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Table of Contents
General Information/Foreword....................................... 2
Specifications ............................................................... 2
Torque Specifications ................................................... 3
Torque Conversions (ft-lb/N-m).................................... 4
Gasoline — Oil — Lubricant ......................................... 4
Preparation for Storage ................................................ 5
Preparation after Storage ............................................. 6
Periodic Maintenance/Tune-Up ...................................... 7
Air Inlet Pre-Filter.......................................................... 7
Air Filter/Housing Drain................................................. 7
Valve/Tappet Clearance................................................ 8
Testing Engine Compression........................................ 9
Spark Plug .................................................................. 10
Muffler/Spark Arrester................................................. 10
Engine/Transmission Oil — Filter ............................... 10
Front Differential — Rear Drive Lubricant....................11
Driveshaft/Coupling .................................................... 12
Headlight — Taillight/ Brake Light — Reverse Light... 12
Shift Cable .................................................................. 13
Hydraulic Brake System ............................................. 14
Burnishing Brake Pads ............................................... 16
Checking/Replacing V-Belt ......................................... 16
Steering/Body/Controls ................................................ 19
Steering Wheel ........................................................... 19
Steering System ......................................................... 19
Steering Knuckles....................................................... 23
Accelerator Pedal ....................................................... 25
Shift Lever .................................................................. 26
Shift Cable .................................................................. 26
LCD Gauge................................................................. 28
Front Wheel Alignment ............................................... 28
Front Fascia/Front Bumper......................................... 28
Hood/Front Storage Compartment ............................. 30
Front Body Panel........................................................ 30
Floor ........................................................................... 31
Dashboard .................................................................. 33
Belly Panel.................................................................. 35
Muffler......................................................................... 35
Cargo Box................................................................... 36
Tailgate ....................................................................... 36
Taillight Assembly ....................................................... 37
Seat ............................................................................ 38
Troubleshooting .......................................................... 39
Engine/Transmission.................................................... 40
Troubleshooting...........................................................41
Removing Engine/Transmission..................................43
Servicing Engine .........................................................47
Installing Engine/Transmission....................................86
Fuel/Lubrication/Cooling.............................................. 91
Throttle Body...............................................................91
Gas Tank .....................................................................92
Oil Pump .....................................................................94
Liquid Cooling System ................................................95
Troubleshooting...........................................................98
Electrical System .......................................................... 99
Battery.........................................................................99
Ignition Switch ...........................................................100
Ignition Coil ...............................................................100
Ignition Timing ...........................................................101
Accessory Connector ................................................101
Switches....................................................................102
Fan Motor..................................................................104
Power Distribution Module (PDM).............................104
EFI Sensors/Components .........................................105
RPM Limiter .............................................................. 110
Stator Coil ................................................................. 110
Regulator/Rectifier .................................................... 110
Starter Motor ............................................................. 111
Starter Relay ............................................................. 111
Electronic Control Module (ECM).............................. 112
EFI Diagnostic System.............................................. 112
Troubleshooting......................................................... 117
Drive System ................................................................118
Front Drive Actuator .................................................. 118
Front Differential........................................................120
Drive Axles ................................................................132
Rear Gear Case ........................................................136
Hub............................................................................142
Hydraulic Brake Caliper.............................................144
Troubleshooting Drive System ..................................148
Troubleshooting Brake System .................................148
Suspension.................................................................. 149
Shock Absorbers .......................................................149
Front A-Arms .............................................................149
Rear A-Arms..............................................................152
Wheels and Tires ......................................................154
Troubleshooting.........................................................155
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