Table of Contents
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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
CVT Air Inlet.................................................................. 7
Engine Air Filter ............................................................ 7
Valve Clearance.......................................................... 10
Spark Plug ...................................................................11
Muffler/Spark Arrester..................................................11
Engine Oil - Filter ......................................................11
Front Differential Lubricant - Transaxle Fluid ........... 12
Driveshaft/Coupling .................................................... 13
Headlight - Taillight/Brake Light................................ 13
Shift Cable .................................................................. 16
Hydraulic Brake System ............................................. 17
Burnishing Brake Pads ............................................... 19
Checking/Replacing Drive Belt ................................... 19
Steering/Body/Controls ................................................ 22
Steering Wheel ........................................................... 22
Steering System ......................................................... 22
Steering Knuckles....................................................... 29
Accelerator Pedal ....................................................... 31
Throttle Cable ............................................................. 31
Shift Lever .................................................................. 31
Shift Cable .................................................................. 33
LCD Gauge................................................................. 35
Front Wheel Alignment ............................................... 35
Hood ........................................................................... 36
Front Fenders/Fender Flares...................................... 40
Doors .......................................................................... 44
Roof (Optional) ........................................................... 44
Front Bumper (Optional) ............................................. 44
Rear Bumper (Optional).............................................. 45
Dashboard (Mid/Upper) .............................................. 48
Dashboard (Lower) ..................................................... 49
Splash Panel .............................................................. 51
Skid Plates.................................................................. 52
Muffler......................................................................... 52
Cargo Box................................................................... 52
Seats .......................................................................... 54
Behind-the-Seat Storage Box Panel........................... 56
Seat Base ................................................................... 58
Troubleshooting .......................................................... 59
Table of Contents
Engine ............................................................................ 60
Removing Engine ........................................................60
Cylinder Head and Related Components....................65
Servicing Left-Side Components.................................84
Engine Block and Components ...................................93
Installing Engine ..........................................................95
Troubleshooting...........................................................99
Fuel/Lubrication/Cooling............................................ 101
Throttle Body .............................................................101
Gas Tank ...................................................................101
Oil Filter/Oil Pump .....................................................102
Liquid Cooling System ..............................................103
Troubleshooting.........................................................108
Electrical System ........................................................ 109
Battery .......................................................................109
Electronic Power Steering (EPS) ..............................109
Ignition Switch ........................................................... 111
Ignition Coils.............................................................. 111
Accessory Receptacle/Connector ............................. 112
Switches .................................................................... 112
Fan Motor .................................................................. 115
Lights......................................................................... 115
Power Distribution Module (PDM) ............................. 116
EFI Sensors/Components ......................................... 117
Winch ........................................................................123
Starter Motor .............................................................124
Starter Relay .............................................................125
Alternator/Regulator ..................................................126
Electronic Control Module (ECM)..............................127
Gauge Diagnostic Menu............................................127
Diagnostic Trouble Codes (DTC) ..............................130
Wiring Diagram..........................................................134
Troubleshooting.........................................................135
Drive System ............................................................... 136
Front Drive Actuator ..................................................136
Front Differential........................................................137
Drive Axles ................................................................148
Driveshaft ..................................................................151
Transaxle...................................................................152
Hub/Brake Disc .........................................................170
Hydraulic Brake Caliper.............................................172
Troubleshooting Drive System ..................................176
Troubleshooting Brake System .................................176
Suspension.................................................................. 177
Shock Absorbers .......................................................177
Front A-Arms .............................................................179
Rear A-Arms..............................................................182
Rear Knuckles ...........................................................184
Wheels and Tires ......................................................185
Troubleshooting.........................................................186
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Troubleshooting
