pump drive gear; then remove the speed sensor housing assembly. Account for two alignment pins, a gasket, and two seal washers. 8. Using the Magneto Rotor Remover Set, break the rotor/flywheel loose from the crankshaft; then remove the puller and crankshaft protector and remove the rotor/flywheel. FI543 FI550 5. Remove the cap screws securing the magneto cover to the crankcase. Note the location of the two internal cap screws and the two longer cap screws. 9.
Servicing Left-Side Components INSPECTING STARTER CLUTCH/ GEAR FI559 12. Remove the shift detent cam arm and spring. 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clockwise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. If it moves or locks up both ways, the starter clutch must be replaced. 2.
FI570 FI583 2. Thoroughly clean the rotor/flywheel; then install the new clutch and secure with the cap screws after applying a drop of red Loctite #271 to the threads. Tighten to 26 ft-lb using a crisscross pattern. Make sure the one-way bearing is installed with the notches directed away from the rotor/flywheel. 2. Thoroughly clean the gear hub; then apply a drop of green Loctite #620 to the bearing outer race and press into the gear hub until even with the lower chamfer radius.
REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sensor, and one cap screw from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor. Account for and note the position of the harness hold-down under the crankshaft position sensor. FI593 FI590 3.
MD1122 FI555A 2. Install the starter motor and tighten the two cap screws to 8 ft-lb. 7. Install the starter clutch gear onto the crankshaft; then install the rotor/flywheel key in the crankshaft. 3. Install the shift detent cam making sure the washer is installed. FI551A MD1086 4. Install the shift detent cam arm and spring. 5. Install the gear shift shaft assembly and washer making sure to align the alignment marks. 8. Install the rotor/flywheel and secure with the nut. Tighten to 107 ft-lb. C.
13. Connect the coolant hoses to the water pump and secure with the hose clamps. Tighten securely. Right-Side Components AT THIS POINT To service center crankcase components only, proceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove and FI547 11. Install two alignment pins and a gasket on the magneto cover; then install the water pump housing assembly. Tighten the cap screws to 8 ft-lb.
KC142A MD1036 3. Mark the movable drive face and the fixed drive face for installing purposes; then remove the nut holding the movable drive face onto the crankshaft. 5. Using a 6 mm cap screw threaded into the fixed driven face, spread the driven pulley by turning the cap screw clockwise; then remove the V-belt. MD1033 KC132 4. Remove the movable drive face and spacer. Account for the movable drive face rollers and outer drive face cover. 6. Remove the fixed drive face. MD1094 MD1035 7.
8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate. MD1286 12. Remove the left-hand threaded nut holding the centrifugal clutch assembly. MD1092 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the positions of the different-lengthed cap screws for installing purposes. CAUTION Care must be taken when removing the nut; it has “lefthand” threads. 10.
NOTE: Always use a new snap ring when installing the oil pump driven gear. 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. FI630 14. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT To service clutch components, see Servicing Right-Side Components sub-section. G. Oil Pump/Oil Strainer NOTE: Steps 1-17 in the preceding sub-sections must precede this procedure. MD1018 15. Remove oil pump drive gear. Account for the pin. 18.
MD1208 AT THIS POINT To service center crankcase components only, proceed to Separating Crankcase Halves. KC330 2. Place the clutch housing onto the clutch shoe/one-way clutch. NOTE: It will be necessary to rotate the clutch housing counterclockwise to properly seat the one-way clutch. Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE Inspect the clutch shoe for uneven wear, chips, cracks, or discoloration. If wear is present, replace the clutch assembly. KC331A 3.
DRIVEN PULLEY ASSEMBLY NOTE: The driven pulley assembly is a non-serviceable component and must be replaced as a complete assembly. Installing Right-Side Components A. Oil Strainer/Oil Pump MD1060 1. Place the oil strainer into position beneath the crankcase. Tighten the Phillips-head screws securely. 4.
9. Install two alignment pins and place the clutch cover gasket into position. Install the clutch cover. MD1017 MD1115 10. Tighten the clutch cover cap screws to 8 ft-lb. MD1018 7. Install the clutch shoe assembly on the crankshaft; then install the flange nut (left-hand thread) (coated with red Loctite #271). Tighten to 147 ft-lb. NOTE: The flat side of the flange nut should be directed towards the clutch shoe. CAUTION MD1117 11. Install the air intake plate.
MD1068 KC127 16. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft protrude through the cover plate, secure with the nut and tighten to 147 ft-lb. KC134 13. Slide the fixed drive face assembly onto the front shaft. 14. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approximately 3/4 in.
KC142A MD1012 19. If removed, install the brake pedal and tighten to 25 ft-lb. 2. Using Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins. Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and RightSide must precede this procedure.
FI639A FI641A 1. Remove the secondary driven shaft assembly (A) noting the location of the front and rear bearing locating pins and the center bearing locating ring. 3. Remove the driveshaft (C); then pull the shift fork locating shaft (D) out of the crankcase locating boss and allow the shift forks to disengage from the gear shift shaft (F). FI660A FI646 FI659A FI653A 4. Remove the gear shift shaft (F) noting the inner and outer washers. FI661A 2. Remove the reverse idler assembly (B).
5. Remove the countershaft assembly (E) along with the shift fork assembly. 8. Remove the secondary drive gear/secondary driven gear retaining nut. From inside the crankcase using a rubber mallet, drive out the output shaft assembly. Account for the output shaft, a shim, a washer, and the nut. AT THIS POINT To service crankshaft assembly, see Servicing Center Crankcase Components sub-section. Servicing Center Crankcase Components FI662 6.
Checking Tooth Contact Correcting Tooth Contact NOTE: After correcting backlash of the secondary NOTE: If tooth contact pattern is comparable to the driven bevel gear, it is necessary to check tooth contact. correct pattern illustration, no correction is necessary. 1. Remove the secondary driven output shaft assembly from the left-side crankcase half. If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the following chart. 2.
Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. H1-006 2. Acceptable width range must be within specifications. COUNTERSHAFT CAUTION CC289D 3. Acceptable gap range must be within specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2. Mount a dial indicator and base on the surface plate.
FI665 FI669 3. Remove the low driven gear washer; then remove the low driven gear along with the bearing and bushing. 5. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer. FI666 FI670 FI667 4. Remove the splined washer; then remove the circlip securing the high-low sliding dog. Remove the sliding dog. FI671 ASSEMBLING 1.
FI671A FI666 4. Place the reverse driven bushing (13) onto the shaft; then install the bearing (14), gear (15), and splined washer (16). Secure with a snap-ring. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7); then install the splined washer (8). FI665A FI668A FI664 3. Install the low driven bushing (10), bearing (9), and gear (11) on the countershaft; then install splined washer (12). 5.
FI662 MD1333 NOTE: The countershaft assembly is now ready to 3. Apply a liberal amount of oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place. be installed. Assembling Crankcase Half NOTE: For ease of assembly, install components on the right-side crankcase half. NOTE: If the output shaft was removed, make sure that the proper shim is installed. 1.
8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase. FI658 6. Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end, install in the crankcase. FI653A FI652A 7. Place the shift forks into position on the assembled countershaft and install into the crankshaft as an assembly. FI655A 9. Install the input driveshaft. FI646 FI662 10.
Joining Crankcase Halves 1. Verify that the two alignment pins (A) are in place and that both case halves are clean and grease free. Apply Loctite #5900 or suitable substitute sealant to the mating surfaces. Place the right-side half onto the left-side half. FI645 11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses; then install the center carrier bearing alignment Cring.
Servicing Engine (700) MD1008 4. From the left side, install the remaining crankcase cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws. Top-Side Components .................................................77 Removing Top-Side Components ................................77 Servicing Top-Side Components .................................81 Installing Top-Side Components..................................
CC001D CD211A NOTE: Keep the mounting hardware with the covers 5. Loosen the cap screw on the end of the tensioner; then remove the two cap screws securing the tensioner adjuster assembly and remove the assembly. Account for a gasket. for assembly purposes or thread them back into the head to keep them separated. 2. Remove the twelve cap screws securing the valve cover to the head. 3. Remove all cap screws except the two top-side cap screws next to the spark plug.
CC017D CC013D 8. While holding the chain, slide the sprocket and camshaft out of the cylinder head. NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. CC018D 11. Remove the four cylinder head bolts. 12. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide. FI620 9. Remove the cap screw securing the chain tensioner (account for a washer); then remove the tensioner.
CC022D CC025D C. Cylinder D. Piston NOTE: Steps 1-12 in the preceding sub-section must precede this procedure. 13. Loosen the clamp securing the coolant hose to the union; then detach the hose. 14. Remove the two nuts securing the cylinder to the crankcase. CC026D AT THIS POINT To service cylinder, see Servicing Top-Side Components sub-section. CAUTION When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston. 16.
2. Place the valve cover on a surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained.
NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. CC136D NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Guide (Bore) 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer. ATV-1011A 4.
CC400D ATV-1070 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only. Measuring Piston-Ring End Gap (Installed) 1.
Cleaning/Inspecting Cylinder Head CAUTION The cylinder head studs must be removed for this procedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert.
Inspecting Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications. CC141D Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2.
CC283D CF061A 2. Rotate the camshaft and note runout; maximum runout must not exceed specifications. Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height. CF060A 2. If damaged, the camshaft must be replaced. ATV1013A 2. The lobe heights must be greater than minimum specifications. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is Installing Top-Side Components A.
C. Cylinder Head D. Valve Cover NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 6. Place the chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. CF083 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston.
15. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface. If rotating the camshaft and sprocket is necessary for alignment, do not allow the crankshaft to rotate and be sure the cam lobes end up in the down position. CC272D 9.
ATV1027 CAUTION Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result. CD466 21. Place the C-ring into position in its groove in the cylinder head. 18. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft. Tighten only until snug. CC012D 22.
CD501 CD471 NOTE: The adjuster shaft will be drawn into the ten- 26. Loosen the four adjuster screw jam nuts; then loosen the four adjuster screws on the rocker arms in the valve cover. sioner as the adjuster screw is rotated clockwise. The adjuster shaft tension will be released in step 25. 24. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws. CC005D 27.
Removing Left-Side Components A. B. C. D. CC003D 30. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 29) to 8.5 ft-lb. 31. Adjust valve/tappet clearance (see Periodic Maintenance). 32. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten to 9 ft-lb. Outer Magneto Cover Water Pump Cover Rotor/Flywheel 1.
7. Using an appropriate side case puller, remove the side cover. Account for a gasket and two alignment pins. 8. Remove the nut securing the magneto rotor to the crankshaft; then install the magneto rotor puller adapter. NOTE: The puller has left-hand threads. 9. Using Magneto Rotor Remover Set and the appropriate crankshaft protector, remove the rotor/flywheel assembly from the crankshaft. Account for the key; then remove the starter clutch gear assembly and washer. CD136 CD140 PR441 11.
NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase. 13. Remove the shift shaft noting the timing marks for assembling purposes. Account for two washers. FI569 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly.
FI576A FI580 INSPECTING STATOR COIL/ MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wiring, broken or missing hold-down clips, or loose cap screws. 2. Inspect the bearings in the magneto housing for discoloration, roughness when rotated, and secure fit in bearing bores. REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR FI578 1.
FI595A CD949 NOTE: The sharp side of the snap ring should be facing outward. Installing Left-Side Components NOTE: Plug the oil passage in the crankcase hous- 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing outward as noted in removing); then secure with the snap ring. ing prior to installing the drive gear/driven gear assembly to prevent loss of an alignment pin. 1.
CD139 PR433A PR447A CD934 4. In order on the crankshaft, install a washer, ring gear, key, and the magneto rotor. Secure with the nut (coated with red Loctite #271). Tighten to 105 ft-lb. 6. Install the shift cam stopper, spring, and two washers (thick washer closest to the nut); then coat the threads on the mounting stud with red Loctite #271 and install the nut. Tighten to 8 ft-lb. CD948A PR434A NOTE: Rotate the shift cam plate to ensure it ratchets with no binding. 7.
CD954A GZ253 CD927A GZ254 8. Lubricate the magneto cover gasket with fresh engine oil; then place it into position on the two alignment pins. Make sure the outer shift shaft washer is in place. 13. Using a new gasket, install the speed sensor housing onto the crankcase and secure with two cap screws. Tighten to 8 ft-lb. PR431A 14. Place the water pump into position and secure with two cap screws. Tighten to 8 ft-lb. CD069 9. Install the magneto cover and secure with the cap screws.
Right-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. CF373A NOTE: The engine/transmission does not have to be removed from the frame for this procedure.
CF632A 7. Remove the cap screws securing the clutch cover. Note the location of the different-lengthed cap screws for installing purposes. Using a rubber mallet, carefully remove the cover. Account for two alignment pins. KEY A. Oil Pump Driven Gear B. Oil Pump Drive Gear C. Clutch Shoe Assembly D. One-Way Clutch E. Final Drive Carrier Bearing Housing CC829B 8. Remove the one-way clutch (D) from the clutch housing.
CF088A CD987 10. Remove the two cap screws securing the gear position switch; then remove the switch. 11. Remove the nut (left-hand threads) securing the clutch shoe assembly (C). CD993 13. Using an impact wrench, remove the cap screws securing the final drive carrier bearing housing (E); then remove the housing and account for two alignment pins. PR410A 12. Remove the cap screw securing the oil pump drive gear (B). Account for a cap screw, washer, pin, and spacer. CD999 CC606 100 14.
CD984 ATV1014 INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 1. Insert the drive into the clutch housing. CD895A 15. Using an impact driver, remove the three torx-head screws securing the oil pump; then remove the pump. 2. Rotate the inner race by hand and verify the inner race rotates only one direction. 3.
Installing Right-Side Components 1. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned. Tighten the new “patch-lock” cap screws to 28 ft-lb. CD991 4. Grease the driven gear pin and insert it into the shaft. Install the washer; then install the driven gear noting the direction on the sides of the gear from removing). Secure with a snap ring. CD999 2. Install the oil pump; then tighten the screws (coated with red Loctite #271) to 8 ft-lb.
PR410A CF085A 6. Install the clutch cover alignment pins into the crankcase, apply oil to the cover gasket, and install the gasket onto the crankcase. 9. Apply grease to the outer edges of the clutch housing; then from inside the clutch cover, install the clutch housing into the cover using a rubber mallet. 7. Install the one-way clutch onto the clutch shoe assembly. 10.
CF270A CF366 CAUTION Make sure the movable drive face plate is fully engaged onto the splines of the clutch shaft before tightening the nut or false torque readings may occur. This will cause the assembly to loosen damaging the shaft and clutch face plate. H1-020A 15. Place the V-belt into position on the driven pulley and over the front shaft. CF379 NOTE: At this point, the cap screw can be removed from between the driven pulley faces. 17.
Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and RightSide must precede this procedure. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Separating Crankcase Halves KEY A. Secondary Driven Shaft Assembly B.
DE677A 5. Remove the countershaft assembly (D). Account for a washer on each end of the countershaft. CD826 8. Remove the crank balancer. NOTE: There is a flat spot on the crank balancer bearing flange to allow clearance past the crankshaft. CC674 NOTE: Do not disassemble the countershaft assembly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section. 6. Using a rubber mallet, tap on the crankcase to remove the driveshaft. CD832B 9.
CAUTION Unless the secondary drive gear, bevel gear, or bearings require service, do not remove the secondary drive assembly from the case. If removed, bevel gear backlash will have to be adjusted requiring re-shimming of the drive bevel gear shaft. 13. To remove the secondary drive/bevel gear, remove the secondary drive bearing housing; then remove the nut securing the drive/bevel gear shaft in the bearing and using a plastic mallet, drive the shaft out of the bearing. Account for shim/shims.
MT008B MT005A NOTE: Do not use a new lock nut at this time as this 5. Acceptable backlash range is 0.127-0.381 mm (0.005-0.015 in.). procedure may have to be repeated. 5. Place the assembled shaft into the left crankshaft case; then lightly coat the gear teeth with machinist’s lay-out dye. Rotate the shafts through several rotations in both directions. Gear contact should extend from the root to the top of the gear teeth.
CC290D 2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) H1-003 3. Zero the indicator and rotate the crankshaft slowly. CAUTION 1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3.
COUNTERSHAFT GZ312 3. Remove the reverse driven gear dog. GZ281A CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/ or the transmission will malfunction. In either case, complete disassembly and assembly will be required. Disassembling 1.
GZ319 GZ317A GZ318A GZ318 6. Remove the low driven gear. Account for a bearing, bushing, and thrust washer. 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ316 GZ319B Assembling 1. From the drive gear end, install a thrust washer, bushing, and bearing; then install the low driven gear and washer. GZ320B 3. Install the reverse driven bushing and bearing; then install the reverse driven gear.
GZ286A GZ313A GZ287 GZ312 4. Install the outer reverse driven washer; then secure the reverse driven gear assembly with a snap ring. 6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F). GZ288A GZ283B 7. Install the two drive gear washers and the shift forks. The countershaft is now ready for installation.
MT014 CD832B 2. Apply a liberal amount of engine oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place. NOTE: It will be necessary to rotate the crank balancer until the counterweight is facing away from the crankshaft; then rotate the crankshaft clockwise into the journal area to allow the crank balancer to be fully seated. 4.
CC674 CC668 7. Place a washer on the end of the gear shift shaft; then install the shaft assembly making sure the two holes on the end of the shaft are positioned vertically. Install the spacer on the shift shaft. 10. Install the front and rear secondary driven shaft assemblies into the left side of the crankcase making sure the bearing locating pins are toward the top of the crankcase and the bearing C-ring is fully seated in the crankcase. DE677A 8.
6. From the left side, install the case half 6 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 7. From the right side, install the 6 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 8. In a crisscross/case-to-case pattern, tighten the 8 mm cap screws (from steps 4-5) until the halves are correctly joined; then tighten to 20 ft-lb.
700 HDX152A HDX252A 8. Install the CVT cooling ducts on the V-bolt housing and secure with clamps. Tighten securely. Install an appropriate nylon tie to secure the exhaust duct. 500 HDX253A 11. On the left side, connect the ECT sensor connector, speed sensor connector, and spark plug cap. HDX135A 9. Install the starter cable to the starter motor, secure with the nut, and tighten securely; then secure the engine/harness ground wires to the engine with a cap screw and tighten to 8 ft-lb.
13. Install the air filter assembly and secure to the frame with four sheet metal screws; then secure the intake boot with the clamp and tighten securely. 16. Connect the MAP sensor connector (A), fuel injector connector (B), ISC connector (C), and TPS connector (D); then install new nylon ties as noted during removing. HDX148A HDX136A 14.
Fuel/Lubrication/Cooling TROUBLESHOOTING 1. Verify that the electric fuel pump is operating by listening for a “whirring” sound for approximately three seconds after the ignition switch is turned to the ON position. If no sound can be heard, see Fuel Pump/Fuel Level Sensor in Electrical System. 2. Check for a flashing EFI icon on the LCD. If EFI is flashing, see EFI Diagnostic System in Electrical System. HDX048A 3. Check the air filter housing and air filter for contamination.
Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. REMOVING FI092A 6. Loosen the clamp securing the throttle body to the intake manifold boot and remove the throttle body assembly. 7. Use tape to cover and seal the intake opening. 1. Remove the seat, seat back, and seat base; then remove the floorboard. 2.
4. Remove four press-nuts securing the gas cap filler panel; then remove the gas cap and panel. Install the gas cap. PR173 PR168 5. Remove the joining cap screw and nut from the rear gas tank hold-down strap; then remove the inside hold-down strap. PR699A 2. Swing the front hold-down to the right into position and install the cap screw and nut. Do not tighten at this time. PR699A 6. Lift and slide the tank forward raising the front of the tank first; then turn the tank and lift out the right side.
7. Position the floorboard into the vehicle and secure with the appropriate hardware; then install the seat base, seat back, and seat. Gas/Vent Hoses Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the vent hoses. Make certain the vent hoses are securely connected and the opposite ends are always open. PR176 5.
2. Remove the Phillips-head screw on the back side of the pump and separate the pump housing and cover. Note the position of the inner and outer rotors and alignment pin for assembly. 3. Remove oil pump components. When pure coolant (no air) flows from the bleed hole, install the bleed plug, tighten securely, and then fill the cooling system to the bottom of the stand pipe in the radiator neck.
INSTALLING INSPECTING 1. Place the radiator into position making sure the grommets are correctly installed; then secure to the mounts with the two shoulder bolts and nuts. Tighten securely. 1. Inspect the thermostat for corrosion, wear, or spring damage. 2. Using the following procedure, inspect the thermostat for proper operation. A. Suspend the thermostat in a container filled with water. B. Heat the water and monitor the temperature with a thermometer. C. The thermostat should start to open at 71.
NOTE: The fan wiring must be in the upper-right position. 2. Install the radiator. Water Pump NOTE: The water pump is not a serviceable component. If the pump is defective or if the mechanical seal is leaking (coolant dripping from the discharge hole), the water pump must be replaced. REMOVING CC786A INSTALLING 1. Remove the radiator cap; then remove the water pump coolant drain plug and drain the coolant. 1. Secure the water pump to the engine with the two cap screws tightened to 8 ft-lb.
5. Check the entire cooling system for leakage. CAUTION After operating the vehicle for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary. 6. Install the seat base and seat. Troubleshooting Problem: Starting impaired Condition 1. Gas contaminated Problem: Idling or low speed impaired Condition 1. TPS out of adjustment Problem: Medium or high speed impaired Condition 1. High RPM “cut out” against RPM limiter Remedy 1.
Charging/Maintenance Charging Electrical System ! WARNING The electrical connections should be checked periodically for proper function. Any time service is performed on a battery, the following must be observed: keep sparks, open flame, cigarettes, or any other flame away. Always wear safety glasses. Protect skin and clothing when handling a battery. When servicing battery in enclosed space, keep the area wellventilated. Make sure battery venting is not obstructed.
Brakelight Switch Component data can be retrieved using the CATT II. Utilize the Sensor Data screen. The switch connector is the two-prong black connector below the master cylinder. NOTE: The ignition switch must be in the ON position. AR621D 3. When the lever is depressed, the meter must show less than 1 ohm. VOLTAGE (Wiring Harness Connector) NOTE: If the meter shows more than 1 ohm of resis- 1. Set the meter selector to the DC Voltage position. tance, replace the switch. 2.
4. Install the sensor and tighten securely; then connect the leads. Fan Motor 2411-886 This component can be tested using the CATT II. Utilize the Test screen. NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section).
RESISTANCE VOLTAGE Primary Coil CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the DC Voltage position; then disconnect the two wires from the coil. NOTE: For these tests, the meter selector should be NOTE: The coil is located to the right of the engine set to the OHMS position. and may be accessed from behind the right-side seat with the cargo box raised. Primary Winding 1.
NOTE: If the meter does not read as specified, replace the sensor. Speed Sensor NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion. 1. Set the meter selector to the DC Voltage position. HDX 247 NOTE: For this test, the meter must be in OHMS position. 2.
3. Install the new speed sensor into the housing with new O-ring lightly coated with multi-purpose grease; then secure the sensor with the cap screw (threads coated with blue Loctite #242). Tighten securely. RPM Limiter Component data can be retrieved using the CATT II. Utilize the Sensor Data screen. NOTE: The ROV is equipped with an ECM that cuts fuel spray and spark when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.
NOTE: If the meter does not show voltages according to the chart, make sure the front drive actuator is plugged in; then troubleshoot the switch, ignition fuses, battery connections, or wiring harness. Drive Select Switch Reverse Override Switch Component data can be retrieved using the CATT II. Utilize the Sensor Data screen. RESISTANCE 1. Remove the switch assembly from the dash; then disconnect the harness from the switch.
Stator Coil VOLTAGE (AC Generator - Regulated Output) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the positive battery post; then connect the black tester lead to the negative battery post. PR293 2. Connect the black lead to the black wire using needle adapters; then select 2WD on the drive select switch. 3. With the vehicle in neutral and the engine running as shown in the chart (with the headlights on), the meter must show 14-15.5 DC volts.
RESISTANCE (AC Generator) CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to OHMS position. 2. Test between the three yellow wires for a total of three tests. 3. The meter reading must be within specification. Starter Motor AR607D NOTE: If the meter showed battery voltage but the ponent. If the starter is defective, it must be replaced.
4. Disconnect the two-wire plug from the starter relay; then connect the red tester lead to the green wire and the black tester lead to the black wire. Fuel Pump/Fuel Level Sensor Component data can be retrieved using the CATT II. Utilize the Sensor Data screen. NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in the Electrical System section).
5. Using duct tape or other suitable means, cover the fuel pump opening. INSPECTING AT THIS POINT If the pump has failed earlier test and must be replaced, proceed to INSTALLING. 1. Inspect the fuel screen and blow clean with low pressure compressed air. XR172 NOTE: The fuel pump will cycle 5-10 seconds after the ignition key is turned on. 4.
NOTE: If voltage rises above 15.5 DC volts, the regulator is faulty or a battery connection is loose or corroded. Clean and tighten battery connections or replace the regulator/rectifier. If voltage does not rise, replace the regulator/rectifier. VOLTAGE (Brakelight) NOTE: Perform this test at the socket end of the taillight-brakelight harness (pigtail). The ignition switch must be in the ON position. 1. Set the meter selector to the DC Voltage position.
2. Install the needle adapters to the multimeter leads; then select DC Voltage on the multimeter. 3. Connect the red tester lead to the blue/brown wire (B) and the black tester lead to the black/yellow wire (A); then turn the ignition switch ON and observe the meter. The meter should read 0.8-3.0 DC volts (700) or 0.3-1.5 DC volts (500). CD706A 2. Turn the ignition switch to the ON position. The multimeter should read battery voltage.
500 Throttle Position Sensor (TPS) Component data can be retrieved using the CATT II. Utilize the Sensor Data screen. NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section). FI673A 700 TESTING 1. Remove the left-side engine cover; then disconnect the three-wire TPS connector plug.
EFI002A NOTE: The display on the gauge will display in SAE (speedometer in MPH mode) or Metric (speedometer in km/h mode), For example to read temperature in degrees Celsius, select km/h mode on the gauge or to read Fahrenheit, select MPH mode. EFI003 *Fan Schedule: Fan ON @ 185 degrees F, OFF @ 175 degrees F. *High Temperature REV Limiter 5000 RPM @ 230 degrees F. *Thermostat opens @ approximately 180 degrees F noted by a 2-5 degree drop momentarily. Coolant (COOL) Diagnostic Mode 3.
Fuel Sensor (FUEL) Diagnostic Mode Display: vehicle speed signal. DTC: P0500 Usage: verify speedometer sensor signal from the following. 1. Speed sensor to ECM. 2. ECM (CAN) signal to gauge (speedometer/odometer). TPS (tPS) Diagnostic Mode EFI010 Display: Fuel level signal from the fuel level sensor (measured in ohms). DTC: C1400, C1401, C1402 Usage: Check output of the fuel level sensor 1. Full fuel is indicated by a reading of 86-100 ohms 2.
Inlet Air Temperature (AIr) Diagnostic Mode Display: System DC voltage. DTC: P0562, P0563, P2531, P2532 Usage: Verify system voltage under following conditions. 1. Battery voltage with engine and accessories off (>12.2 VDC for fully charged). 2. Battery voltage with engine running (charging = 13.8 VDC or greater). 3. Battery voltage with electrical accessories operating, engine idling (13.5 VDC or greater). 4. Battery voltage starter cranking (10.5-11.5 VDC).
Code P0132 P0171 P0172 P0219 Fault Description Possible Cause P0500 O2 Sensor High/SP Sensor or interconnect harness shorted to battery power O2 Feedback Below Minimum Correction Low fuel rail pressure, dirty fuel filter, or dirty injectors O2 Feedback Exceeds Maximum Correction Excessive fuel rail pressure, MAP or temp sensors out-of-spec Engine Over-Speed Condition Engine speed (RPM) has exceeded the ECM over-speed setpoint/ limit Fuel Pump Relay Circuit Low/SG/Open Relay has been removed or interconn
Troubleshooting Problem: Spark absent or weak Condition 1. 2. 3. 4. Ignition coil defective Spark plug(s) defective CKP sensor defective ECM defective Problem: Spark plug fouled with carbon Condition 1. 2. 3. 4. 5. Gasoline incorrect Air cleaner element dirty Spark plug(s) incorrect (too cold) Valve seals cracked - missing Oil rings worn - broken Problem: Spark plug electrodes overheat or burn Condition 1. Spark plug(s) incorrect (too hot) 2. Engine overheats 3.
3. Remove the mounting cap screw from above the actuator on the suspension side. Drive System GENERAL INFORMATION All gear cases are tagged beneath a cover bolt. This tag is marked with a production date code, sequence code, and a ratio code. All gear cases are 4.0:1 ratio. The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing; then use the following torque values.
3. While holding the actuator firmly forward, tighten the front cap screw to hold the actuator in place; then install but do not tighten the two remaining cap screws. NOTE: The jack stands should be placed under the main frame to avoid contact with front suspension components. ! WARNING Make sure the vehicle is solidly supported on the jack stands to avoid injury. 2. Remove the drain plug and drain the gear lubricant into a drain pan; then install the plug and tighten to 45 in.-lb. GC001 4.
PR191 PR729C 8. Remove the lower and upper ball joint cap screws taking care not to strip the threads on the ball joint shaft; then using a rubber mallet, tap the end of the axle and free it from the knuckle assembly. 13. Remove the lower differential mounting cap screw. Account for a lock nut and four washers. Note the position of the washers for assembling. PR193 14. Remove the upper differential mounting cap screw. Account for a lock nut and two washers. PR205A 9.
4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. GC004A 2. Using a rubber mallet, remove the housing. Account for a gasket. Remove the fork, collar, and spring. Note the location of all the components for assembling purposes. GC010 5. Remove the snap ring securing the input shaft bearing; then place the pinion housing in a press and remove the bearing. GC015 GC011 CD106 3. Remove the snap rings from the input shaft; then remove the input shaft from the pinion housing.
Assembling Input Shaft 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside. 4. Install the input shaft into the pinion housing; then secure the bearing with a circlip. GC009A GC012 5. Place the pinion housing with new gasket onto the differential housing; then secure with existing cap screws. Tighten to 23 ft-lb.
GC015 KX175 2. Using a T-40 torx wrench, remove the cap screws securing the differential cover. Account for and make note of the ID tag location for assembling purposes. 5. Remove the left differential bearing flange assembly and account for a shim. Mark the shim as left-side. KX177 GC003 3. Using a plastic mallet, tap lightly to remove the differential cover. Account for an O-ring. KX178 KX174 6. Place the differential with the open side down; then lift the housing off the spider assembly.
KX181 CC879 4. Remove any reusable parts from the gear case housing; then discard the housing and lock collar. Disassembling Pinion Gear 1. Remove the internal snap ring securing the pinion bearing in the housing. Assembling Pinion Gear 1. Install the bearing onto the pinion shaft. Install the pinion shaft collar. WC430 2. Using a suitable pinion gear/shaft removal tool and a hammer, remove the pinion gear from the gear case housing. CC882 CC883 CC878 3.
NOTE: All bearings must be installed in the gear case and the pinion properly installed before proceeding. Backlash NOTE: Always set backlash prior to any other shimming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly. CC884 3. Using a propane torch, heat the gear case housing to approximately 200° F; then install the pinion assembly. 4. Install the internal snap ring with the sharp side directed away from the bearing. GC031A 2.
GC033A GC039A 4. Install the existing shim or a 0.063 in. shim on the cover side of the ring gear; then place the assembled gear case cover onto the gear case and secure with three cap screws. Tighten evenly using a crisscross pattern. 6. Zero the dial indicator; then while holding the pinion stationary, rock the ring gear assembly forward and back and record the backlash. Backlash must be 0.011-0.015 in. If backlash is within specifications, proceed to Ring Gear End-Play.
2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. Assemble the fork and sliding collar into the cover assembly; then install the left bearing flange/bearing assembly and seat firmly into the cover. 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness. NOTE: Once proper backlash and end play are established, the gear case can be assembled. Assembling Differential Assembly 1.
6. Install the shift fork shaft w/spring into the housing making sure the shaft O-ring is positioned to the inside. CD110 Removing/Installing Axle Seal CC892 7. Install the shift fork assembly making sure the fork leg is facing upward. Apply a small amount of oil to the gasket; then install the gasket. NOTE: This procedure can be performed on a rear gear case. 1. Remove the seal using a seal removal tool. CC899 CC893 8.
INSTALLING DIFFERENTIAL 1. Place the differential assembly into position in the frame; then install the top mounting cap screw, two washers, and lock nut. Do not tighten at this time. 2. Install the lower differential mounting cap screw, washers, and lock nut. Note the correct location for the washers. PR193 8. Secure the lower shock eyelets with cap screws and lock nuts. Tighten to 20 ft-lb. PR205A 3. Tighten the nuts to 38 ft-lb. 4. Pour 275 ml (9.
PR256 PR221 12. Install the wheels; then using a crisscross pattern, tighten the wheel nuts in 27 N-m (20 ft-lb) increments to the final torque shown in the table below. 5. Remove the cap screw and lock nut securing the knuckle to the upper A-arm. Discard the lock nut. Steel Wheel 54 N-m (40 ft-lb) Aluminum Wheel (Black Nuts) 80 N-m (60 ft-lb) Aluminum Wheel (Chrome Nuts) 108 N-m (80 ft-lb) 13. Remove the vehicle from the support stand. 14. Install the belly panel.
CF337 PR729C 2. Place the white-striped end of the CV joint into a vise. REMOVING FRONT DRIVE AXLE NOTE: For removing a front drive axel, see Front Differential in this section. CLEANING AND INSPECTING AXLES NOTE: Always clean and inspect the drive axle components to determine if any service or replacement is necessary. 1. Using a clean towel, wipe away any oil or grease from the axle components. CF335 3.
ATV-1048 CD027 3. Apply 80 grams (2/3 of contents) of grease from the pack into the bearing housing. 5. Install the wheel; then using a crisscross pattern, tighten the wheel nuts in 27 N-m (20 ft-lb) increments to the final torque shown in the table below. NOTE: Steps 1-3 can be used to replace the outboard boot.
7. Install the wheel; then using a crisscross pattern, tighten the wheel nuts in 27 N-m (20 ft-lb) increments to the final torque shown in the table below. Steel Wheel 54 N-m (40 ft-lb) Aluminum Wheel (Black Nuts) 80 N-m (60 ft-lb) Aluminum Wheel (Chrome Nuts) 108 N-m (80 ft-lb) 8. Remove the vehicle from the support stand. 9. Check the front differential lubricant level and add lubricant as necessary.
GC058A GZ182A 3. If clearance is as specified, remove the ring gear and thrust button; then place a drop of red Loctite #271 on the threads and tighten to 8 ft-lb (left-hand threads). 3. Remove the snap ring retaining the input bearing and using an appropriate bearing driver, press the bearing from the housing. 4. If clearance is not as specified, repeat steps 1 and 2 using thicker shim (clearance too great) or thinner shim (clearance too small) until correct specification is reached.
2. Pack the driveline boot with the appropriate grease; then secure with the boot clamps using CV Boot Clamp Tool. 3. Secure the differential to the frame with two through-bolts and secure with lock nuts and flat washers. Tighten to 38 ft-lb. 4. Install the rear drive axles. 5. Install the brake caliper and tighten the new “patchlock” cap screws to 20 ft-lb. 6. Fill the gear case with the appropriate lubricant. GZ184 Hub 2.
3. Using a socket and ratchet handle, tighten the nut until the stud is fully drawn into the hub. PR243A 5. Remove the hub assembly. PR252A 6. Remove the four cap screws securing the brake disc. INSTALLING 1. Secure the brake disc (if applicable) to the hub with the four cap screws coated with red Loctite #271. Tighten to 15 ft-lb. 2. Apply grease to the splines in the hub. PR254A CLEANING AND INSPECTING 1. Clean all hub components. 2. Inspect all threads for stripping or damage. 3.
! WARNING Never let brake fluid contact the eyes. Damage to the eyes will occur. Always wear appropriate protective safety goggles and latex gloves when handling brake fluid. 2. Drain the brake fluid from the caliper, hose, and master cylinder through the bleed screw by pumping the brake pedal. PR258 5. Secure the brake calipers to the knuckle with two new “patch-lock” cap screws tightened to 20 ft-lb. PR235 CAUTION Brake fluid is highly corrosive.
PR715 PR238 5. Remove the caliper holder from the caliper and discard the O-ring. ! WARNING Make sure to hold the towel firmly in place or the piston could be ejected from the housing causing injury. 7. Using an appropriate seal removal tool, carefully remove the seals from the brake caliper housing; then remove four O-rings from the brake caliper housing noting the location of the different sized O-rings. Discard all seals, O-rings, and crush washers. CLEANING AND INSPECTING 1.
4. Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented. NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly. PR717A 2. Press the piston into the caliper housing using hand pressure only. Completely seat the piston; then wipe off any excessive brake fluid. PR239C 5.
8. Fill the reservoir; then bleed the brake system (see Periodic Maintenance - Hydraulic Brake System). ! WARNING Never use brake fluid from an open container or reuse brake fluid. Moisture-contaminated brake fluid could cause vapor build-up (expansion) during hard braking resulting in greatly increased stopping distance or loss of control leading to injury or death. 9.
3. Remove the cap screws securing the driveshaft flange to the output flange; then remove the driveshaft. PR367B 2. Verify the yoke legs are parallel. HDX157 4. Install a U-joint separator tool on the universal joint fixed yoke; then remove the bearing cup retainers. 5. Using a suitable socket and ratchet handle, rotate the jackscrew to push the bearing cup out of the yoke; then remove the tool and the bearing cup. PR367A 3. Check splines and flanges for excessive wear, thread damage, or warpage.
3. Install the retainer in the bearing cup; then remove the yoke from the separator tool. NOTE: Repeat steps 2-3 for the opposite-side bearing cup. 4. Remove the separator tool from the vise and install the universal joint, bearing cups, and movable yoke into the fixed yoke using the same procedure as steps 2-3 except the vise cannot be used. PR368 2. Secure a U-joint separator tool in a vise; then place the yoke, joint, and bearing cup into position and press the cup into the yoke. PR355 5.
Troubleshooting Brake System Problem: Braking poor Condition 1. Pad worn 2. Brake fluid leaking 3. Master cylinder/brake cylinder seal worn Problem: Brake pedal travel excessive Condition 1. Brake fluid low 2. Piston seal - cup worn Problem: Brake fluid leaking Condition 1. Connection fittings loose 2. Hose cracked 3. Piston seal worn Problem: Brake pedal spongy Condition 1. Air trapped in hydraulic system 2. Brake fluid low 170 Remedy 1. Replace pads 2. Repair - replace hydraulic system 3.
Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods bent, pitted, or damaged. B. Rubber damper cracked, broken, or missing. C. Shock absorber body damaged, punctured, or leaking. CF341 D. Shock absorber eyelets broken, bent, or cracked. E. Shock absorber eyelet bushings worn, deteriorated, cracked, or missing. F. Shock absorber spring broken or sagging. CLEANING AND INSPECTING 1.
PR257 3. Remove the nut securing the hub. 4. Remove the brake caliper. Account for two cap screws. AF626D 10. Remove the cap screws securing the A-arms to the frame. AF610D CD007 5. Remove the hub assembly. 11. Remove the snap ring from the ball joint; then remove the ball joint from the A-arm. 6. Remove the cotter pin and slotted nut securing the tie rod end to the knuckle; then remove the tie rod end from the knuckle. 7. Remove the cap screws securing the ball joints to the knuckle.
INSTALLING 1. Apply Loctite Primer “T” to the A-arm socket; then apply green Loctite #609 to the entire outside diameter of the ball joint. Install the ball joint into the A-arm and secure with the snap ring. AF628D 7. Install the tie rod end and secure with the nut (coated with red Loctite #271). Tighten to 30 ft-lb; then install a new cotter pin and spread the pin to secure the nut. NOTE: During assembly, new cotter pins should be AF616D installed. 2.
4. Remove the cotter pin securing the hex nut; then remove the hex nut. 5. Remove the cap screws and lock nut securing the shock absorber to the frame and lower A-arm; then remove the shock absorber. 6. Remove the cap screws securing the boot guard to the lower A-arm. PR377B 11. Secure the hub nut (from step 9) to the shaft/axle. Tighten to 200 ft-lb. 12. Install a new cotter pin and spread the pin to secure the nut.
2. Slide the knuckle onto the drive axle and into position on the A-arms; then secure the knuckle to the A-arms with cap screws and new lock nuts. Tighten to 35 ft-lb. 3. Tighten the hardware securing the A-arms to the frame mounts (from step 1) to 35 ft-lb. Wheels and Tires TIRE SIZE 4. Apply grease on the drive axle splines; then install the hub assembly onto the drive axle. ! WARNING Use only Toro approved tires when replacing tires. Failure to do so could result in unstable vehicle operation.
CHECKING/INFLATING 1. Using an air pressure gauge, measure the air pressure in each tire. Adjust the air pressure as necessary to meet the recommended inflation pressure. 2. Inspect the tires for damage, wear, or punctures. NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Be sure all tires are the specified size and have identical tread pattern. ! WARNING Do not operate the vehicle if tire damage exists.
Printed in U.S.A.