Toro UTV500AAC00000, UTV700AAC00000 Service Manual
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. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
This service manual is designed primarily for use by a Toro USD (Unlisted Service Dealer). The procedures found in
this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to
be completed. The technician should use sound judgement when determining which procedures can be completed
based on their skill level and access to appropriate special tools.
All Toro 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 damage. Follow the directive because it deals with the possibility
of damaging part or parts of the vehicle. The symbol NOTE: identifies supplementary information worthy of partic-
ular attention. The symbol
mote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because ToroExmark constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
AT THIS POINT directs the technician to certain and specific procedures to pro-
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Toro
© 2015 Toro April 2015
®™ Trademarks of Toro
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
1
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
Tire Size (front)
Tire Inflation Pressure 1.12 kg/cm² (16 psi) - 500
Spark Plug Type NGK CR7E - 500
Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)
Gas Tank Capacity 31 L (8.2 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Front Differential Capacity 275 ml (9.3 fl oz)*
Rear Drive Capacity 250 ml (8.5 fl oz)*
Engine Oil Capacity (approx) (500)
Gasoline (recommended) 87 Octane Regular
Engine Oil (recommended) Toro ACX All Weather Syn-
Front Differential/Rear Drive Lubricant
(One inch below plug threads)
Belt Width (minimum) 28.5 mm (1.12 in.) - 500
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (4)
ELECTRICAL SYSTEM
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Cap
Ignition Coil Resistance (primary)
(secondary)
Ignition Coil Primary Voltage Battery Voltage
Stator Coil Resistance (CKP Sensor)
AC Generator Output (no load)
Crankshaft Position Sensor AC Voltage 2.5 volts or more - 500
(AC generator)
Specifications subject to change without notice.
26 x 10R-14
(rear)
26 x 12R-14
1.41 kg/cm² (20 psi) - 700
NGK CPR8E - 700
-500
0.5-0.6 mm (0.019-0.024 in.)
- 700
3.3 L (3.5 U.S. qt) - Overhaul
2.8L(3.0U.S.qt)-Change
(700)
2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
Unleaded
thetic
SAE Approved 80W-90 Hyp-
oid
35.0 mm (1.38 in.) - 700
5000 ohms
Less than 5.0 ohms - 500
Less than 1 ohm - 700
12k-19k ohms - 500
1.8M ohms - 700
104-156 ohms
Less than 1 ohm
60 AC volts @
2.0 volts or more - 700
5000 RPM
CYLINDER, PISTON, AND RINGS (500)
Piston Skirt/Cylinder Clearance 0.025-0.055 mm
Piston Diameter 8 mm from Skirt End 88.96-88.98 mm
Piston Ring Free End Gap (max) (1st)
Bore x Stroke 89.0 x 71.2 mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap - Installed (min) 0.15 mm
Piston Ring to Groove Clearance (max) (1st/
2nd)
Piston Ring Groove Width (1st)
Piston Ring Thickness (1st)
Piston Pin Bore (max) 20.008 mm
Piston Pin (min) 19.994 mm
CYLINDER, PISTON, AND RINGS (700)
Piston Skirt/Cylinder Clearance (min) 0.06 mm
Cylinder Bore 101.992-102.008 mm
Piston Diameter 15 mm from Skirt End 101.930-101.949 mm
Piston Ring Free End Gap (1st/2nd) 12.5 mm
BorexStroke 102x85mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap - Installed (min) 0.38 mm
Piston Ring to Groove Clearance (max)
(1st/2nd)
Piston Ring Groove Width (1st/2nd)
Piston Ring Thickness (1st/2nd) 1.970-1.990 mm
Piston Pin Bore (max) 23.0 mm
Piston Pin Outside Diameter (min) 22.99 mm
(2nd)
(2nd)
(2nd)
(oil)
(oil)
11.6 mm
10.1 mm
0.06 mm
1.01-1.03 mm
1.21-1.23 mm
2.01-2.03 mm
0.97-.99 mm
1.17-1.19 mm
0.03 mm
1.202-1.204 mm
2.01-2.03 mm
VALVES AND GUIDES (500)
Valve Face Diameter (intake)
Valve/Tappet Clearance (intake)
(cold engine) (exhaust)
Valve Guide/Stem (intake)
Clearance (max) (exhaust)
Valve Guide Inside Diameter 5.000-5.012 mm
Valve Seat Angle (intake/exhaust) 45°
Valve Spring Free Length (min)
Valve Spring Tension @ 35.2 mm
VALVES AND GUIDES (700)
Valve Face Diameter (intake)
Valve/Tappet Clearance (intake)
(cold engine) (exhaust)
Valve Guide/Stem Clearance 0.013 mm
Valve Guide Inside Diameter 5.000-5.012 mm
Valve Head Thickness (min) 2.3 mm
Valve Seat Angle 45° +15’/+30’
Valve Spring Free Length (min) 38.7 mm
Valve Spring Tension @ 31.5 mm 19.0 kg (42 lb)
(exhaust)
(exhaust)
35.0 mm
30.5 mm
0.10 mm
0.17 mm
0.10 mm
0.30 mm
44.73 mm
17.23 kg (37.98 lb)
31.6 mm
27.9 mm
0.1016 mm
0.1524 mm
2
CRANKSHAFT (500)
Connecting Rod (small end) (max)
Connecting Rod (big end side-to-side)
(max)
Connecting Rod (big end width)
Connecting Rod (small end deflection)
(max)
Crankshaft (web-to-web)
Crankshaft Runout (max)
20.021 mm
0.7 mm
21.95-22.00 mm
3.0 mm
60.9 mm
0.03 mm
CRANKSHAFT 700)
Connecting Rod (small end inside (max)
(diameter)
Connecting Rod (big end side-to-side)(min) 0.6 mm
Connecting Rod @ 150 mm (max)
(small end deflection)
Crankshaft (web-to-web) (min) 71 mm
Crankshaft Runout (max) 0.03 mm
23.021 mm
0.3 mm
CAMSHAFT AND CYLINDER HEAD (500)
Cam Lobe Height (min) (intake)
Camshaft Journal Holder(right & center)
Inside Diameter (left)
Camshaft Journal Outside(right & center)
Diameter (left)
Camshaft Runout (max) 0.03 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
(exhaust)
34.71 mm
34.48 mm
22.01-22.04 mm
17.51-17.54 mm
17.466-17.480 mm
21.966- 21.980 mm
CAMSHAFT AND CYLINDER HEAD (700)
Cam Lobe Height (min) 33.53 mm
Camshaft Journal Oil Clearance (max) 0.04 mm
Camshaft Runout (max) 0.05 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
EXHAUST COMPONENTS
Part Part Bolted To
Exhaust Pipe Cylinder Head
Spark Arrester Muffler
O2 Sensor Exhaust Pipe
BRAKE COMPONENTS
Brake Disc** Hub
Brake Hose Caliper
Brake Hose Master Cylinder
Master Cylinder Frame
Caliper**** Knuckle
Rear Driveline **** Rear Differential
ELECTRICAL COMPONENTS
Coil* Frame
Torque
ft-lb N-m
20 27
50
in.-lb
19 26
15 20
20 27
20 27
25 34
20 27
12 16
811
5
DRIVE TRAIN COMPONENTS
Part Part Bolted To
Rear Differential/Gear Case Frame
Front Engine Mounting
Bracket
Rear Engine Mounting BracketFrame
Engine Mounting Through-Bolt Frame
Front Differential Frame/Differential Bracket
Rear Output Flange Rear Driven Flange
Input Shaft Assembly Gear Case Housing
Pinion Housing Differential Housing
Secondary Shaft Bearing
Housing
Rear Cradle Frame
Driveshaft (Front/Rear) Engine
Shift Cable Bracket Engine
Front Input Drive Flange Front Drive Yoke Flange
Differential Housing Cover*** Differential Housing
Thrust Button** Gear Case Cover
Drive Bevel Gear Nut*** Shaft
Lock Collar Differential Housing
Hub Nut Front/Rear Shaft/Axle (min)
Oil Drain Plug Front Differential - Rear
Oil Fill Plug Front Differential - Rear
Oil Drain Plug Engine
Wheel (Aluminum) Hub
Wheel (Steel) Hub
Frame
Crankcase
Drive
Drive
STEERING COMPONENTS
Steering Wheel** Steering Wheel Shaft
Steering Wheel Shaft*** Intermediate Shaft (Upper)
Intermediate Shaft (Lower)*** Steering Pinion Shaft
Rack and Pinion Assembly Frame
Tie Rod Rack
Tie Rod End** Knuckle
Jam Nut Tie Rod End
Intermediate Shaft Coupler Inter mediate Shaft
Steering Shaft Housing (6
mm)
Steering Shaft Housing (8
mm)
Frame
Frame
CHASSIS/ROPS ASSEMBLY
Shift Axle Support Frame
Front/Rear ROPS Tube Arm Rest/Steering Support
Top ROPS Support Front/Rear ROPS Tubes
Rear ROPS Tube Lower ROPS Support
Shift Cable Shift Arm Stud
Shift Cable Mounting/Adjuster Shift Cable
Cargo Box Hinge Cargo Box Frame
Side Panel/Spacer Cargo Box Frame
Tilt Pivot Bushing Cargo Box Frame
Latch Striker Cargo Box Liner
SUSPENSION COMPONENTS
A-Arm Frame
Knuckle Ball Joint
Shock Absorber Frame/Upper A-Arm
Shock Absorber (Front) Lower A-Arm
Shock Absorber (Rear) Lower A-Arm
Knuckle A-Arm
Sway Bar Bracket (Rear) Frame
Torque
ft-lb N-m
38 48
45 61
45 61
40 54
38 52
40 54
23 31
23 31
28 38
25 34
20 27
811
20 27
23 31
811
87 118
125 170
200 272
45
in.-lb
16 22
16 22
80 108
40 54
25 34
31 42
36 49
35 48
37 50
30 41
10 14
31 42
811
20 27
48
in.-lb
35 48
35 48
35 48
834
20 27
20 27
25 34
15 20
60
in.-lb
35 48
35 48
35 48
20 27
35 48
35 48
35 48
5
5
7
* w/Blue Loctite #243 ** w/Red Loctite #271
*** w/Green Loctite #270 **** w/“Patch-Lock”
3
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 Adjuster Jam Nut Valve Adjuster
Starter Motor** Crankcase
Oil Fitting Engine
Starter One-Way Clutch** Rotor/Flywheel
Oil Pump** Crankcase
Movable Drive Face Nut** Clutch Shaft
Output Shaft Flange Nut Output Shaft
Cam Chain Tensioner Guide Cylinder
Valve Inspection Cover Cylinder Head Cover
Cam Chain Tensioner Cylinder
Magneto Cover Crankcase
Water Pump Cover/Housing Magneto Cover
Water Pump Drive Gear Crankshaft
Air Filter Frame
Oil Strainer Cap Crankcase
V-belt Cover Crankcase
Torque
ft-lb N-m
147 199
811
10 13.5
21 28
811
28 38
20 27
811
63 86
147 199
811
107 146
11 15
7 9.5
811
811
26 35
811
147 199
59 80
11 15
811
10 13.5
811
811
28 38
12 16
10 13.5
811
ENGINE/TRANSMISSION (700)
Part Part Bolted To
Clutch Shoe** Crankshaft
Clutch Cover/Housing Assem-
bly
Crankcase Half (6 mm) Crankcase Half
Crankcase Half (8 mm) Crankcase Half
Cylinder Head (Cap Screw) Crankcase
Cylinder Head Nut (6 mm) Cylinder
Cylinder Head Nut (8 mm) Cylinder
Valve Cover Cylinder Head
Driven Pulley Nut Dr iveshaft
Movable Drive Face Nut** Driveshaft
Ground Wire Engine
Magneto Cover Crankcase
Crankshaft Spacer Crankshaft
Oil Pump** Crankcase
Oil Pump Drive Gear** Crank Balancer Shaft
Output Shaft Flange Nut** Output Shaft
One-Way Clutch** Rotor/Flywheel
Outer Magneto Cover Side Cover
Magneto Rotor Nut** Crankshaft
Cam Sprocket** Camshaft
Speed Sensor Housing Crankcase
V-Belt Cover Crankcase
Output Yoke Nut** Secondary Driven Output
Output Shaft Flange Yoke/
Nut**
Secondary Shaft Bearing
Housing
Stator Coil* Magneto Cover
Intake Manifold Boot Clamp Intake Boot
Water Pump Engine
Oil Strainer Cap Crankcase
Air Filter Frame
Shift Cam Plate** Camshaft
Crankshaft Bushing Crankshaft
Crankcase
Shaft
Output Shaft
Crankcase Half
Torque
ft-lb N-m
221 300
811
10 13.5
20 27
40 54
811
18 24
811
162 220
165 224
811
811
28 38
811
62 84
62 84
26 35
811
105 143
11 15
811
811
74 100
59 80
28 38
13 18
30 in.-lb3.4
811
10 13.5
12 16
811
25 34
4
Torque Conversions
(ft-lb/N-m)
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
1 1.4 26 35.4 51 69.4 76 103.4
2 2.7 27 36.7 52 70.7 77 104.7
3 4.1 28 38.1 53 72.1 78 106.1
4 5.4 29 39.4 54 73.4 79 107.4
5 6.8 30 40.8 55 74.8 80 108.8
6 8.2 31 42.2 56 76.2 81 110.2
7 9.5 32 43.5 57 77.5 82 111.5
8 10.9 33 44.9 58 78.9 83 112.9
9 12.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
Gasoline - Oil - Lubricant
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.
OILCHARTJ
RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT
NOTE: Toro recommends the use of genuine Toro
lubricants.
The recommended front differential/rear drive lubricant
is SAE approved 80W-90 hypoid. This lubricant meets
all of the lubrication requirements of this vehicle.
CAUTION
Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive
damage.
RECOMMENDED GASOLINE
The recommended gasoline to use in this vehicle is 87
minimum octane regular unleaded. In many areas, oxygenates are added to the gasoline. Oxygenated gasolines
containing up to 10% ethanol or 5% methane are acceptable gasolines.
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
CAUTION
Do not use white gas. Only recommended gasoline additives should be used.
RECOMMENDED ENGINE/ TRANSMISSION OIL
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.
FILLING GAS TANK
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the gas tank near any open flames or with
the engine running. DO NOT SMOKE while filling the
gas tank.
Since gasoline expands as its temperature rises, the gas
tank must be filled to its specified capacity only. Expansion room must be maintained in the tank particularly if
the tank is filled with cold gasoline and then moved to a
warm area.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materializ e. Always allow the engine to
cool before filling the gas tank.
Tighten the gas tank cap securely after filling the tank.
! WARNING
Do not over-fill the gas tank.
5
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.
8. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed coolant.
9. Disconnect the battery cables (negative cable first);
then remove the battery, clean the battery posts and
cables, and store in a clean, dry area.
NOTE: For storage, use a battery maintainer or
make sure the battery is fully charged (see Battery
section in this manual).
Special Tools
A number of special tools must be available to the technician when performing service procedures in this manual.
Refer to the current Special Tools Catalog for the appropriate tool description.
Description p/n
Crankcase Separator/Crankshaft Remover
Gear Case Seal Installer Tool
Magneto Rotor Remover Set
Valve Clearance Adjuster
Driven Clutch Holder
Clutch Cover Seal Installation Tool
Slide Hammer 6 mm Adapter
Spanner Wrench
Fuel Pressure Tester Kit
CVT Pulley Holder
132-3161
132-3162
132-3164
132-3165
132-3166
132-3167
132-3168
132-3188
132-3198
132-3180
NOTE: Special tools are available from the Toro Ser-
vice Department.
Preparation For Storage
10. Store the vehicle indoors in a level position.
CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the vehicle
causing rusting.
Preparation After
Storage
Taking this vehicle out of storage and correctly preparing
it will assure many miles and hours of trouble-free riding.
Toro recommends the following procedure.
1. Clean the vehicle thoroughly.
2. Clean the engine. Remove the cloth from the exhaust
system.
3. Check all control wires and cables for signs of wear
or fraying. Replace if necessary.
4. Change the engine/transmission oil and filter.
5. Check the coolant level and add properly mixed
coolant as necessary.
CAUTION
Prior to storing the vehicle, it must be properly serviced
to prevent rusting and component deterioration.
1. Clean the seat cushions with a damp cloth and allow
to dry.
2. Clean the vehicle thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire vehicle. Allow the vehicle to dry thoroughly. DO NOT
get water into any part of the engine or air intake.
3. Either drain the gas tank or add a fuel stabilizer to the
gas in the gas tank.
4. Clean the interior of the air filter housing.
5. Plug the hole in the exhaust system with a clean cloth.
6. Apply light oil to the upper steering shaft bushing
and plungers of the shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws. Make sure
rivets holding components together are tight. Replace all
loose rivets. Care must be taken that all calibrated nuts,
cap screws, and bolts are tightened to specifications.
6. Charge the battery; then install. Connect the battery
cables making sure to connect the positive cable first.
CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace if necessary.
8. Check the tire pressure. Inflate to recommended
pressure as necessary.
9. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are
tightened to specifications.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as necessary.
6
Periodic Maintenance
This section has been organized into sub-sections which show
common maintenance procedures for the T oro ROV .
Periodic Maintenance
Chart
A = Adjust I = Inspect C = Clean R = Replace T = Tighten L = Lubricate
Item
Battery
Fuses
Air Filter
Valve/Tappet Clearance
Engine Compression
Spark Plug
Muffler/Spark Arrester
Gas Hoses
Throttle Cable Ends/Accelerator Pedal Pivot
Engine-Transmission Oil Level
Engine-Transmission Oil/Filter
Front Differential - Rear Drive Lubricant
Tires/Air Pressure
Steering Components
V-Belt
Suspension (Ball joint boots, drive axle
boots front and rear, tie rods, differential
and rear drive bellows)
Nuts/Bolts/Cap Screws
Ignition Timing
Headlight/Taillight-Brakelight
Switches
Shift Lever
Gauges/Indicators
Frame/Welds
Electrical Connections
Complete Brake System (Hydraulic)
Brake Pads
Brake Fluid
Brake Hoses
Coolant/Cooling System
Wheel Lug Nuts
Initial Service
After Break-In
(First Month or
100 Miles)
II C
II* R
IIA
I I I R (4000 Mi or
I I R (2 Yrs)
II C-L A-R
R R*/R**/R*** R
I I R (4 Yrs)
II R
II I R
IlR
II R
TT A
II R
II R
II R
II l
II
II* R
I I R (2 Yrs)
I I R (4 Yrs)
I I R (2 Yrs)
TT
Every
Every Month or
Day
Every 100 Miles
I A
Every 3
Months or
Every 300
Miles
IR
Every 6
Months or
Every 500
Miles
CR
IA-L
lC
* Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil.
***
When using Toro 0W-40 All Weather synthetic oil, oil change interval can be increased to every 1600 km (1,000) miles or every year.
Every Year or
Every 1500
Miles
I
I
As
Needed
18 Mo)
7
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.
A. Accelerator Pedal Pivot/Cable Ends
B. Brake Pedal Pivot
C. Shift Cable
Air Inlet Pre-Filter
This vehicle is equipped with a foam pre-filter to filter
dirt from the inlet air prior to reaching the main air filter.
1. Raise the cargo box; then gently squeeze the pre-filter cover and lift it up to expose the pre-filter.
CAUTION
Failure to inspect the air filter frequently if the vehicle is
used in dusty, wet, or muddy conditions can damage
the engine.
NOTE: To access the air filter, raise the cargo box.
1. Remove dirt and debris from around the filter housing.
2. Unsnap the four spring-clip fasteners and remove the
air filter cover.
HDX050A
3. Remove the two knobs securing the filter; then
remove the metal hold-down and filter.
HDX237A
2. Loosen the clamp securing the pre-filter.
HDX235
2. Remove the pre-filter assembly and wash thoroughly
in warm, soapy water; then rinse and dry.
3. Install and secure with the clamp. Tighten securely;
then with the pre-filter cover installed, lower the
cargo box.
HDX226A
4. Fill a wash pan larger than the element with a soapy
water; then dip the element in the soapy water and
wash it.
5. Squeeze the element by pressing it between the
palms of both hands to remove excess soapy water.
Do no twist or ring the element or it will tear.
6. Dry the element.
7. Put the element in a plastic bag; then pour in air filter
oil and work the oil into the element.
8
8. Squeeze the element to remove excess oil.
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.
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
Feeler Gauge Procedure
9. Clean any dirt or debris from inside the filter housing.
10. Install the air filter and metal hold-down, secure with
the two knobs tightened to 16 N-m (12 ft-lb), and
install the cover. Secure with the four clips.
11. Lower the cargo box.
AIR FILTER HOUSING DRAINS
500
TC033A
700
Using a feeler gauge, check each valve/tappet clearance.
If clearance is not within specifications, loosen the jam
nut and rotate the tappet adjuster screw until the clearance is within specifications. Tighten each jam nut to 7
ft-lb after completing the adjustment.
CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate measurement of clearance. Failure to measure the valve clearance accurately could cause valve component damage.
VALVE/TAPPET CLEARANCE
Intake 0.1016 mm (0.004 in.)
Exhaust 0.1524 mm (0.006 in.)
TC034A
Inspect and squeeze the “duck bill” drain beneath the
main housing for debris and for proper sealing.
Remove the tube drain and clean out any water, oil, or
debris. Reinstall and secure with the clamp.
Valve/Tappet Clearance
NOTE: The engine must be cold for this procedure.
NOTE: The seat, seat back, seat base, and spark
plug must be removed for this procedure.
1. Remove the spark plug and timing inspection plug; then
remove the tappet covers (for more detailed information, see the Engine/Transmission section - Servicing
Top-Side Components).
CC007D
Valve Adjuster Procedure
A. Place the Valve Clearance Adjuster onto the jam
nut securing the tappet adjuster screw; then rotate
the valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.
B. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
C. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
D. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
NOTE: Refer to the specifications in Feeler Gauge
Procedure sub-section for the proper valve/tappet
clearance.
NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
E. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.
9
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
NOTE: The engine should be warm (operating tem-
perature) and the battery fully charged for an accurate compression test. The throttle must be in the
wide-open throttle (WOT) position. In the event the
engine cannot be run, cold values are included.
NOTE: The seat, seat back, and seat base must be
removed for this procedure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from around
the spark plug.
! WARNING
Always wear safety glasses when using compressed
air.
3. Remove the spark plug; then attach the high tension
lead to the plug and ground the plug on the cylinder
head well away from the spark plug hole.
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.
ATV-0051
CAUTION
Before removing the spark plug, be sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.
Adjust the gap to 0.5-0.6 mm (0.019-0.024 in.).
4. Attach a suitable compression tester.
5. While holding the throttle in the full-open position,
crank the engine over with the electric starter until the
gauge stops climbing (five to 10 compression strokes).
PSI Hot (WOT) PSI Cold (WOT)
125-145 100-140
6. If compression is abnormally low, inspect the following items.
A. Starter cranks engine over.
B. Gauge is functioning properly.
C. Throttle in the full-open position.
D. Valve/tappet clearance correct.
E. Engine warmed up.
F. Intake obstructed.
NOTE: To service top-side components, see the
Engine/Transmission section.
7. Pour approximately 30 ml (1 fl oz) of oil into the spark
plug hole, reattach the gauge, and retest compression.
8. If compression is now evident, service the piston rings
(see the appropriate Engine/Transmission - Top Side
Components).
ATV0052
A new spark plug should be tightened 1/2 turn once the
washer contacts the cylinder head. A used spark plug
should be tightened 1/8 - 1/4 turn once the washer contacts the cylinder head.
Muffler/Spark Arrester
Clean the spark arrester using the following procedure.
! WARNING
Wait until the muffler cools to avoid burns.
1. Open the cargo box and remove the two springs
securing the muffler to the exhaust pipe.
10
HDX238A
2. Remove the muffler by pulling it rearward out of the
vehicle.
3. Remove the heat shield.
HDX242
NOTE: If the screen or gasket is damaged in any
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. Remove the three cap screws securing the exhaust
pipe/spark arrester assembly to the muffler.
HDX243A
5. Using a wire brush, clean the carbon deposits from
the screen taking care not to damage the screen.
Change the engine oil and oil filter at the scheduled intervals. The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the vehicle on level ground.
2. Remove the seat; then remove the backrest and seat
base.
3.
Loosen the oil fill cap using a 27 mm socket (700) or
oil level stick (500). Be careful not to allow contaminants to enter the opening.
700
HDX042A
11
500
HDX234A
4. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan.
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).
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.
GZ461A
10. Inspect the area around the drain plug and oil filter
for leaks.
PR078A
5. Use an appropriate oil filter wrench to remove the old oil
filter and dispose of properly. Do not re-use oil filter.
NOTE: To access the filter, remove the seat, seat
back, and seat base (see Seats in General Information).
NOTE: Clean up any excess oil after removing the filter.
6. Apply oil to the new filter O-ring and check to make sure
it is positioned correctly; then install the new oil filter.
Tighten 3/4 turn after contact with the sealing flange.
11. Install the seat base, seat, and backrest.
Front Differential - Rear
Drive Lubricant
To check lubricant, use the following procedure.
1. Remove the level plug (B); the lubricant should be
level with the bottom threads.
HDX221A
2. If low, remove the fill plug (A) and add the appropriate lubricant until it appears at the bottom of the level
plug threads.
12
TC031
To change the lubricant, use the following procedure.
1. Place the vehicle on level ground.
2. Remove the front differential and rear drive fill
plugs.
3. Drain the lubricant into a drain pan by removing the
drain plug from the front differential and rear drive.
Headlight/Taillight-
Brakelight
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.
HDX255
HDX220A
4. After all the lubricant has been drained, install the
drain plugs and tighten to 5 N-m (45 in.-lb).
5. Pour SAE approved 80W-90 hypoid lubricant into
each fill hole until it flows out of the hole.
6. Install the fill plugs and tighten to 22 N-m (16 ft-lb).
NOTE: If the lubricant is contaminated with water,
inspect the drain plug, fill plug, and/or bladder.
! WARNING
Do not attempt to remove the bulb when it is hot. Severe
burns may result.
To replace the headlight bulb, use the following procedure.
1. Remove the wiring harness connector from the back
of the headlight.
2. Grasp the bulb housing, turn it counterclockwise,
and remove the housing. Remove the bulb.
3. Install the new bulb into the housing; then install the
housing and rotate it completely clockwise.
4. Install the wiring harness connector.
To replace the taillight/brakelight bulb, use the following
procedure.
1. Remove the mounting screws securing the taillight/
brakelight assembly to the rear ROPS tube.
2. Rotate the socket counterclockwise and remove it
from the housing.
3. To remove the bulb from the socket, pull it straight
out of the socket.
Driveshaft/Coupling
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Coupling cracked, damaged, or worn.
C. Universal joints worn or missing bearings.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure rivets
holding components together are tight. Replace all loose
rivets. Care must be taken that all calibrated nuts, bolts,
and cap screws are tightened to specifications.
4. To install the bulb, push it straight into the socket.
5. Insert the socket into the housing and rotate it clockwise.
6. Position the taillight/brakelight assembly on the rear
ROPS tube; then tighten the mounting screws
securely.
CHECKING/ADJUSTING HEADLIGHT AIM
The headlights can be adjusted vertically. The center of
the HIGH beam light zone is to be used for aiming.
1. Position the vehicle on a level floor so the headlights
are approximately 6.1 m (20 ft) from an aiming surface (wall or similar aiming surface).
13
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. Using the measurements obtained in step 2, make
horizontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal
marks on the aiming surface directly in front of the
headlights.
5. Switch on the lights. Make sure the HIGH beam is
on. DO NOT USE LOW BEAM.
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.
700
HDX251
6. Observe each headlight beam aim. Proper aim is
when the HIGH beam is centered on the vertical
mark 5 cm (2 in.) below the horizontal mark on the
aiming surface.
7. Turn the adjuster nut clockwise to raise the beam and
counterclockwise to lower the beam.
TC004A
Shift Lever
CHECKING SHIFT CABLE ADJUSTMENT
500
HDX254
3. Loosen nuts (A) and (B) and adjust the cable housing
to align the shift cable end to the shift arm stud.
PR568A
4. Install the E-clip; then tighten the nuts (A) and (B) to
8 ft-lb.
1. Turn the ignition switch on; then with the shift lever
in the neutral position, look for the (N) indication on
the LCD. Shift into high range and look for the (H)
indication, low range for the (L) indication, and
reverse for the (R) indication.
14
5. Check each gear shift position for proper gear selection and make sure the proper icon illuminates on the
LCD.
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.
REAR 700
AF637D
FRONT
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.
To bleed the brake system, use the following procedure.
A. Remove the cover and fill the reservoir with DOT
4 Brake Fluid; then install and secure the cover.
B. Slowly depress the brake pedal several times.
C. Remove the protective cap, install one end of a
clear hose onto the RIGHT REAR (700) or REAR
DRIVELINE (500) bleeder screw, and direct the
other end into a container; then while holding
slight pressure on the brake pedal, open the
bleeder screw and watch for air bubbles. Close the
bleeder screw before releasing the brake pedal.
Repeat this procedure until no air bubbles are
present. Repeat B and C for the rear left.
PR377C
NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always a
sufficient amount of brake fluid. When the level falls
below MIN, refill the reservoir before the bleeding
procedure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air
in the system.
D. At this point, perform steps B and C on the REAR
LEFT bleeder screw (700 only); then move to the
FRONT RIGHT bleeder screw and follow the
same procedure. Finally, complete the procedure
on the FRONT LEFT bleeder screw.
E. Repeat steps B and C until the brake pedal is firm.
3. Carefully check the entire hydraulic brake system to
ensure all hose connections are tight, the bleed
screws are tight, the protective caps are installed, and
no leakage is present.
CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must be
taken as brake fluid is very corrosive to painted surfaces.
REAR 500
HDX236A
INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.
15
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.
PR376A
3. If thickness of either brake pad is less than 1.0 mm
(0.039 in.), the brake pads must be replaced.
PR377B
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.
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)
NOTE: The brake pads should be replaced as a set.
4. T o replace the brake pads, use the following procedure.
A. Remove the cap screws securing the caliper holder to
the knuckle; then remove the pads from the caliper.
PR237
B. Install the new brake pads.
C. Secure the caliper holder to the knuckle with new
“patch-lock” cap screws. Tighten to 20 ft-lb.
PR941A
CAUTION
Using an impact wrench could result in incorrect torque
which could damage the wheel or hub studs.
6. Burnish the brake pads.
BRAKE DISC
Using a micrometer, measure the thickness of the brake
disc in the contact surface. If thickness is 0.125 in. or
less, the disc must be replaced. To replace the brake disc,
see Drive System – Hub.
Burnishing Brake Pads
Brake pads must be burnished to achieve full braking
effectiveness. Braking distance will be extended until
brake pads are properly burnished. To properly burnish
the brake pads, use the following procedure.
16
! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.
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 V-
Belt
REMOVING
1. Remove the seat, seat back, and seat base; then
remove the floor and gas tank.
2. Remove the cap screws securing the CVT cover noting the location of the different-lengthed cap screws
for installing purposes; then using a rubber mallet,
gently tap on the cover tabs to loosen the cover.
Remove the cover.
CD966A
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. Remove the Vbelt.
CF363
3. Remove the nut securing the movable drive face;
then remove the face. Account for the spacer.
NOTE: Keep the drive face plate in contact with the
drive face when removing or installing the drive face
to prevent the rollers from falling out.
GZ076
GZ085
INSTALLING
1. Place the V-belt into position on the driven pulley
and over the front shaft.
CF364A
17
GZ085
NOTE: The arrows on the V-belt should point in
direction of engine rotation (forward).
CF379
NOTE: At this point, the CVT cover cap screw can
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).
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.
3. With the vehicle in neutral, rotate the V-belt and
clutches counterclockwise until the V-belt is flush
with the top of the driven pulley.
4. Place the CVT cover gasket into position; then install
the cover and secure with the cap screws making
sure the different-lengthed cap screws are in their
proper location. Tighten the cap screws to 8 ft-lb.
CF363
5. Install the gas tank and floor; then install the seat
back, seat base, and seat.
18
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 full-
right capability.
C. Steering assembly mounting bolts tight.
D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
The frame and welds should be checked periodically for
damage, bends, cracks, deterioration, broken components, and missing components.
Steering Wheel
REMOVING
HDX131A
Tie Rods
REMOVING
1. Remove the steering rack assembly (see Steering
Assembly in this section).
2. Support the steering rack assembly in a suitable
holding fixture or bench vise; then cut the securing
band and slide the boot toward the outer tie rod end.
3. Using a punch or chisel, bend the lock washer away
from the flats on the tie rod joint.
1. Remove the steering wheel cover; then match mark
the steering shaft and steering wheel.
NOTE: Any time steering components are disas-
sembled, all connecting components should be
marked for proper alignment during assembling.
2. Remove the lock clip from the steering shaft; then
remove the nut securing the steering wheel and
remove the steering wheel.
INSPECTING
1. Inspect the steering wheel for cracks, missing padding, or broken spokes.
2. Inspect the splines for wear.
3. Check that the steering wheel is not bent.
INSTALLING
1. Install the steering wheel aligning the two match
marks; then apply a drop of red Loctite #271 to the
threads of the nut and secure the steering wheel.
Tighten to 25 ft-lb.
NOTE: If a new steering wheel is being installed,
mark the wheel as close as possible to the old wheel
mark; then check for proper positioning with the front
wheels straight forward.
2. Install the lock clip on the steering shaft.
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.
PR780
4. Using an appropriate crow-foot and backing wrench,
remove the tie rod assembly.
NOTE: Tie rods come as a complete assembly. No
further disassembly is required.
5. Remove and discard the lock washer.
INSTALLING
1. Remove the tie rod end and lock nut from the tie rod;
then install the tie rod boot onto the tie rod.
2. Install the tie rod lock nut and tie rod end.
3. Coat the tie rod joint threads with red Loctite #271;
then with a new lock washer, thread the tie rod into
the rack.
19
PR784
4. While holding the rack shaft with a wrench, tighten
the tie rod joint to 37 ft-lb using an appropriate crowfoot.
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.
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.
PR528A
5. Install the boot onto the rack and secure with the
nylon tie.
6. Center the rack in the steering rack assembly and
align the white paint line on the pinion with the mark
on the rack housing.
20
PR301
3. Remove the cap screws securing the steering rack
assembly to the rack bracket and remove from the
left side.
INSPECTING
1. Inspect the tie rod ends for damaged threads, torn
boots, or excessive wear.
2. Inspect the tie rods for bends or deformation.
3. Inspect the rack and pinion-to-tie rod boots for tears
or deterioration.
PR785
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. Tighten to 35 ft-lb.
2. Place the tie rod ends into the knuckles and secure
with the castle nuts (coated with red Loctite #271).
Tighten to 30 ft-lb; then install new cotter pins.
NOTE: If the slots in the castle nut are not aligned
with the hole in the tie rod end, tighten until the cotter
pin can be installed.
PR764A
PR765A
3. Remove the steering shaft housing and shaft from the
steering support and intermediate shaft.
NOTE: Any time steering components are disas-
sembled, all connecting components should be
marked for proper alignment during assembling.
INSPECTING
3. 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)
Upper Steering Shaft
REMOVING
1. Remove the dashboard (see Dashboard in this section).
2. Remove the four cap screws and nuts securing the
steering shaft housing to the steering support; then
remove the cap screw securing the intermediate shaft
yoke to the steering shaft.
1. Inspect the steering wheel shaft for excessive wear.
2. Check for worn splines, cracks, or damaged threads.
3. Roll the steering wheel shaft on a flat surface to
check for bends.
4. Inspect the nylon bushings in the steering shaft housing for cracking or excessive wear.
INSTALLING
1. Install the steering shaft housing with steering shaft and
connect the steering shaft and intermediate shaft first;
then slide the housing into place on the steering support.
2. 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.
21
PR764B
3. Install the cap screw in the intermediate shaft coupler
and tighten to 31 ft-lb.
PR765A
Intermediate Steering
Shaft Assembly
AT THIS POINT
Before beginning this procedure, the upper steering shaft
must be removed.
PR759B
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.
PR764B
4. Install the cap screw in the intermediate shaft coupler
and tighten to 31 ft-lb; then tighten the cap screw
(from step 1) to 11 ft-lb.
REMOVING
With the upper steering shaft removed, remove the cap
screw from the intermediate shaft coupler and remove the
shaft from the vehicle.
INSPECTING
NOTE: The lower steering shaft assembly is not
repairable or rebuildable. If any damage or excessive
wear is detected, the assembly must be replaced.
1. Inspect the joints for excessive wear or looseness.
2. Inspect welds.
INSTALLING
1. Place the steering shaft assembly into position
through the opening in the splash panel; then align
the slot in the intermediate steering shaft coupler to
the index (flattened) spline on the input shaft and
install. Install but do not tighten the cap screw.
22
PR765A
5. Install the dash and connect the two electrical connectors. Secure with sheet metal screws and tighten
securely. Do not over-tighten.
6. Install the steering housing boot; then install the boot
support and secure with two machine screws.
7. Install the steering wheel; then apply a drop of red
Loctite #271 to the threads of the castle nut. Secure
the steering wheel and tighten to 25 ft-lb. Install the
lock clip and cover.
Steering Knuckles
REMOVING AND DISASSEMBLING
1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.
! WARNING
Make sure the vehicle is solidly supported on the support stand to avoid injury.
2. Remove the cotter pin from the axle.
3. Remove the nut securing the hub.
4. Remove the brake caliper.
5. Remove the hub assembly.
6. Remove the cotter pin from the tie rod end and
remove the tie rod end from the knuckle.
2. Inspect the bearing for pits, scoring, rusting, or premature wear.
3. Inspect the knuckle for cracks, breaks, or galling of
the bearing surface.
ASSEMBLING AND INSTALLING
1. Using a suitable press and driver, press the bearing
into the knuckle until firmly seated; then install the
snap ring.
7. Remove the two cap screws securing the ball joints
in the knuckle.
PR193
8. Tap the ball joint end out of the knuckle; then
remove the knuckle.
9. Remove the snap ring securing the bearing in the
knuckle; then press the bearing out of the knuckle.
PR292A
PR289
2. Install the knuckle to the upper and lower ball joints
and secure with the two cap screws. Tighten to 35 ftlb.
CLEANING AND INSPECTING
1. Clean all knuckle components.
PR202
PR289
23
PR203
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.
NOTE: During assembling, new cotter pins should
be installed.
4. Apply a small amount of grease to the hub splines.
PR256
7. Install a new cotter pin and secure by spreading as
shown.
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. Install the hub assembly onto the splines of the shaft.
CD009
6. Secure the hub assembly with the nut. Tighten to 200
ft-lb.
8. Secure the brake caliper to the knuckle with the two
new “patch-lock” cap screws. Tighten to 20 ft-lb.
PR377B
9. 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)
10. Remove the vehicle from the support stand.
24
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.
PR709
HDX166A
HDX168A
HDX256
INSTALLING
Align the mounting holes with the holes in the splash
panel and secure with the two torx-head screws and nuts;
then snap the throttle cable holding grommet into the
actuator arm.
Shift Lever
REMOVING
1. Remove the dashboard (see Dashboard in this section).
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.
HDX168
2. Secure the shift cable end to the shift arm stud with
the cap screw and nut. Tighten to 8 ft-lb.
Shift Cable
2. Remove the nut securing the shift cable to the shift
arm; then remove the four cap screws securing the
shift axle supports to the frame and remove the shift
lever.
REMOVING
1. Remove the dashboard (see Dashboard in this section).
25
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.
HDX166A
HDX132A
INSTALLING
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. Install the shift cable into the shift cable support;
then connect the shift cable end to the shifter and
secure with a cap screw and nut. Tighten to 8 ft-lb.
HDX178A
3. Tilt the cargo box back and remove the E-clip from
the shift arm on the transmission; then loosen the
adjuster nut on the shift cable housing and remove
the shift cable from the transmission.
HDX137B
4. Remove the center floorboard and remove all nylon
ties securing the cable housing to the frame; then
remove the shift cable.
4. Adjust the shift cable (see Periodic Maintenance Shift Lever).
5. Install nylon ties on the shift cable where removed;
then install the center floorboard and tighten the
machine screws securely.
6. Install the dashboard (see Dashboard in this section).
7. Shift the transmission through all positions making
sure the gear position icons indicate the appropriate
gears selected and that the Park Indicator illuminates
only when fully in Park (see Periodic Maintenance Shift Lever).
LCD Gauge
REPLACING
1. Remove the steering wheel; then remove the steering
wheel boot.
2. Remove the two machine screws securing the steering wheel boot support to the steering support assembly. Remove the boot support.
NOTE: If the cable is being replaced, connect the
new cable to the end of the cable being removed and
pull the new cable into place.
26
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.
10. Install the steering wheel boot support.
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.
PR181A
5. Remove the nuts securing the gauge assembly to the
dash; then unplug the multi-pin connector and
remove the gauge from the vehicle.
PR284A
6. Place the new gauge into the dash panel opening;
then place the gauge holder over the mounting
screws and secure with the nuts.
7. Plug the multi-pin connector into the gauge; then
turn the ignition switch to the ON position and check
gauge functions.
HDX131A
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 6-12 mm (1/4-1/2 in.)
greater than the rear measurement (toe-out).
8. Slide the dash into position and secure with the six
screws.
9. Install the shifter handle; then install the shift lever
boot.
27
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.
TC044
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.
INSTALLING
Place the bumper assembly into position on the frame;
then secure with the four cap screws and nuts making
sure the flat washers and lock washers are properly positioned. Tighten securely.
Hood
PR085A
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 in equal
increments to achieve the proper toe-out; then
tighten the jam nuts securely.
28
REMOVING
1. Open the hood; then disconnect the four headlight
connectors and remove two nylon ties.
PR328A
2. Loosen but do not remove the four cap screws and
flange nuts securing the hood hinge to the frame;
then lower the hood.
Loading...