Toro UTV500AAC00000, UTV700AAC00000 Setup Instructions

Model #UTV500AAC00000 - Serial #4UF15MPV3FT307514 & Up

Model #UTV700AAC00000 - Serial #4UF15MPV2FT307524 & Up

 Activate/charge/install battery

Form Number 3394-900 Rev. A

Effective February, 2015

PRE-DELIVERY SETUP INSTRUCTIONS

CHECKLIST

 Check engine/transmission oil

 Check tire inflation pressure

 Check wheel lug nut torque

 Install left-side foot restraint

 Install ROPS/seat belts/side restraints

 Check cooling system — level and hoses

 Install steering wheel

 Check/adjust front wheel alignment

 Check hydraulic brake fluid level — pedal firmness

 Burnish the brake pads

 Check throttle cable adjustment

NOTE: Read these instructions thoroughly before
starting the Pre-Delivery Setup.

Even though the vehicle has been set up (with some
minor exceptions) and inspected at the factory, it is
mandatory that EVERY vehicle be properly inspected
and serviced at the dealership prior to being released to
the customer. Experience has shown that dealerships
that properly prepare each vehicle have fewer warranty
problems and more satisfied customers.

RECOMMENDED TOOLS

The following tools will assist the technician during the
set-up process:

• Drill w/Torx Bits

• Impact Wrench

• Metric Socket Set

• Torque Wrench

BATTERY

NOTE: Refer to all warnings and cautions pro­vided with the battery or battery charger.

This ROV is shipped with a sealed battery. The battery
requires an initial charge after activation as well as periodic
maintenance-charging during periods of non-use or storage.

Activating Battery

Always activate and maintain the battery in accordance
with the following instructions to ensure maximum ser­vice life and performance from the battery.

 Check gear case lubricant

 Check shift lever for proper operation

 Check headlight aim

 Check gasoline level

 Start engine and check electrical switches and lights

 Test drive

 Check decals/clean vehicle

 Explain Operator’s Manual, Limited Warranty, and

legal obligations to the customer

 Complete Owner Registration form with the customer

on the date of the sale

Each sealed battery comes with an electrolyte container and
proper amount for each specific battery type. DO NOT add
additional electrolyte to any sealed battery. Sealed battery
electrolyte has a higher concentration of sulfuric acid.

1. Carefully remove and save the sealing strip from the
battery electrolyte container. This will be used to seal
the battery later.

2. Remove and discard the foil sealing strip covering
the fill holes from the battery.

3. Place electrolyte container with the foil-sealed top of
the cells facing down into the fill ports of the battery.

4. Hold the container level in the fill ports of the bat­tery. Push down to break the seals. Air bubbles will
appear as the ports fill. Do not tilt the electrolyte con­tainer. Do not remove the container from the battery
until all cells are completely empty.

5. Let the battery stand for 120 minutes (2 Hr) prior to
charging. This will allow the electrolyte to permeate
into the plates for optimum performance.

6. Fully insert the sealing strip over the fill holes by
hand. DO NOT use a hammer.

7. Charge the battery completely before installation.

Charging New Battery

NOTE: Batteries filled with electrolyte are only at
80% of their capacity.

Batteries can be charged two ways - Standard Charge and
Fast Charge. Standard charging is the only recommended
way to charge a battery. It gives the battery optimal per­formance and battery life.

1. Be sure the charger is unplugged from the 110-volt
electrical outlet.

1

2. Connect the red terminal lead from the charger to the
positive terminal of the battery; then connect the
black terminal lead of the charger to the negative ter­minal of the battery.

3. Plug the charger into a 110-volt electrical outlet.

4. Charge the battery for a minimum of five full hours
at a rate of 10% of the battery amp-hour rating for
optimal battery performance and battery life (ex: 30
AH battery should be charged at 3.0 amps).

NOTE: If the battery becomes hot to the touch,
stop charging. Resume after it has cooled.

5. Once the battery has reached full charge (typically

13.5 volts), unplug the charger from the 110-volt
electrical outlet and disconnect the charging leads.

6. Allow the battery to sit for 2 hours before installing
in the vehicle.

Installing Battery

NOTE: The battery box is under the seat on the
operator’s side. To access the box, remove the
seat and pry off the battery compartment cover;
then remove the thumb screw securing the battery
box cover and lift the cover to access the battery.

PR942

NOTE: Loss of battery charge may be caused by
ambient temperature, ignition OFF current draw,
corroded terminals, self-discharge, or other fac­tors. Maintenance charging is required to keep the
battery at a “fully-charged” state.

TIRES

This vehicle is equipped with low-pressure tubeless
tires. Do not under any circumstances substitute tires of
a different type or size.

TIRE INFLATION PRESSURE

! WARNING

Operating this vehicle with improper or uneven tire
inflation pressure is hazardous. Always maintain
proper tire inflation pressure.

Front and rear tire inflation pressure should be 110 kPa
(16 psi) (UTV500) or 138 kPa (20.0 psi) (UTV700).

A low-pressure gauge is provided in the tool kit to mea­sure the air pressure in the tires. Check the air pressure
in all tires before use of the vehicle.

PR943A

1. Route the battery cables into the battery compartment.

2. Install the battery; then connect the battery cables
(positive cable first) as shown. Tighten securely.

TC019

NOTE: When installing the battery into a vehicle,
coat the battery terminals with a light coat of
grease to minimize battery terminal corrosion and
then cover with the terminal boot if provided.

2

WHEEL LUG NUTS

Using a crisscross pattern, tighten the wheel nuts in 27 N­m (20 ft-lb) increments to the final torque shown 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)

PR941A

CAUTION

Using an impact wrench could result in incorrect
torque which could damage the wheel or hub studs.

INSTALLING LEFT-SIDE FOOT
RESTRAINT

1. Remove the left-side foot restraint from the package
containing the side restraints.

2. Remove two sheet metal screws from the dashboard
attachment location and the second and third floor
retainer screws.

PR751A

PR800A

6. Tighten the cap screws securing the restraint to the
angle bracket securely.

PR752A

3. Remove the angle bracket from the foot restraint
(retain the screws) and attach to the floor using the
existing screws from the floor. Tighten securely.

4. Install the foot restraint and attach to the angle
bracket with the existing two cap screws. Do not
tighten at this time.

PR827

INSTALLING ROPS/SEAT BELTS/
SIDE RESTRAINTS

! WARNING

The ROPS must be installed prior to operating the

vehicle or delivery to a customer. Safety devices such
as taillight/brakelight, seat belts, and the passenger
hand holds are incorporated in the assembly. The
ROPS is part of the vehicle structure.

NOTE: The screws securing the front and rear
tubes during delivery will be used to secure the
ROPS tubes. There are nuts that secure the back
side of the ROPS tubes for shipping; these nuts
should be removed and discarded.

1. Loosen the Allen Head Screws securing the front
and rear ROPS tubes; then tip the front and rear
ROPS tubes from horizontal to vertical.

PR827

5. Secure the restraint and the dashboard with the
channel bracket (from the hardware pack) and two
sheet metal screws. Do not over-tighten.

3

UTV-068

UTV-148

2. Raise the cargo box; then while holding the rear
ROPS, remove the screws securing the ROPS.
Loosely secure the ROPS in the correct position
using Allen Head Screws and new Nyloc Nuts. Do
not tighten at this time. Repeat for the front ROPS.

3. Place the Top X-brace into position between the
front and rear tubes and secure with eight Cap
Screws (installed from the top) and eight Zinc
Nyloc Nuts. Tighten to 47 N-m (35 ft-lb).

TC022A

5. Secure the bottom (middle) of the rear canopy tube
to the center support using two M6 Torx Screws.
Tighten to 11 N-m (8 ft-lb). Connect the brakelight/
taillight harness to the main harness.

TC030A

6. Tighten the front and rear tubes (from step 2) to 47
N-m (35 ft-lb). Ensure the flats of the nuts engage
the recesses of the ROPS tubes when tightened.

UTV-070

4. Secure the seat back to the rear ROPS tube with the
two cap screws. Tighten to 11 N-m (8 ft-lb).

4

TC027

TC029

7. Install the seat belts (cap screws installed from the
front) into the appropriate mounting tabs along the
headrest support tube on the rear ROPS. Tighten to
47 N-m (35 ft-lb).

8. Place Right-Side Occupant Side Restraint onto the
passenger-side tube and secure using four Cap
Screws. Tighten to 13.5 N-m (10 ft-lb).

PR835A

9. Secure the outer side restraint using two Cap
Screws making sure to keep the straps properly
positioned.

10. Route the lower side restraint straps inside the side
tube; then secure to the frame using two Shoulder
Screws and Flange Nuts. Tighten to 13.5 N-m (10
ft-lb).

13. Secure both side restraints to the kick panels using
the buckle.

PR833

CHECKING COOLING SYSTEM

Remove the filler cap and check coolant level. Coolant
level should be at the bottom of the standpipe in the
radiator neck. If coolant is required, add to bring coolant
to the specified level and install the cap.

NOTE: If coolant is required, mix coolant for a
temperature of -36°C (-34°F). Follow mixing recom­mendations of the manufacturer.

CAUTION

It is extremely important that the cooling system is
properly filled. If the system isn’t properly filled,
engine damage will occur.

PR834A

11. Loop the rear anchor strap around the ROPS mount­ing tube and secure with the buckle. Tighten so
strap rests as shown.

INSTALLING STEERING WHEEL

NOTE: The vehicle should be on level ground
with the front wheels oriented straight forward and
rearward.

1. Remove the nut and the steering wheel from the
steering shaft.

2. Install and align the steering wheel and loosely
secure with the nut.

NOTE: This model has a castle nut/lock clip and
drilled steering shaft. The lock clip will be in the
steering wheel hardware package.

3. Verify that the steering wheel is oriented correctly
and the front wheels are aligned straight forward;
then apply one drop of red Loctite #271 to the
threads and tighten the nut to 34 N-m (25 ft-lb).

4. Install the lock clip through the steering shaft and
nut. Install the steering wheel cover.

12. Repeat steps 9-11 for opposite side.

PR831A

5

HDX131A

PR792A

NOTE: If the hole in the steering shaft does not
align with the slots in the castle nut, tighten the nut
slightly until the next slot aligns with the hole.

CHECKING/ADJUSTING FRONT
WHEEL ALIGNMENT

NOTE: All measurements and adjustments must
be made with the vehicle unloaded.

Mark the center-line of the front tires at the front and
rear of the tire; then using a tape measure, measure and
record the distance between the marks at the front and
rear. The front measurement should be 3-6 mm (1/8-1/4
in.) greater than the rear measurement (toe-out).

CAUTION

Always use a wrench to hold the tie rod ends when
loosening or tightening the jam nuts or damage to
the boots could occur.

2. Turn the left-side and right-side tie rods (C) in equal
increments to achieve the proper toe-out; then
tighten the jam nuts securely.

3. Check for free steering operation (full-left/full-right).

CHECKING HYDRAULIC BRAKE
SYSTEM

The hydraulic brake system has been filled and bled at the

factory.

1. With the hydraulic brake reservoir in a level posi­tion, check the fluid level. It must be visible at the
MAX line.

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 (A), loosen the
right-side and left-side jam nuts (B).

HDX098B

6

TC021A

2. Press the brake pedal several times to check for
firmness. If the pedal is not firm, the brake system
must be bled.

3. To bleed the brake system, use the following procedure:

A. Remove the cover and fill the reservoir with

DOT 4 approved brake fluid.

B. Install and secure the cover; then slowly press

the brake pedal several times.

C. Install one end of a clear hose onto the REAR

bleed screw and direct the other end into a con­tainer; then while holding slight pressure on the
brake pedal, open the bleed screw and watch for
air bubbles. Close the bleed screw before
releasing the brake pedal. Repeat this procedure
until no air bubbles are present.

PR080A

NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always
a sufficient amount of brake fluid. If the fluid level
gets low in the reservoir, refill the reservoir before
the bleeding procedure is continued.

2. Depress the accelerator pedal completely and pull
rearward on the cable end. There should not be any
free-play and the tension sleeve should not be com­pressed.

PR709A

3. To adjust the throttle cable, remove the throttle arm
cover on the throttle body; then loosen the two
adjuster nuts and adjust for proper free-play.

D. Repeat step C until the brake pedal is firm.
E. At this point, perform step B, C, and D on the

FRONT RIGHT bleed screw; then move to the
FRONT LEFT bleed screws and follow the same
procedure.

4. Carefully check the entire hydraulic brake system
that all hose connections are tight, the bleed screws
are tight, and no leakage is present.

5. Make sure to burnish the brake pads during the test ride.

CHECKING THROTTLE CABLE
ADJUSTMENT

1. Check cable free-play by grasping the cable at the
top of the accelerator pedal and lightly pulling rear­ward to remove slack. Free-play should be 1-2 mm
(0.040-0.080 in.).

TC020A

4. Tighten the jam nut securely.

CHECKING ENGINE/
TRANSMISSION OIL LEVEL

NOTE: Inspect the area around the drain plug
(under the vehicle) and oil filter (front of the
engine) for leaks.

PR708A

PR078A

NOTE: To access the oil filter, remove the seat.
Remove the screws securing the seat back and
remove the seat back; then remove the screws
securing the seat base and remove the seat base.

7

NOTE: The vehicle should be on level ground
when checking the engine oil level.

Recommended Engine/
Transmission Oil

1. Raise the cargo box; then unscrew the oil level stick
and wipe it with a clean cloth.

700

PR053B

500

CAUTION

Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These
oils can adversely affect clutch operation. Also, not
recommended are racing, vegetable, non-detergent,
and castor-based oils.

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 recom-

mended for use in this engine, use of any API certified
SM All-Weather synthetic 0W-40 oil is acceptable.

OILCHARTJ

HDX234A

2. Install the oil level stick into the engine case thread­ing the stick in for checking purposes.

3. Remove the oil level stick; the engine oil level
should be within the operating range but not above
the FULL mark.

GZ461A

CAUTION

Do not over-fill the engine with oil. Always make sure
the oil level is within the operating range.

CHECKING GEAR CASE
LUBRICANT LEVELS

1. Remove the front differential level plug; lubricant should
be visible at the plug threads. If low, add SAE approved
80W -90 hypoid lubricant to the fill plug as necessary.
Install the plug and tighten to 22 N-m (16 ft-lb).

CAUTION

Any lubricant used in place of the recommended lubri­cant could cause serious front differential damage.

HDX083A

2. Remove the rear drive level plug; lubricant should be
visible at the plug threads. If low, add SAE approved
80W -90 hypoid lubricant to the fill plug as necessary.
Install the plug and tighten to 22 N-m (16 ft-lb).

CAUTION

Any lubricant used in place of the recommended
lubricant could cause serious rear drive damage.

8