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General Information/
Foreword
This Service Manual contains service, maintenance, and
troubleshooting information for the 2021 500S model.
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 disassem-
bling, inspecting, and assembling instructions. When
using this manual as a guide, the technician should use
discretion as to how much disassembly is needed to cor-
rect any given condition.
This service manual is designed primarily for use by a
basic level technician. The procedures found in this man-
ual are of varying difficulty, and certain service proce-
dures in this manual require one or more special tools to
be completed. The technician should use sound judgment
when determining which procedures can be completed
based on their skill level and access to appropriate special
tools.
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
When replacement of parts is necessary, use only genuine
parts. They are precision-made to ensure high quality and
correct fit. Refer to the appropriate Illustrated Parts Man-
ual for the correct part number, quantity, and description.
All publications and decals display the words Warning,
Caution, Note, and At This Point to emphasize important
information. The symbol !WARNING identifies
personal safety-related information. Be sure to follow the
directive because it deals with the possibility of serious
personal injury or even death. A CAUTION identifies
unsafe practices which may result in vehicle-related dam-
age. Follow the directive because it deals with the possi-
bility of damaging part or parts of the vehicle. The
symbol NOTE: identifies supplementary information
worthy of particular attention. The symbol
AT
THIS POINT directs the technician to certain and
specific procedures to promote efficiency and to improve
clarity.
At the time of publication, all information, photographs,
and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes
only and are not designed to depict actual conditions.
Because we constantly refine and improve our products,
no retroactive obligation is incurred.
All materials and specifications are subject to change
without notice.
Specifications
NOTE: Specifications subject to change without notice.
CHASSIS
Dry Weight (approx) 496.7 kg (1095 lb)
ROPS Tested Curb Weight 997.9 kg (2200 lb)
Length (overall) 270.3 cm (106.4 in.)
Height (overall) 194.8 cm (76.7 in.)
Width (overall) 143.3 cm (56.4 in.)
Tire Size (front)
(rear)
25 x 8-12
25 x 10-12
Tire Inflation Pressure (w/cargo) (front)
(rear)
82.7 kPa (12 psi)
137.9 kPa (20 psi)
MISCELLANEOUS
Spark Plug Type NGK CR6E
Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)
Gas Tank Capacity 32.2 L (8.5 U.S. gal.)
Coolant Capacity 2.5 L (2.65 U.S. qt)
Front Differential Capacity (change) 250 ml (8.45 fl oz)*
Rear Drive Capacity (change) 230 ml (7.78 fl oz)*
Engine Oil Capacity (approx) 2.8 L (3.0 U.S. qt) —
Overhaul
2.4 L (2.5 U.S. qt) —
Change
Gasoline (recommended) 87 Octane Regular
Unleaded
Engine Oil (recommended) ACX All Weather Synthetic
Front Differential/Rear Drive Lubricant
(At level plug hole)
SAE Approved 80W-90
Hypoid
Drive Belt Width 28.5 mm (1.12 in.)
Brake Fluid DOT 4
Taillight/Brake Light/Reverse light 12V/5W/21W
Headlight (high beam/low beam) 12V/60W/55W
ELECTRICAL SYSTEM
Ignition Timing 12° BTDC @ 1425 RPM
Spark Plug Cap 4000-6000 ohms
Ignition Coil Resistance (primary)
(secondary)
Less than 1 ohm
N/A
Ignition Coil Primary Voltage Battery Voltage
Stator Coil Resistance (CKP Sensor)
(AC generator)
104-156 ohms
Less than 1 ohm
AC Generator Output (no load)
75 AC volts @
5000 RPM
Crankshaft Position Sensor AC Voltage 2.0 volts or more
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
30.6 mm
27.0 mm
Valve/Tappet Clearance (intake)
(cold engine) (exhaust)
0.10 mm
0.17 mm
Valve Guide/Stem (intake)
Clearance (max) (exhaust)
0.04 mm
0.06 mm
Valve Guide Inside Diameter 5.000-5.012 mm
Valve Seat Angle (intake/exhaust) 45°
Valve Spring Free Length (min) 42.8 mm
Valve Spring Tension @ 35.2 mm
18.6 kg (41.1 lb)
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