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Table of Contents
General Information ........................................................ 2
General Specifications.........................................................2
Torque Specifications ..........................................................3
Torque Conversions (ft-lb/N-m)............................................5
Gasoline - Oil - Lubricant.....................................................5
Genuine Parts......................................................................6
Special Tools........................................................................6
Preparation For Storage ......................................................6
Preparation After Storage....................................................6
Periodic Maintenance...................................................... 7
Periodic Maintenance Chart ................................................7
Lubrication Points ................................................................8
Air Inlet Pre-Filter.................................................................8
Air Filter ...............................................................................8
Valve/Tappet Clearance.......................................................9
Testing Engine Compression.............................................10
Spark Plug .........................................................................10
Muffler/Spark Arrester .......................................................10
Engine/Transmission Oil - Filter .........................................11
Front Differential - Rear Drive Lubricant ............................12
Driveshaft/Coupling ...........................................................13
Nuts/Bolts/Cap Screws......................................................13
Headlight/Taillight-Brakelight .............................................13
Shift Lever.......................................................................... 14
Hydraulic Brake System ....................................................15
Burnishing Brake Pads ......................................................16
Checking/Replacing V-Belt ................................................17
Steering/Frame/Controls............................................... 19
Steering Wheel ..................................................................19
Tie Rods ............................................................................19
Steering Assembly.............................................................20
Upper Steering Shaft .........................................................21
Intermediate Steering Shaft Assembly ..............................22
Steering Knuckles..............................................................23
Accelerator Pedal ..............................................................25
Shift Lever.......................................................................... 25
Shift Cable .........................................................................25
LCD Gauge........................................................................26
Checking/Adjusting Front Wheel Alignment.......................27
Front Bumper Assembly ....................................................28
Hood ..................................................................................28
Fenders..............................................................................29
Floor ..................................................................................29
Dashboard .........................................................................30
Belly Panel.........................................................................30
Exhaust System.................................................................31
Cargo Box..........................................................................31
Taillight Assembly ..............................................................32
Seat ...................................................................................32
Troubleshooting .................................................................33
Engine/Transmission .................................................... 34
Troubleshooting .................................................................35
Removing Engine/Transmission ........................................37
Servicing Engine (500) ......................................................40
Servicing Engine (700) ......................................................77
Installing Engine/Transmission ........................................115
Fuel/Lubrication/Cooling............................................ 118
Throttle Body ...................................................................118
Gas Tank .........................................................................119
Gas/Vent Hoses .............................................................. 121
Oil Filter/Oil Pump ...........................................................121
Liquid Cooling System ....................................................122
Radiator...........................................................................122
Thermostat ......................................................................123
Fan ..................................................................................123
Water Pump ....................................................................124
Troubleshooting ............................................................... 125
Electrical System ........................................................ 126
Battery............................................................................. 126
Accessory Receptacle/Connector ................................... 126
Brakelight Switch............................................................. 127
Engine Coolant Temperature (ECT) Sensor....................127
Fan Motor ........................................................................128
Power Distribution Module (PDM) ...................................128
Ignition Coil ..................................................................... 128
EFI Sensors/Components ............................................... 129
Speed Sensor ................................................................. 130
RPM Limiter .................................................................... 131
Ignition Switch ................................................................. 131
Headlight Switch ............................................................. 131
Drive Select Switch ......................................................... 132
Reverse Override Switch.................................................132
Front Drive Actuator ........................................................132
Stator Coil ....................................................................... 133
Starter Motor ...................................................................134
Starter Relay ...................................................................134
Electronic Control Module (ECM).................................... 135
Fuel Pump/Fuel Level Sensor ......................................... 135
Regulator/Rectifier ..........................................................136
Headlights ....................................................................... 137
Taillight-Brakelight ...........................................................137
Ignition Timing .................................................................137
Tilt Sensor ....................................................................... 137
Throttle Position Sensor (TPS)........................................139
EFI Diagnostic System .................................................... 139
Troubleshooting ............................................................... 144
Drive System ............................................................... 145
Front Drive Actuator ........................................................145
Front Differential.............................................................. 146
Drive Axles ...................................................................... 157
Rear Gear Case ..............................................................160
Hub..................................................................................162
Hydraulic Brake Caliper................................................... 164
Universal Joints ...............................................................167
Troubleshooting Drive System.........................................169
Troubleshooting Brake System........................................170
Suspension.................................................................. 171
Shock Absorbers .............................................................171
Front A-Arms ...................................................................171
Rear A-Arms ................................................................... 174
Wheels and Tires ............................................................ 175
Troubleshooting ............................................................... 176
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