Page 1 2008-2012 All-Wheel Drive Maintenance and Service Manual Carryall 295/295 SE, XRT 1550/1550 SE and IntelliTach Gasoline and Diesel Vehicles Manual Number 103373117 Edition Code 1007F0811E...
Page 3 If it appears that a service question is not answered in this manual, please contact your nearest authorized Club Car dealer or distributor for assistance. You may also write to us at: Club Car, LLC; P.O. Box 204658; Augusta, GA 30917-4658 USA, Attention: Technical Services.
Page 4 There are no warranties expressed or implied in this manual. See the limited warranty found in the vehicle owner’s manual or write to Club Car, LLC, P.O. Box 204658, Augusta, GA 30917-4658 USA, Attention: Warranty Department.
Page 5: Table Of Contents
CONTENTS SECTION 1 – SAFETY ............................1-1 Safety Details ..............................1-1 Personal Safety ............................1-1 Machine Safety............................1-1 Information..............................1-2 General Warnings............................1-2 Disabling the Vehicle..........................1-3 Disconnecting the Battery – Gasoline/Diesel Vehicles .................. 1-3 Connecting the Battery – Gasoline/Diesel Vehicles ..................1-4 Recycling Lead-Acid Batteries ........................
Page 6 Seat Adjustment ............................4-9 Seat Installation............................4-9 Seat Support Removal ..........................4-9 Seat Support Installation .......................... 4-10 Seat Belts ..............................4-10 Bench Seat Belt Removal – 2008 Models....................4-10 Bench Seat Belt Installation – 2008 Models ....................4-11 Bench Seat Belt Removal – 2009 and Newer Models..................4-11 Bench Seat Belt Installation –...
Page 7 Brake Pad and Caliper Installation ......................6-18 Brake Discs – Starting 2012 Model Year......................6-19 Disc Removal ............................6-19 Disc Installation ............................6-20 Hydraulic Line Replacement......................... 6-20 Front Brake Line Removal........................6-20 Front Brake Line Installation ........................6-21 Rear Brake Line Removal ........................6-22 Rear Brake Line Installation........................
Page 8 Tire Installation ............................8-3 SECTION 9 – REAR SUSPENSION ........................9-1 Rear Coil-Over Shock Absorber – 2008-2011 Models..................9-1 Rear Shock Absorber Removal........................9-1 Rear Shock Absorber Installation........................ 9-2 Swing Arms – 2008-2011 Models........................9-3 Swing Arm Removal ..........................9-3 Swing Arm Installation..........................
Page 9 Relay Installation ............................. 13-2 Neutral Switch ............................. 13-2 Testing the Neutral Switch ........................13-2 Neutral Switch Removal ........................... 13-2 Neutral Switch Installation ........................13-2 Carburetor Solenoid............................. 13-3 Testing the Carburetor Solenoid........................ 13-3 Carburetor Solenoid Removal........................13-3 Carburetor Solenoid Installation........................ 13-3 Carburetor Heater............................
Page 10 Ignition Coil and Charge Coil ........................13-16 Testing the Ignition Coil ...........................13-16 Ignition Coil and/or Charge Coil Removal ....................13-16 Oil Pressure Sensor............................13-17 Headlights..............................13-17 Testing the Headlight Bulb and Socket .....................13-17 Headlight Bulb Removal..........................13-17 Headlight Bulb Installation ........................13-17 Wire Harness Diodes ..........................13-18 Testing the Wire Harness Diodes ......................13-18 Wire Harness Diode Removal........................13-18 Wire Harness Diode Installation.......................13-18...
Page 11 Bed Lift Switch Installation........................14-9 Bed Lift Circuit Breaker ..........................14-9 Testing the Bed Lift Circuit Breaker ......................14-9 Bed Lift Circuit Breaker Removal ......................14-9 Bed Lift Circuit Breaker Installation ......................14-9 Light Switch..............................14-10 Testing the Light Switch ..........................14-10 Light Switch Removal ..........................14-10 Light Switch Installation...........................14-10 Fuse ................................14-10...
Page 12 SECTION 15 – GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES ......... 15-1 Gasoline Engine ............................15-1 Engine Removal ............................15-1 Engine Installation ........................... 15-3 Oil Filter Hoses............................15-5 Exhaust System ............................15-6 Muffler Removal ............................15-6 Intermediate Pipe Removal ........................15-6 Intermediate Pipe Installation........................
Page 13 Air Canister Removal ..........................16-23 Air Canister Installation ...........................16-23 Air Filter Intake Hose Removal ........................16-24 Air Filter Intake Hose Installation......................16-24 Air Filter Outlet Hose Removal ........................16-25 Air Filter Outlet Hose Installation......................16-25 Clutches..............................16-26 Clutch Troubleshooting ...........................16-27 Drive Belt ...............................16-27 Drive Clutch ............................16-28 Driven Clutch ............................16-34 Clutch Cover ............................16-37 SECTION 17 –...
Page 14 SECTION 19 – HYDRAULIC ATTACHMENT SYSTEM..................19-1 Model Identification..........................19-1 Relieving Hydraulic System Pressure......................19-1 To Relieve Hydraulic Fluid Pressure......................19-1 Attachment Interface............................ 19-2 Inspection ............................... 19-2 Removing and Installing the Attachment Arm Mechanism................19-3 Electrical ..............................19-8 Joystick..............................19-10 Joystick ON/OFF Switch .........................19-12 Attachment Arm Float Switch........................19-13 Auxiliary Hydraulic Switch ........................19-15 Relays ..............................19-16...
Page 15: Section 1 - Safety
SECTION 1 – SAFETY SAFETY DETAILS WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury, or death. PERSONAL SAFETY It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION.
Page 16: Information
General Warnings SAFETY INFORMATION NOTE: Instructions that clarify steps, procedures, or other information in this manual. GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. Other specific safety statements appear throughout this manual and on the vehicle. DANGER •...
Page 17: Disabling The Vehicle
SAFETY General Warnings WARNING • Prior to leaving the vehicle unattended or servicing the vehicle, place attachment on the ground, set the park brake, place the Forward/Reverse handle in the NEUTRAL position, turn the key switch to the OFF position, and remove the key. Chock the wheels when servicing the vehicle. •...
Page 18: Connecting The Battery - Gasoline/Diesel Vehicles
Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. Page 1-4...
Page 19: International Safety Symbols On Batteries
SAFETY General Warnings 1403 Figure 1-3 Dispose of Lead-acid Batteries Properly INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using, repairing, or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries. 1. Shield eyes. 3. No smoking, no open flames, no sparks. 5.
Page 21: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS 295/295 SE AND 1550/1550 SE SPECIFICATIONS FOUR FOUR SPECIFICATIONS PASSEN- PASSEN- PASSEN- PASSEN- GASO- GASO- POWER SOURCE DIESEL DIESEL LINE LINE Engine: (Kawasaki) 4-cycle OHV, 675 cc, 23.0 maximum HP @3600 rpm (per SAE J •...
Page 22 General Warnings VEHICLE SPECIFICATIONS FOUR FOUR SPECIFICATIONS PASSEN- PASSEN- PASSEN- PASSEN- GASO- GASO- POWER SOURCE DIESEL DIESEL LINE LINE NOTE: Items marked with an asterisk (*) indicate approximate values. *Overall length (box bed configuration, without brushguard): 122 in. (309.9 cm) 154 in.
Page 23 VEHICLE SPECIFICATIONS General Warnings FOUR FOUR SPECIFICATIONS PASSEN- PASSEN- PASSEN- PASSEN- GASO- GASO- POWER SOURCE DIESEL DIESEL LINE LINE 3 qt. 3 qt. Engine crankcase with filter: SAE 10W-30, API classification CF (2.8 L) (2.8 L) Front differential: Mobil 424, Exxon Hydraul 560, or Esso Hydraul 56 lubricant 5 oz.
Page 24: 295 Homologated Specifications
General Warnings VEHICLE SPECIFICATIONS 295 HOMOLOGATED SPECIFICATIONS SPECIFICATIONS DIESEL VEHICLES POWER SOURCE Engine: Three-cylinder, liquid-cooled, with pressure lubrication system • Fuel system: Mechanical injection, fuel water separator, fuel filters, and electric fuel pump • Governor: internal to engine, mechanical, centrifugal ball •...
Page 25 VEHICLE SPECIFICATIONS General Warnings SPECIFICATIONS DIESEL VEHICLES Maximum payload capacity (level surface only) Standard option: High capacity option: (cargo load, optional accessories, and trailer tongue weight) 706 lb. (320 kg) 961 lb. (436 kg) Vehicle rated capacity (payload and occupants; level surface only) 1106 lb.
Page 26: Intellitach Specifications
General Warnings VEHICLE SPECIFICATIONS INTELLITACH SPECIFICATIONS CARRYALL 295 & SPECIFICATIONS XRT 1550 INTELLITACH POWER SOURCE DIESEL Engine: 4-cycle OHV, 719 cc, 20.0 maximum HP @3600 RPM (per SAE J 1940/1349), three-cylinder, • liquid-cooled, with pressure lubrication system Fuel system: Mechanical injection, fuel water separator, fuel filters, and electric fuel pump •...
Page 27 VEHICLE SPECIFICATIONS General Warnings CARRYALL 295 & SPECIFICATIONS XRT 1550 INTELLITACH 25 mph Forward speed (40 kph) Governed RPM 3825 Turning radius (per SAE J 695) 138 in. (350.5) Load bed height 32.5 in. (83 cm) 48.0 x 49.8 x 10.9 in.
Page 29: Section 3 - General Information
SECTION 3 – GENERAL INFORMATION DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. Throughout this manual, important features unique to each model are highlighted. The manufacturer recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s). Refer to the owner’s manual provided with the vehicle for information on the following topics: •...
Page 30: Model Identification - Domestic
Model Identification – Domestic GENERAL INFORMATION 1. Hood 2. ROPS 3. Fuel Fill Cap 4. Cargo Bed 5. Bed Lift Latch – vehicles with manual (standard) bed lift only 6. Engine Compartment, Battery, Fuel Tank (under seat; for four-passenger model, engine compartment is under rear seat) 7. Seat 8. Brake Fluid Reservoir (under hood) 9. Radiator and Coolant Reservoir (under hood) –...
Page 31: Identification Numbers
GENERAL INFORMATION Model Identification – Domestic The two letters (1) at the beginning of the serial number indicate the vehicle model. The following four digits (2) indicate the model year and production week during which the vehicle was built. The six digits (3) following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year.
Page 32 Model Identification – Domestic GENERAL INFORMATION Figure 3-6 Gasoline Engine Serial Number Location Figure 3-7 Diesel Engine Serial Number Location 1633 Figure 3-8 Differential Serial Number Location Page 3-4 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 33: Model Identification - Homologated
GENERAL INFORMATION Model Identification – Homologated MODEL IDENTIFICATION – HOMOLOGATED The vehicle identification number (Figure 3-9) is located on the center cross bar underneath the bed at the rear of the car . See following NOTE. 1437 Figure 3-9 Vehicle Identification Number Decal NOTE: Have the vehicle identification number available when ordering parts or making inquiries.
Page 34 Model Identification – Homologated GENERAL INFORMATION SERIAL NUMBER PH0901-123456 BC54679 ASSEMBLED IN USA 1400 2474 Figure 3-10 Serial Number Decal with the Vehicle Build Figure 3-11 ROPS Serial Number Location Code 1633 Figure 3-12 Diesel Engine Serial Number Location Figure 3-13 Differential Serial Number Location Page 3-6 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 35: Storage
GENERAL INFORMATION Storage STORAGE See General Warnings on page 1-2. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. • Clean up any spilled fuel before operating the vehicle. • Store fuel in an approved fuel container only. Store in a well-ventilated area away from sparks, open flames, heaters, or heat sources.
Page 36: Preparing The Vehicle For Extended Storage
Storage GENERAL INFORMATION PREPARING THE VEHICLE FOR EXTENDED STORAGE Unload the vehicle so that the tires are supporting only the weight of the vehicle. Store the vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, have it charged by a trained technician.
Page 37: Lifting The Vehicle
GENERAL INFORMATION Lifting The Vehicle Gasoline vehicles only: Completely open the fuel shut-off valve (Figure 3-14, Page 3-7). Ensure the valve is fully open. A partially closed fuel shut-off valve combined with the use of the choke can result in a fouled spark plug and engine failure.
Page 38: Lifting The Entire Vehicle
Lifting The Vehicle GENERAL INFORMATION Lift rear of vehicle and support on jack stands (Figure 3-16, Page 3-10). See WARNING “Lift only one end...” in General Warnings on page 1-2. 2034 Figure 3-16 Rear Jack Stand Placement LIFTING THE ENTIRE VEHICLE WARNING •...
Page 39: Using A Booster Battery (Jump Starting)
GENERAL INFORMATION Using A Booster Battery (Jump Starting) USING A BOOSTER BATTERY (JUMP STARTING) WARNING • Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face shield and rubber gloves when working on or near batteries. •...
Page 40 Using A Booster Battery (Jump Starting) GENERAL INFORMATION Figure 3-17 Jump Starting Page 3-12 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 41: Section 4 - Body And Trim
SECTION 4 – BODY AND TRIM DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. CLEANING THE VEHICLE See General Warnings, Section 1, Page 1-2. CAUTION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats.
Page 42: Front Body Repair
Front Body Repair BODY AND TRIM For More Difficult Stains – Perform previous procedure using full-strength bleach, or allow bleach to puddle on affected area for approximately 30 minutes. Rinse with a water dampened cloth to remove any remaining bleach concentration.
Page 43: Front Body Components
BODY AND TRIM Front Body Components FRONT BODY COMPONENTS See General Warnings, Section 1, Page 1-2. INSTRUMENT PANEL REMOVAL Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Remove the key. Chock the wheels. Disconnect battery.
Page 44: Front Fascia Removal
Front Body Components BODY AND TRIM 10. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 11. Unchock wheels. FRONT FASCIA REMOVAL Remove both side cowl panels (fenders). See Side Cowl Panel (Fender) Removal on page 4-5. Remove the four Torx ®...
Page 45: Center Cowl Panel Installation
BODY AND TRIM Front Body Components Rotate front edge upward and lift off the entire center cowl panel to disengage the Tuflok fasteners and the rear tabs of the panel out of the slots in the instrument panel structural support. CENTER COWL PANEL INSTALLATION Position the center cowl panel to the vehicle, making sure that the rear tabs of the panel engage the slots in the instrument panel structural support.
Page 46: Front Fender Flare Removal
Roll-Over Protective Structure (ROPS) BODY AND TRIM Replace, lower and secure hood. See Hood Installation on page 4-4. 10. Reinstall Roll-over Protective Structure (ROPS). See ROPS Installation on page 4-8. FRONT FENDER FLARE REMOVAL Remove hood. See Hood Removal on page 4-4. Remove center cowl panel.
Page 47 BODY AND TRIM Roll-Over Protective Structure (ROPS) Remove the upper four bolts (1) and four flanged nuts (2) that secure the top structure (3) to the two side supports (4), and remove the top structure (Figure 4-1, Page 4-7). *Four Passenger 2357 Figure 4-1 Roll-Over Protective Structure (ROPS) –...
Page 48: Rops Installation
Roll-Over Protective Structure (ROPS) BODY AND TRIM ROPS INSTALLATION NOTE: Follow steps 1 through 3 for 2-passenger vehicles and steps 1 through 8 for 4-passenger vehicles. ROPS installation will be easier with the aid of an assistant. Position the side support tubes (4) to the seat support (7) and front cowl supports (8) and secure with hex-head bolts (5), and flanged lock nuts (6).
Page 49: Seat
BODY AND TRIM Seat SEAT See General Warnings, Section 1, Page 1-2. SEAT REMOVAL Bucket seats 1.1. Lift the seat back up and forward to raise it. 1.2. Remove the seat by lifting the front edge hinges from the vehicle frame hinge slots. Bench seat 2.1.
Page 50: Seat Support Installation
Seat Belts BODY AND TRIM Remove the seat support. SEAT SUPPORT INSTALLATION Install the seat support (7) (Figure 4-1, Page 4-7). Secure the seat support to the seat side plates with bolts (9), washers (10 and 11), and flanged locknuts (12). Tighten the hardware to 37 ft-lb (50 N·m).
Page 51: Bench Seat Belt Installation - 2008 Models
BODY AND TRIM Seat Belts 2476 2477 Figure 4-2 Coiled Seat Belt Assembly – 2008 Bench Seat Figure 4-3 Center Seat Belt Fastener – 2008 Bench Seat Models Models BENCH SEAT BELT INSTALLATION – 2008 MODELS Install the center seat belt buckle assembly to the seat belt bracket with a new thread-forming bolt (Figure 4-3, Page 4-11).
Page 52: Bench Seat Belt Installation - 2009 And Newer Models
Seat Belts BODY AND TRIM 1446 1447 Figure 4-4 Coiled Seat Belt Assembly – 2009 Bench Seat Figure 4-5 Center Seat Belt Fastener – 2009 Bench Seat Models Models BENCH SEAT BELT INSTALLATION – 2009 AND NEWER MODELS Install the center seat belt buckle assembly to the seat belt bracket with hardware previously removed except for the lock nut (Figure 4-5, Page 4-12).
Page 53: Seat Belt Installation - Homologated Models
BODY AND TRIM Cargo Bed – Electric Lift 2475 Figure 4-6 Driver Seat Belt – Homologated Models SEAT BELT INSTALLATION – HOMOLOGATED MODELS Driver seat: Install the seat belt buckle assembly and coiled seat belt assembly to the driver seat as shown with hardware previously removed except for the lock nut (Figure 4-6, Page 4-13).
Page 54: Bed Lift Motor Installation
Cargo Bed – Electric Lift BODY AND TRIM Remove the locknut, bolt, sleeve, spacers and washers from the rod end of the bed lift motor and bed frame. Remove the locknut, bolt, sleeve, spacers and washers from the base of the bed lift motor and vehicle frame and remove the bed lift motor.
Page 55: Cargo Bed - Manual Lift
BODY AND TRIM Cargo Bed – Manual Lift Install the electric actuator. See Bed Lift Motor Installation on page 4-14. CARGO BED – MANUAL LIFT See General Warnings, Section 1, Page 1-2. CARGO BED REMOVAL NOTE: Cargo bed removal and installation will be easier with the aid of an assistant. Raise the bed and ensure that the prop rod is securely engaged.
Page 56 Cargo Bed – Manual Lift BODY AND TRIM 1884 Figure 4-7 Cargo Bed Page 4-16 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 57: Rear Fender
BODY AND TRIM Rear Fender REAR FENDER See General Warnings, Section 1, Page 1-2. REAR FENDER REMOVAL Lift bed. Carefully remove the three Tuflok plastic fasteners securing the top of the fender to the rear frame. 2.1. Using a size P2 Phillips head screwdriver, back out the Tuflok screws at least 1/2 inch (1.25 cm). 2.2.
Page 59: Section 5 - Accelerator And Brake Pedal Assemblies
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. ACCELERATOR PEDAL – THROUGH EARLY 2010 MODEL YEAR See General Warnings, Section 1, Page 1-2. ACCELERATOR PEDAL REMOVAL –...
Page 60: Accelerator Pedal Installation - Through Early 2010 Model Year
Accelerator Pedal – Through Early 2010 Model Year ACCELERATOR AND BRAKE PEDAL ASSEMBLIES ACCELERATOR PEDAL INSTALLATION – THROUGH EARLY 2010 MODEL YEAR Twist the accelerator pedal assembly to return the pedal assembly into the frame location. Position pedal between the frame members. Secure the pedal assembly to the upper and lower frame member with bolts and locknuts.
Page 61: Accelerator Pedal - From Late 2010 Model Year
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Accelerator Pedal – From Late 2010 Model Year Use 1/4-turn adjustments, and check the RPM setting after each adjustment. ACCELERATOR PEDAL – FROM LATE 2010 MODEL YEAR See General Warnings, Section 1, Page 1-2. ACCELERATOR PEDAL REMOVAL – FROM LATE 2010 MODEL YEAR Disconnect battery and spark plug wire(s).
Page 62 Accelerator Pedal – From Late 2010 Model Year ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Tighten pedal pivot bolt (1) and locknut (2) to 30 ft-lb (68 N·m). Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4.
Page 63: Brake Pedal
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal BRAKE PEDAL See General Warnings, Section 1, Page 1-2. BRAKE PEDAL REMOVAL Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Remove the rue pin and the clevis pin.
Page 64: Park Brake Pedal
Park Brake Pedal ACCELERATOR AND BRAKE PEDAL ASSEMBLIES PARK BRAKE PEDAL See General Warnings, Section 1, Page 1-2. PARK BRAKE PEDAL ASSEMBLY REMOVAL – BELL CRANK SYSTEM Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Remove the driver side cup holder to access the E-clip and washer securing the cable end to the park brake pedal assembly.
Page 65: Park Brake Pedal Assembly Installation - Cable Only System
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Park Brake Pedal Disconnect the cable end from the park brake pedal assembly by removing the bow tie locking pin (1) and clevis pin (2) (Figure 5-9, Page 5-7). Remove the three bolts (3) and locknuts (4) that secure both the park brake pedal assembly and the cable anchor bracket (5) to the chassis.
Page 67: Section 6 - Hydraulic And Park Brake Systems
SECTION 6 – HYDRAULIC AND PARK BRAKE SYSTEMS DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. CAUTION • Worn or damaged brake discs cannot be machined to refinish them. Replace as necessary. BRAKE SYSTEM INSPECTION See General Warnings, Section 1, Page 1-2.
Page 68: Master Cylinder Inspection
Brake System Inspection HYDRAULIC AND PARK BRAKE SYSTEMS MASTER CYLINDER INSPECTION • Inspect the exterior of the master cylinder. Replace any leaking components and bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-24. • Check the brake fluid level. See Brake Fluid, Section 10, Page 10-8. •...
Page 69: Brake Line Inspection
HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Inspection BRAKE LINE INSPECTION • Inspect the brake lines and fittings for leakage. They must be flexible and free of leaks, cuts, cracks or bulges. Replace as needed. See Hydraulic Line Replacement on page 6-20. •...
Page 70: Brake System Troubleshooting
Brake System Troubleshooting HYDRAULIC AND PARK BRAKE SYSTEMS BRAKE SYSTEM TROUBLESHOOTING The procedures used in making the checks provided in the following troubleshooting guide can be found in the referenced sections of this maintenance and service manual. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Excessive clearance between the disc and...
Page 71 HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Replace the brake pads. See Brake Pads and Incorrect or distorted brake pads Caliper – 2008-2011 Models on page 6-6. Replace hub, axle seal, or caliper, and replace Grease or brake fluid on the brake pads the brake pads.
Page 72: Brake Pads And Caliper - 2008-2011 Models
Brake Pads and Caliper – 2008-2011 Models HYDRAULIC AND PARK BRAKE SYSTEMS TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Improper park brake adjustment See Park Brake System on page 6-27. Replace the caliper. See Brake Pads and Sticking caliper pistons Caliper –...
Page 73: Front Brake Pad And Caliper Installation
HYDRAULIC AND PARK BRAKE SYSTEMS Brake Pads and Caliper – 2008-2011 Models Remove and discard the two hex-head bolts that secure the caliper assembly to the upright and remove the caliper and, if equipped, its two shim washers (one per bolt). Repeat steps 1 through 3 for the opposite front wheel if necessary.
Page 74: Rear Brake Pad And Caliper Removal
Brake Pads and Caliper – 2008-2011 Models HYDRAULIC AND PARK BRAKE SYSTEMS Front Brake Pad Installation NOTE: To help prevent noise, a silicone-based brake lubricant may be applied to the surfaces (on the back side of the brake pads) that contact the caliper. A thin film may also be applied to the slide-pins. Always follow lubricant manufacturer’s directions.
Page 75: Rear Brake Pad And Caliper Installation
HYDRAULIC AND PARK BRAKE SYSTEMS Brake Pads and Caliper – 2008-2011 Models 1893 1894 Figure 6-4 Rear Brake Pad and Caliper Figure 6-5 Rear Brake Line and Banjo Bolt REAR BRAKE PAD AND CALIPER INSTALLATION WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components.
Page 76: Brake Disc And Hub - 2008-2011 Models
Brake Disc and Hub – 2008-2011 Models HYDRAULIC AND PARK BRAKE SYSTEMS WARNING • To reduce the possibility of diminished brake performance or failure, never use petroleum-based lubricants on brake system components, and ensure lubricant does not contact friction surfaces of brake pads or rotors.
Page 77 HYDRAULIC AND PARK BRAKE SYSTEMS Brake Disc and Hub – 2008-2011 Models 1895 1896 Figure 6-6 Axle Spindle Nut and Washer Figure 6-7 Brake Caliper and Upright Remove and discard the two hex-head bolts that secure the caliper assembly to the upright (Figure 6-7, Page 6-11).
Page 78 Brake Disc and Hub – 2008-2011 Models HYDRAULIC AND PARK BRAKE SYSTEMS CAUTION • Take care when separating the ball joint stud from the upright so as not to tear or puncture the rubber seal around the ball socket. If damaged, the ball joint with rubber boot must be replaced. Remove the wheel hub, disc, and bearing assembly from the splined spindle and CV joint half shaft.
Page 79 HYDRAULIC AND PARK BRAKE SYSTEMS Brake Disc and Hub – 2008-2011 Models Press ram 2.835 in. (72 cm) 2.909 in. Max. (73.9 cm Max.) .281 in. 1/2 in. (7 mm) (12 mm) Radius 2030 Figure 6-11 Bearing Removal 9.2. Shim the ball joint arms (2 and 3) with steel blocks to provide a level surface for bearing removal (block 2 height is 9/16"...
Page 80: Front Wheel Disc And Hub Installation
Brake Disc and Hub – 2008-2011 Models HYDRAULIC AND PARK BRAKE SYSTEMS 11. Press the shaft on the disc and hub into the bearing (Figure 6-13, Page 6-13). 11.1. Position the disc and hub (6) onto a 2 x 2-inch, or larger, steel block as shown (Figure 6-13, Page 6-13). See following CAUTION.
Page 81: Rear Wheel Disc Removal
HYDRAULIC AND PARK BRAKE SYSTEMS Brake Disc and Hub – 2008-2011 Models Secure the upright, wheel, and bearing assembly to the lower ball joint. Use a new nylon locknut and tighten the hardware to 18 ft-lb (24 N·m). Secure the outer tie rod end to the upright arm. Use a new nylon locknut and tighten the hardware to 70 ft-lb (95 N·m).
Page 82: Rear Wheel Disc Installation
Brake Disc and Hub – 2008-2011 Models HYDRAULIC AND PARK BRAKE SYSTEMS 2034 2036 Figure 6-15 Rear Axle Stand Figure 6-16 Rear Wheel Disc and Hub NOTE: If the wheel hub does not slide easily from the axle spindle, use a two or four-jaw wheel puller to remove the wheel hub.
Page 83: Brake Pads And Caliper - Starting 2012 Model Year
HYDRAULIC AND PARK BRAKE SYSTEMS Brake Pads and Caliper – Starting 2012 Model Year Install the tire and wheel and loosely attach the lug nuts. 10. Raise the vehicle, remove the jack stands, and lower the vehicle. 11. Tighten the axle nut to 80 ft-lb (108 N·m). Position the locking cap and attach a new cotter pin. 12.
Page 84: Brake Pad And Caliper Installation
Brake Pads and Caliper – Starting 2012 Model Year HYDRAULIC AND PARK BRAKE SYSTEMS 2493 Figure 6-17 Front Caliper Banjo Bolt Figure 6-18 Rear Caliper Banjo Bolt Remove the two socket-head slide-pin bolts securing the caliper to its mounting bracket (Figure 6-19, Page 6-18). Pull the caliper off the mounting bracket and remove the pads (Figure 6-20, Page 6-18).
Page 85: Brake Discs - Starting 2012 Model Year
HYDRAULIC AND PARK BRAKE SYSTEMS Brake Discs – Starting 2012 Model Year WARNING • To reduce the possibility of diminished brake performance or failure, never use petroleum-based lubricants on brake system components, and ensure lubricant does not contact friction surfaces of brake pads or rotors.
Page 86: Disc Installation
Hydraulic Line Replacement HYDRAULIC AND PARK BRAKE SYSTEMS CAUTION • Worn or damaged brake discs cannot be machined to refinish them. Replace as necessary. Remove the caliper. See Brake Pad and Caliper Removal on page 6-17. See following CAUTION. CAUTION •...
Page 87: Front Brake Line Installation
HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line Replacement Raise hood. Use a flare-nut wrench to remove the front brake line at the master cylinder. See following NOTE. NOTE: Place a plastic bag around the master cylinder to catch brake fluid before the brake line is removed. Wrap the bag around the master cylinder to prevent debris from entering the brake line port.
Page 88: Rear Brake Line Removal
Hydraulic Line Replacement HYDRAULIC AND PARK BRAKE SYSTEMS CAUTION • Ensure that the hydraulic lines cannot contact any portion of the half-shafts or CV boot. • The banjo bolts are metric. Use only metric thread replacements. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Bleeding the Hydraulic Brake System on page 6-24.
Page 89: Master Cylinder And Reservoir
HYDRAULIC AND PARK BRAKE SYSTEMS Master Cylinder and Reservoir Secure the brake lines to the clamp and grommet locations. Secure the brake lines, banjo bolts, and new copper washers to each rear wheel caliper. Tighten the hardware to 13 ft-lb (18 N·m). See following NOTE and CAUTION. NOTE: Position the brake line perpendicular to the caliper assembly and pointing directly toward the base bracket on the shock absorber.
Page 90: Master Cylinder Installation
Bleeding the Hydraulic Brake System HYDRAULIC AND PARK BRAKE SYSTEMS MASTER CYLINDER INSTALLATION Secure the master cylinder to the master cylinder bracket with two bolts and locknuts. Tighten the hardware to 16 ft-lb (22 N·m). Loosen the jam nut on the push rod clevis and secure the clevis to the brake pedal with a clevis pin and rue pin (Figure 6-23, Page 6-24).
Page 91: Bleeding Brakes On A Dot 5 Fluid Filled System
HYDRAULIC AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System Pressure or vacuum bleeding, with preference given to the pressure bleeding method, is the recommended way to remove air from a brake system filled with DOT 5 silicone brake fluid. If a pressure or vacuum brake bleeding tool is not available, manually bleeding the system can be accomplished when done carefully.
Page 92: Purging The Hydraulic System
Bleeding the Hydraulic Brake System HYDRAULIC AND PARK BRAKE SYSTEMS 6.1. Lift and support the vehicle and remove the wheels. See Lifting The Vehicle on page 3-9. 6.2. Start at the brake caliper farthest away from the master cylinder. Attach a clear plastic hose to the caliper’s bleeder valve and place the other end into a clear container (a clean plastic 16 oz.
Page 93: Park Brake System
HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System PARK BRAKE SYSTEM See General Warnings, Section 1, Page 1-2. PARK BRAKE ADJUSTMENT – AT REAR CALIPERS NOTE: The hydraulic portion of the brake system has an automatically adjusting brake pad system. The park brake system does not and requires regular adjustment depending on use.
Page 94: Front Park Brake Cable Adjustment - Cable Only System
Park Brake System HYDRAULIC AND PARK BRAKE SYSTEMS FRONT PARK BRAKE CABLE ADJUSTMENT – CABLE ONLY SYSTEM CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before the vehicle is pushed. NOTE: Adjust rear brake calipers and park brake before adjusting park brake cable.
Page 95 HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System 2039 2040 Figure 6-24 Park Brake Cable Attachment Figure 6-25 Park Brake Frame Bracket Left Rear Cable Removal Chock the rear wheels and release the park brake. Remove the P-clamp and nylon wire tie securing the cable to the frame. Remove the C-clip from the right rear cable sheath adjacent to the caliper.
Page 96: Front Park Brake Cable Removal - Bell Crank System
Park Brake System HYDRAULIC AND PARK BRAKE SYSTEMS 2041 Figure 6-26 Air Filter and Park Brake Cable Clamp Left Rear Cable Installation Install the caliper end of the cable into the brake caliper arm (Figure 6-24, Page 6-29). Slide the sheath ferrule through the hole in the caliper mounting bracket. Install a C-clip to hold the cable ferrule in place.
Page 97: Front Park Brake Cable Installation - Bell Crank System
HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Figure 6-27 Park Brake Equalizer – Bell Crank System Figure 6-28 Park Brake Cable Attachment – Bell Crank System FRONT PARK BRAKE CABLE INSTALLATION – BELL CRANK SYSTEM Position the front park brake cable to the vehicle. Hold the plastic splash panel forward to access and route the cable end up to the lower-most park brake bell crank and secure the cable ferrule to the frame bracket.
Page 98: Front Park Brake Cable Installation - Cable Only System
Park Brake System HYDRAULIC AND PARK BRAKE SYSTEMS Remove the front park brake cable from the vehicle. 1449 1450 Figure 6-29 Park Brake Equalizer – Cable Only System Figure 6-30 Park Brake Cable Attachment – Cable Only System FRONT PARK BRAKE CABLE INSTALLATION – CABLE ONLY SYSTEM Route cable through cable anchor bracket (7) and anchor the cable ferrule into bracket (Figure 6-30, Page 6-32).
Page 99: Park Brake Equalizer Removal - Cable Only System
HYDRAULIC AND PARK BRAKE SYSTEMS Park Brake System Secure the extension spring to the end of the threaded end of the cable and the vehicle frame. Adjust the brake cable equalizer. See Front Park Brake Cable Adjustment – Bell Crank System on page 6-27. PARK BRAKE EQUALIZER REMOVAL –...
Page 101: Section 7 - Steering And Front Suspension
SECTION 7 – STEERING AND FRONT SUSPENSION DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. STEERING WHEEL See General Warnings, Section 1, Page 1-2. STEERING WHEEL REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Gasoline vehicles: Disconnect the spark plug wires.
Page 102: Steering Wheel Installation
Steering Column STEERING AND FRONT SUSPENSION 2478 2043 Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION Install the steering wheel (3) on the hex portion of the steering shaft. Align the hex fitting of the wheel with the steering column shaft (Figure 7-1, Page 7-2).
Page 103: Steering Column Installation
STEERING AND FRONT SUSPENSION Rack and Pinion 2044 2045 Figure 7-3 Steering Column Assembly Figure 7-4 Steering Universal Joint STEERING COLUMN INSTALLATION Slide the steering column through the frame opening and down through the hole in the splash guard. Position the steering column against the dash mounting plate, and install new locknuts. Tighten the hardware to 22 ft-lb (30 N·m).
Page 104: Rack And Pinion Inspection
Rack and Pinion STEERING AND FRONT SUSPENSION RACK AND PINION INSPECTION Look for obvious damage to the chassis, where the rack and pinion is mounted, and the rack and pinion housing. Particularly check the housing for broken mounting points. Compare the toe-in against the specification. See Toe-in Measurement on page 7-11. If obvious visible damage is found, such as a bent tie rod, check the steering gear for abnormal free-play, noise, binding or clunking while it is under a load.
Page 105: Rack And Pinion Disassembly
STEERING AND FRONT SUSPENSION Rack and Pinion NOTE: Be sure to tighten the bolt at the universal joint on the rack and pinion shaft before tightening the steering column coupling bolt. Tighten the universal joint bolt on the steering column to 18 ft-lb (24 N·m). Install both outer drag link ball joints, and advance the bolt approximately 6 threads.
Page 106 Rack and Pinion STEERING AND FRONT SUSPENSION 2050 Figure 7-9 Dust Bellows Clamp Remove the two hex nuts from the inner ball-joint ends, and remove both of the dust seal bellows. Remove the rack screw nut (8), rack guide screw (7), rack guide pressure spring (6), and the rack guide (5) (Figure 7-16, Page 7-8).
Page 107 STEERING AND FRONT SUSPENSION Rack and Pinion 1. Press Ram 2. Pinion Gear 3. Bearing 2053 2054 Figure 7-12 Remove Pinion from Housing Figure 7-13 Remove Pinion Gear 12. Inspect the bushing (17) and needle bearing (14) for excessive wear. If wear is excessive, replace the complete rack and pinion steering assembly (Figure 7-16, Page 7-8).
Page 108 Rack and Pinion STEERING AND FRONT SUSPENSION 2057 Figure 7-16 Steering Gear Assembly Page 7-8 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 109: Rack And Pinion Assembly
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing (17) and housing (1) (Figure 7-16, Page 7-8). CAUTION •...
Page 110: Front Suspension
Front Suspension STEERING AND FRONT SUSPENSION 2060 2061 Figure 7-19 Adjust Rack and Pinion Resistance Figure 7-20 Install Inner Ball Joint 11. Insert a 3/8-inch, 1/4-drive deep-well socket into the steering column end of the universal joint (2), and tighten the bolts (1) to 15 ft-lb (20.3 N·m) (Figure 7-19, Page 7-10).
Page 111 STEERING AND FRONT SUSPENSION Front Suspension Toe-in Measurement On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. See following NOTE. NOTE: Do not turn the steering wheel again during this procedure. Mark each front tire at the center of the tread face that is facing the rear of the vehicle.
Page 112: Front Suspension Components
Front Suspension Components STEERING AND FRONT SUSPENSION NOTE: Do not turn the steering wheel again during this procedure. Use a large carpenter’s square and position it a few inches (cm) away from the center of one wheel (Figure 7-24, Page 7-12). Measure distance (A) between the edge of the square and a top location on the inside bead of the wheel rim.
Page 113 STEERING AND FRONT SUSPENSION Front Suspension Components Lift and support the front of vehicle and remove the wheels. See Lifting The Vehicle on page 3-9. Remove the front brake caliper. See Front Brake Pad and Caliper Removal, Section 6, Page 6-6. Rest the brake caliper on the A-arm.
Page 114: Upper A-Arm Removal
Front Suspension Components STEERING AND FRONT SUSPENSION UPPER A-ARM REMOVAL Lift and support the front of vehicle and remove the wheels. See Lifting The Vehicle on page 3-9. Remove the brake line bracket from the A-arm. Remove the shock absorber. 3.1.
Page 115: Upper A-Arm Installation
STEERING AND FRONT SUSPENSION Front Suspension Components 2070 Figure 7-31 Ball Joint C-Clip UPPER A-ARM INSTALLATION Install a new ball joint if necessary. See Upper Ball Joint Installation on page 7-14. Install new A-arm frame bushings. See following NOTE. NOTE: The urethane bushings fit tightly. It may be necessary to press them into place. Use the assembly bolts and large flat washers to draw the bushings together in the frame brackets.
Page 116: Lower A-Arm Installation
Front Suspension Components STEERING AND FRONT SUSPENSION 2071 2072 Figure 7-32 Lower A-Arm Attachment Figure 7-33 A-Arm Frame Bushings Lower Ball Joint Removal Inspect the ball joint. Replace the ball joint if it is worn, loose, or if the rubber boot is damaged. 1.1.
Page 117: Front Coil-Over Shock Absorber Removal
STEERING AND FRONT SUSPENSION Front Suspension Components Install a new bolt, washer, and new flanged locknut. Tighten the hardware to 110 ft-lb (148 N·m), applying torque to the bolt side. Repeat steps 1 through 4 for the remaining side if necessary. Align the front wheels, and adjust the toe-in and the camber.
Page 118: Front Coil-Over Shock Absorber Installation
Front Suspension Components STEERING AND FRONT SUSPENSION FRONT COIL-OVER SHOCK ABSORBER INSTALLATION WARNING • 2012 Model Year and newer vehicles equipped with 4-link rear suspension have front coil-over shocks with spring rates that differ from previous shocks. To prevent altering the stability or handling of the vehicle, never use these shocks on older models;...
Page 119: Section 8 - Wheels And Tires
SECTION 8 – WHEELS AND TIRES DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. GENERAL INFORMATION These vehicles are equipped with either all-terrain or mud tires. The same size tire is used for the front and rear. See Vehicle Specifications on page 2-1.
Page 120: Wheels
Wheels WHEELS AND TIRES • Check the park brake cables. The cables should not come in contact with the tires or wheels. NOTE: Small holes in the tire can be plugged with a standard automotive tubeless tire repair kit available at auto supply stores.
Page 121: Tire Installation
WHEELS AND TIRES Tires TIRE INSTALLATION Use a tire machine to install the new tire on the wheel. See following NOTE. NOTE: When installing mud tires, determine which side of the vehicle they will be used on. The arrow molded on the sidewall indicates designed rotation when vehicle is moving forward (Figure 8-1, Page 8-1).
Page 123: Section 9 - Rear Suspension
SECTION 9 – REAR SUSPENSION DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. REAR COIL-OVER SHOCK ABSORBER – 2008-2011 MODELS See General Warnings, Section 1, Page 1-2. WARNING • 2012 Model Year and newer vehicles equipped with 4-link rear suspension have different length rear coil-over shocks than previous model years.
Page 124: Rear Shock Absorber Installation
Rear Coil-Over Shock Absorber – 2008-2011 Models REAR SUSPENSION NOTE: Note the adjustment position of the coil-over spring. New coil-over shock absorbers should be adjusted to the same position coil spring location as the previous shock absorbers. Use the adjustment position of the existing shock absorbers as a reference. Repeat steps 5 through 8 for the remaining shock absorber.
Page 125: Swing Arms - 2008-2011 Models
REAR SUSPENSION Swing Arms – 2008-2011 Models SWING ARMS – 2008-2011 MODELS See General Warnings, Section 1, Page 1-2. SWING ARM REMOVAL Remove the rear axle. See Rear Axle Removal, Section 17, Page 17-8. Remove the rue pin, locknut and washer from the swing arm pivot bolt (Figure 9-3, Page 9-3). Remove the swing arm bolt and grease fitting (Figure 9-4, Page 9-3).
Page 126: Rear Coil-Over Shock Absorber - Starting 2012 Model Year
Rear Coil-Over Shock Absorber – Starting 2012 Model Year REAR SUSPENSION CAUTION • Do not hammer or drive against the grease fitting. Install the washer and locknut on the pivot bolt and tighten to 14 ft-lb (18 N·m) (Figure 9-3, Page 9-3). Attach a new rue pin to the pivot bolt.
Page 127: Rear Shock Installation
REAR SUSPENSION Rear Coil-Over Shock Absorber – Starting 2012 Model Year 1. Location of brake hose with rubber grommet 2494 Figure 9-5 Rear Shock Absorber Removal REAR SHOCK INSTALLATION Ensure that the adjustment position of the coil spring on the new shock absorber is the same as the previous shock absorber.
Page 128: Trailing Arms And Lateral Links - Starting 2012 Model Year
Trailing Arms and Lateral Links – Starting 2012 Model Year REAR SUSPENSION TRAILING ARMS AND LATERAL LINKS – STARTING 2012 MODEL YEAR See General Warnings, Section 1, Page 1-2. LATERAL LINK REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 129 REAR SUSPENSION Trailing Arms and Lateral Links – Starting 2012 Model Year 2495 Figure 9-6 Rear Suspension Components – 4 Link 2008-2012 All-Wheel Drive Maintenance and Service Manual Page 9-7...
Page 130: Trailing Arm Removal
Trailing Arms and Lateral Links – Starting 2012 Model Year REAR SUSPENSION TRAILING ARM REMOVAL See General Warnings on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. Raise the cargo bed. See Body and Trim, Section 4, Page 4-1. Lift and support the rear of vehicle and remove the wheel.
Page 131: Section 10 - Periodic Maintenance
SECTION 10 – PERIODIC MAINTENANCE DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. PERIODIC SERVICE SCHEDULE See General Warnings, Section 1, Page 1-2. WARNING • Service, repairs, and adjustments must be made per instructions in this maintenance and service manual.
Page 132 Periodic Service Schedule PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Check engine circulating air passage; visually inspect unshrouded area around engine Engine exhaust for grass and debris and clean if necessary. Diesel vehicles: Check for grass and debris around the radiator. Check air pressure and adjust if necessary.
Page 133 PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Check clamps for tightness; check hose for cracks. Check for loose hardware and tighten if General vehicle necessary. Replace. Dispose of used filters properly. Fuel filters Check safety decals. Replace if damaged or Safety decals illegible.
Page 134: Periodic Lubrication Schedule
Periodic Lubrication Schedule PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Gasoline vehicle: Kawasaki engine- First change 10 hours Gasoline (Kawasaki engine) vehicles: Diesel vehicle: First change 1 qt. and 19 oz (1.5L) with filter 50 hours Additional change Change engine oil and oil filter Diesel vehicles: 3 qt.
Page 135 PERIODIC MAINTENANCE Periodic Lubrication Schedule Figure 10-2 Lubrication Points – Diesel Vehicles 2008-2012 All-Wheel Drive Maintenance and Service Manual Page 10-5...
Page 136: Periodic Lubrication Schedule - Intellitach
Periodic Lubrication Schedule – Intellitach PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE – INTELLITACH PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Diesel vehicle: First change 50 hours – additional change Diesel vehicles: 3 qt. (2.8 L) with filter. See for both every 100 hours of Change engine oil and oil filter Oil Viscosity on page 10-12.
Page 137: Lubricating The Attachment Arm And Interface
PERIODIC MAINTENANCE Lubricating the Attachment Arm and Interface LUBRICATING THE ATTACHMENT ARM AND INTERFACE Always use a good quality, lithium-based, multi-purpose grease. Apply lubricant until extra grease shows. Grease the 8 grease fittings every 50 hours of operation, 2 times a year (whichever occurs first) or whenever the attachment arm and interface are removed and reinstalled on the vehicle.
Page 138: Brake Fluid Reservoir
Brake Fluid Reservoir PERIODIC MAINTENANCE BRAKE FLUID RESERVOIR See General Warnings, Section 1, Page 1-2. 1. Full Level 2. Safe Level 3. Low Level Figure 10-5 Brake Fluid (remote reservoir shown) and Figure 10-6 Brake Fluid Reservoir (remote reservoir Coolant Access (diesel only) shown) The brake fluid reservoir (1) is located under the hood (Figure 10-5, Page 10-8).
Page 139: Oil Pressure - Gasoline Engine
PERIODIC MAINTENANCE Engine Oil OIL PRESSURE – GASOLINE ENGINE Kawasaki engine: The Kawasaki gasoline engine has an oil filter that is mounted on a bracket between and in front of the engine and transmission. Inlet and outlet oil-carrying hoses enable oil circulation to and from the engine. See following NOTE.
Page 140 Engine Oil PERIODIC MAINTENANCE After that, the oil should be changed every 100 hours of operation or annually, whichever comes first. Engine Oil Draining Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.
Page 141 PERIODIC MAINTENANCE Engine Oil Figure 10-11 Replace Engine Oil Filter – Kawasaki Gasoline Vehicles Engine Oil Filter Change Drain the engine oil. See Engine Oil Draining on page 10-10. Place the oil drain pan under the engine oil filter (2) (Figure 10-10 or Figure 10-11). Remove the engine oil filter.
Page 142: Oil Viscosity
Engine Oil PERIODIC MAINTENANCE Figure 10-14 Add Engine Oil – Gasoline Vehicles Figure 10-15 Add Engine Oil – Diesel Vehicles Engine Oil Filling Add engine oil (Figure 10-14 or Figure 10-15). With filter change, the engine requires the following amounts: –...
Page 143: Spark Plugs
PERIODIC MAINTENANCE Spark Plugs Using multi-grade oils (5W-20, 10W-30, and 10W-40) may increase oil consumption. If multi-grade oil is used, check the oil level more frequently. SAE 30 SAE 30 SAE 20 SAE 10W SAE 10W-30/ SAE 10W-40 SAE 10W-30/SAE 10W-40 SAE 5 W-30 Figure 10-16 Oil Viscosity Chart –...
Page 144: Lubrication Change For Front Differential, Transmission, And Rear Differential
Gearcase Lubrication PERIODIC MAINTENANCE LUBRICATION CHANGE FOR FRONT DIFFERENTIAL, TRANSMISSION, AND REAR DIFFERENTIAL Use the lower plug (2) for drainage (Figure 10-18, Figure 10-19, or Figure 10-20). Remove both plugs to allow the lubricant to drain faster. See preceding NOTE. Metal particles may be discovered in the fluid or on the magnetic drain plug when changing the differential or transmission fluid.
Page 145: Hydraulic System - Intellitach Vehicle
PERIODIC MAINTENANCE Hydraulic System – Intellitach Vehicle 2480 Figure 10-20 Rear Differential Lubrication Level Figure 10-21 Rear Differential Fill and Drain Plugs (2012 (2008-2011 vehicles) and newer vehicles) HYDRAULIC SYSTEM – INTELLITACH VEHICLE WARNING • Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death.
Page 146: Engine Coolant - Diesel Vehicles
Engine Coolant – Diesel Vehicles PERIODIC MAINTENANCE Move the joystick (1) to the right and tilt the attachment interface fully in. Press the auxiliary hydraulic rocker switch (2) so that the cylinders are retracted. (If equipped with auxiliary hydraulics). Turn the key to the OFF position. The hydraulic oil level must be between the Maximum Fluid Level and the Minimum Fluid Level lines on the hydraulic tank (Figure 10-23, Page 10-15).
Page 147: Biodiesel Fuel (Diesel Vehicles Only)
PERIODIC MAINTENANCE Fueling Instructions CAUTION • Gasoline vehicles: Use unleaded gasoline only. • Whenever possible, avoid using oxygenated and blended fuels. • Do not use any fuel with an alcohol content that exceeds 10% by volume (such as E85). Ethanol is an alcohol that readily absorbs moisture causing corrosion of fuel system components.
Page 148: Draining Water From Fuel Filter
Fueling Instructions PERIODIC MAINTENANCE CAUTION • Never use any fuel that does not meet specifications or fuel in which the contents cannot be identified. Using blends higher than 5% biodiesel content can affect engine life and cause deterioration of hoses, tube lines, injectors, injector pump and seals.
Page 149: Battery
PERIODIC MAINTENANCE Battery 1452 2327 Figure 10-26 Fuel Filter with Water Separator – Style A Figure 10-27 Fuel Filter with Water Separator – Style B BATTERY For periodic battery maintenance, see Battery on page 13-19 (gasoline vehicles) or page 14-21 (diesel vehicles). 2008-2012 All-Wheel Drive Maintenance and Service Manual Page 10-19...
Page 151: Section 11 - Troubleshooting And Electrical System: Gasoline Vehicles
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difficulties should they occur. The guide includes the symptom, probable cause(s) and suggested checks.
Page 152 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: GASOLINE VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug is fouled or in poor condition Spark Plugs on page 10-13 See the Kawasaki FH680D engine manual Spark plug wire is damaged or loose (CC P/N 103351201).
Page 153 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO See the Kawasaki FH680D engine manual Exhaust valve is restricted with carbon deposit (CC P/N 103351201). Muffler or exhaust pipe restricted with carbon Exhaust System on page 15-6 or other substance Test Procedure 21 –...
Page 154 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: GASOLINE VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Test Procedure 6 – Starter Control Circuit on Starter control circuit is not operating page 11-16 Start relay failure Test Procedure 7 – Start Relay on page 11-17 Fuse is blown Test Procedure 2 –...
Page 155 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO See Section 15 – Gasoline Engine, Muffler, Engine mounting nuts or bolts are loose Fuel System, and Clutches. Misaligned muffler mounting clamp Exhaust System on page 15-6 Damaged drive belt Clutches on page 15-30 Excessive vehicle vibration.
Page 156 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: GASOLINE VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Front differential limit switch wires Test Procedure 17 – Front Differential Limit disconnected Switch on page 11-25 Test Procedure 17 – Front Differential Limit Front differential limit switch wired incorrectly Switch on page 11-25 Test Procedure 15 –...
Page 158: Wiring Diagram
TROUBLESHOOTING AND ELECTRICAL Wiring Diagram SYSTEM: GASOLINE VEHICLES WIRING DIAGRAM DIODE 3 DIODE 2 DIODE 1 FRONT DIFFERENT IAL LIMIT SWITCH WD1033057-7-L Figure 11-1 Wiring Diagram – Gasoline Utility Vehicles (Front) Page 11-8 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 159 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Wiring Diagram DIODE 4 DIODE 5 WD1033057-7-R Figure 11-2 Wiring Diagram – Gasoline Utility Vehicles (Rear) 2008-2012 All-Wheel Drive Maintenance and Service Manual Page 11-9...
Page 160: Test Procedures
TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURES Index of Test Procedures 1 – Battery 2 – Fuse 3 – Ground Cables 4 – Key Switch (ON Position) 5 – Key Switch (Starter Circuit) 6 – Starter Control Circuit 7 –...
Page 161 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures DANGER rubber gloves when working on or near batteries. For added protection, cover top of the battery when servicing the vehicle. • Battery – Poison! Contains acid! Causes severe burns! Avoid contact with skin, eyes, or clothing. –...
Page 162 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 1.250 1.280 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 MM) above plates or to level indicator. View at eye level. Figure 11-3 Hydrometer Test Figure 11-4 Battery Electrolyte Level Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 °F (27 °C).
Page 163 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures Load Test NOTE: Ensure that the battery is fully charged before performing the following test procedure. Disable the vehicle. See Disabling the Vehicle on page 1-3. Check for loose or corroded battery terminal connections. Clean, tighten and replace connections as necessary. Connect a 160-ampere load tester to the battery posts.
Page 164 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 2081 Figure 11-5 Electrical Component Mounting Plate TEST PROCEDURE 3 – Ground Cables See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 165 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 2082 2083 Figure 11-6 Frame Ground Figure 11-7 Engine Ground to Frame TEST PROCEDURE 4 – Key Switch (ON Position) See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 166 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES Ensure that the key switch connector is connected correctly and is tight. If it is not, repair or replace as necessary. Remove the key switch. See Key Switch Removal on page 13-8. Set the multimeter to 200 ohms.
Page 167 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures – Check diode 5. See Test Procedure 14 – Diode 5 on wire 131 and 129 on page 11-23. – Check the neutral switch on the transmission housing. See Test Procedure 15 – Neutral Switch (Transmission) on page 11-24.
Page 168 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 2085 2086 Figure 11-10 Start Relay Coil Circuit Test Figure 11-11 Start Relay Contact Test If the reading obtained in step 5 is not 12 VDC with the key in the START position, perform the following test procedures: –...
Page 169 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 2087 2088 Figure 11-12 Carburetor Heater Relay Coil Circuit Test Figure 11-13 Carburetor Heater Relay Contact Test If the reading is 12 VDC and the relay clicks when the engine starts, check the relay contacts. 6.1.
Page 170 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 9 – Wire Harness Diodes See General Warnings, Section 1, Page 1-2. A diode is designed to conduct current in one direction only. Depending on the application, diodes are used in the vehicle to control electrical system logic, or to help protect relay and switch contacts from excessive arcing.
Page 171 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures DIODE TROUBLESHOOTING GUIDE IN-LINE WIRE FAILURE DIODE LOCATION FUNCTION SYMPTOM/COMMENT CONDITION (WIRES) Blocking diode for carburetor solenoid Open Difficult starting or not start at all control (powers carburetor solenoid Diode 2 w40 and w41 Starter will be activated when key when key switch is in the START Closed...
Page 172 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 11 – Diode 2 on wire 40 and 41 See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 173 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures Connect the black (–) probe of the multimeter to the 18-gauge purple wire (w47) at the key switch multi-pin connector. Connect the red (+) probe of the multimeter to the female side of the carburetor solenoid bullet connector. 10.
Page 174 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 15 – Neutral Switch (Transmission) See General Warnings, Section 1, Page 1-2. The neutral switch is located on the transmission housing. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 175 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures Check for continuity on the switch contacts with the Forward/Reverse handle in the REVERSE position (Figure 11-19, Page 11-24). The multimeter should indicate no continuity. If any of the continuity readings are incorrect, replace the neutral switch. See Neutral Switch Removal on page 13-2.
Page 176 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES Check for proper wiring and tight connections at the front differential limit switch (Figure 11-20, Page 11-25) or (Figure 11-21, Page 11-25). Move the accelerator pedal and listen for an audible click from the switch. If there is no click, check the limit switch for proper alignment and switch arm movement.
Page 177 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 2095 Figure 11-22 Charge Coil Test (At Voltage Regulator Multi-Pin Connector) TEST PROCEDURE 20 – Voltage Regulator See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Disable the vehicle.
Page 178 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES If there is a strong blue spark between the probes of the spark gap tester, stop the engine and perform the test on the remaining spark plug. There should be a strong blue spark between the probes of the spark gap tester when both spark plug circuits are tested.
Page 179 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures NOTE: Disconnecting the engine kill wire removes the engine ignition circuit from the vehicle start/stop circuit. Turn the key switch to the START position and release it after the engine starts. If the engine starts and continues to idle, check the kill wire for grounding.
Page 180 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 2098 Figure 11-25 Reverse Warning Buzzer and Limit Switch Place the Forward/Reverse handle in the REVERSE position to activate the limit switch. The multimeter should indicate continuity when the limit switch lever is activated. If either reading is incorrect, replace the limit switch (Figure 11-25, Page 11-30).
Page 181 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 1.6. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF position. The reading should indicate approximately 12 VDC when the key is in the ON and START positions; if the multimeter does indicate 12 VDC, proceed to step 2.
Page 182 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES Leave the 18-gauge purple wire (w42) connected to the low oil warning light. Place a jumper wire on the terminal of the low oil warning light where the blue/white wire (w17) was removed. Touch the frame (ground) with the remaining end of the jumper wire.
Page 183 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 2100 Figure 11-27 Fuel Level Sending Unit Test The following resistance readings (in ohms) should be indicated, depending on the position of the float inside the fuel tank. The resistance reading will vary according to the exact position of the float. The following table may be used as a guideline to determine if the fuel level sending unit is operating correctly.
Page 184 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 31 – Fuel Gauge See General Warnings, Section 1, Page 1-2. 1. Black(Jumper Wire From 6) 2. Blue 4. Orange 6. Black 7. White Figure 11-28 Fuel Gauge/Hour Meter NOTE: Keep the battery connected during this test procedure. Disable the vehicle.
Page 185 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 32 – Hour Meter See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. With the key switch OFF, check the hour meter display. It is powered by an internal battery and should always be on, even with the engine off and the key removed.
Page 186 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1130 Figure 11-31 Light Switch Test Connect the black (–) probe of the multimeter to the negative (–) post of the battery. With the light switch in the OFF position, the reading should indicate 0 volts. With the light in the ON position, the reading should indicate between 11 and 12.5 volts.
Page 187 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-32 Voltage Measurement at Headlight Socket If there is no voltage reading at the wire harness, check the continuity of the 16-gauge blue wires (w01 and w03) from the headlight to the light switch.
Page 188 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 2102 2103 Figure 11-34 Bed Lift Motor Voltage Reading with Switch Figure 11-35 Bed Lift Motor Voltage Reading with Switch in UP position in DOWN position TEST PROCEDURE 35 – Bed Lift Motor NOTE: Keep the battery connected during this test procedure.
Page 189 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 36 – Bed Lift Switch Remove the bed lift switch. See Bed Lift Switch Removal on page 13-10. Check continuity between the terminals (Figure 11-36, Page 11-39) of the switch and compare the readings with the Bed Lift Switch Continuity Table.
Page 191: Section 12 - Troubleshooting And Electrical System: Diesel Vehicles
SECTION 12 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difficulties should they occur. The guide includes the symptom, probable cause(s) and suggested checks.
Page 192 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: DIESEL VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Fuel tank is empty Fuel System on page 16-8 Fuel with low cetane number Use specified fuel. See owner’s manual. Use specified fuel and engine oil. See owner’s Excessively high viscosity fuel or engine oil manual.
Page 193 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Battery is discharged Test Procedure 1 – Battery on page 12-12 Test Procedure 4 – Key Switch (Starter Circuit) Key switch failed on page 12-17 Test Procedure 7 –...
Page 194 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: DIESEL VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Oil level is low Add engine oil. See owner’s manual. See the Kubota D722 diesel engine manual Oil level sensor failure Low oil warning light stays on. (CC P/N 103840201).
Page 195 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Oil ring worn Piston ring groove worn See the Kubota D722 diesel engine manual Excessive engine oil consumption. (CC P/N 103840201). Valve stem and/or guide worn Crankshaft bearing and crank pin bearing worn See the Kubota D722 diesel engine manual Fuel mixed into engine lubricant oil.
Page 196 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: DIESEL VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Test Procedure 20 – Front Drive Gearcase Failed front drive gearcase engagement coil Coil on page 12-32 Test Procedure 19 – Front Differential Limit Failed differential limit switch Switch on page 12-31 Front differential does not engage front wheels.
Page 198: Wiring Diagram
TROUBLESHOOTING AND ELECTRICAL Wiring Diagram SYSTEM: DIESEL VEHICLES WIRING DIAGRAM FUEL GAUGE/ HOUR METER (Intel litac h Die s e l Veh icles Only Th rou gh mid-2009 ) 18_ORG(W23) 18_BLU(W41) 18_BLK(W16) DETAIL FUEL GAUGE/ HOUR METER (All Non-Intellitach Dies el Ve hicles a nd Only Late-20 09 Intellitac h Ve hicle s) (See De ta il for othe r ga ug e us ed .)
Page 199 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Wiring Diagram WD1032775B7-R Figure 12-2 Wiring Diagram for Diesel Utility Vehicles (Rear) 2008-2012 All-Wheel Drive Maintenance and Service Manual Page 12-9...
Page 200 TROUBLESHOOTING AND ELECTRICAL Wiring Diagram SYSTEM: DIESEL VEHICLES WD1033181B3 Figure 12-3 Main Light Wiring Diagram – Carryall 295 Homologated Vehicle Page 12-10 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 201 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Wiring Diagram WD1033173B4 Figure 12-4 High Beam Wiring Diagram – Carryall 295 Homologated Vehicle 2008-2012 All-Wheel Drive Maintenance and Service Manual Page 12-11...
Page 202: Test Procedures
TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES TEST PROCEDURES Index of Test Procedures 1 – Battery 2 – Fuse 3 – Ground Cables 4 – Key Switch (Starter Circuit) 5 – Key Switch (ON Position) 6 – Key Switch (Glow Plug Circuit) 7 –...
Page 203 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or using in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 204 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 1.250 1.280 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 MM) above plates or to level indicator. View at eye level. Figure 12-5 Hydrometer Test Figure 12-6 Battery Electrolyte Level Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 °F (27 °C).
Page 205 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures Load Test NOTE: Ensure that the battery is fully charged before performing the following test procedure. Disable the vehicle. See Disabling the Vehicle on page 1-3. Check for loose or corroded battery terminal connections. Clean, tighten and replace connections as necessary. Connect a 160-ampere load tester to the battery posts.
Page 206 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 2105 Figure 12-7 Electrical Component Mounting Plate TEST PROCEDURE 3 – Ground Cables See General Warnings, Section 1, Page 1-2. Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Check the frame ground connection for loose connections and damaged terminals (Figure 12-8, Page 12-17).
Page 207 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 2106 2107 Figure 12-8 Frame Ground Figure 12-9 Engine Ground (Under Starter) TEST PROCEDURE 4 – Key Switch (Starter Circuit) See General Warnings, Section 1, Page 1-2. Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Remove the key switch.
Page 208 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 6.1. Use alligator clips to connect the multimeter probes between the B and I terminals. With the key in the START position, the multimeter should indicate continuity (Figure 12-10, Page 12-17). If the multimeter does not indicate continuity, the key switch has failed and should be replaced.
Page 209 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 7 – Starter Control Circuit See General Warnings, Section 1, Page 1-2. Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect the 16-gauge green wire (w127) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 12-11, Page 12-19).
Page 210 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 2111 2112 Figure 12-13 Start Relay Coil Circuit Test Figure 12-14 Start Relay Contact Test TEST PROCEDURE 8 – Start Relay See General Warnings, Section 1, Page 1-2. Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect the 16-gauge green wire (w127) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 12-11, Page 12-19).
Page 211 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures – Check the 30-amp fuse (on w125). See Test Procedure 2 – Fuse on page 12-15. – Check the key switch. See Test Procedure 4 – Key Switch (Starter Circuit) on page 12-17. –...
Page 212 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 2113 2114 Figure 12-15 Check Power To Fan Relay Figure 12-16 Fan Relay Contact Test If the fan runs constantly, even with the key switch OFF, remove the relay. If fan stops, the relay contacts have failed closed and the relay must be replaced.
Page 213 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 4.1. Set a multimeter to 200 ohms. 4.2. Use an alligator clip to connect the black (–) probe of the multimeter to the frame (ground). 4.3. Use an alligator clip to connect the red (+) probe of the multimeter to the white wire terminal. 4.4.
Page 214 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES WARNING • Allow surfaces to cool adequately before touching them. 2116 Figure 12-18 Fan Thermostat Switch Test Setup TEST PROCEDURE 11 – Fan Motor See General Warnings, Section 1, Page 1-2. The fan relay activates the radiator fan when the engine coolant reaches a temperature range of 187 °F to 198 °F (86 °C to 92 °C) and closes the fan thermostat switch.
Page 215 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 2117 2118 Figure 12-19 Fan Motor Connector Figure 12-20 Thermostat Switch Connector Connect the battery cables, positive (+) cable first. Leave the Forward/Reverse handle in the NEUTRAL position. 10. Monitor the multimeter while turning the key switch to the ON position. The multimeter should indicate 0 (zero) VDC with the key in the OFF position and approximately 12 VDC with the key switch in the ON position.
Page 216 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES TEST PROCEDURE 12 – Wire Harness Diodes See General Warnings, Section 1, Page 1-2. A diode is designed to conduct current in one direction only. Depending on the application, diodes are used in the vehicle to control electrical system logic, or to help protect relay and switch contacts from excessive arcing.
Page 217 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures DIODE TROUBLESHOOTING GUIDE IN-LINE WIRE FAILURE DIODE LOCATION FUNCTION SYMPTOM/COMMENT CONDITION (WIRES) Will contribute to the premature failure Open of the fan relay contacts. Diode 2 w40 and w41 Fan motor flyback diode The 30-amp fuse (on w109) will blow Closed repeatedly until the diode has been...
Page 218 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES Connect the black (–) probe of the multimeter to the frame (ground). Connect the red (+) probe of the multimeter to the 14-gauge blue wire (w52) on the two-pin connector (wire harness side). The reading should indicate an over limit (no continuity).
Page 219 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 2120 2121 Figure 12-23 Fuel Solenoid Three-Pin Connector Figure 12-24 Fuel Pump Bullet Connector Connect the black (–) probe of the multimeter to the frame (ground). Connect the red (+) probe of the multimeter to the 18-gauge gray wire (w140) at the bullet connector (wire harness side).
Page 220 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES TEST PROCEDURE 17 – Neutral Switch (Transmission) See General Warnings, Section 1, Page 1-2. The neutral switch is located on the transmission housing. Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Disconnect the two-pin connector between the neutral switch and the wire harness (w143 and w142).
Page 221 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 2092 2094 Figure 12-26 Neutral Switch – Neutral Position Figure 12-27 Neutral Switch – Reverse Position TEST PROCEDURE 18 – Wire Continuity See General Warnings, Section 1, Page 1-2. Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. To test a wire for continuity, disconnect either end from the electrical component to which it is attached.
Page 222 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 2093 2363 Figure 12-28 Front Differential Switch – Through Early Figure 12-29 Front Differential Switch – From Late 2010 2010 Model Year Model Year Move the accelerator pedal and listen for an audible click from the switch. If there is no click, check the limit switch for proper alignment and switch arm movement.
Page 223 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 21 – Alternator See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Disable the vehicle. See Disabling the Vehicle on page 1-3. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Check engine RPM setting to ensure it is adjusted correctly.
Page 224 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES Place the red (+) probe on the fusible link ring terminal atttached to the alternator stud. The reading should indicate approximately 12 VDC (or full battery voltage). If the multimeter did not indicate voltage, check the following: –...
Page 225 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 10. If the voltage reading obtained in step 8 is correct, check the filament of the warning light. 10.1.Set the multimeter to 200 ohms. 10.2.Check for continuity between the warning light terminals. 10.3.The reading should indicate continuity.
Page 226 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES TEST PROCEDURE 25 – Reverse Warning Buzzer Limit Switch (If Equipped) See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. The reverse warning buzzer limit switch is located on the Forward/Reverse handle under the hood. Disable the vehicle.
Page 227 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 27 – Fuel Solenoid Pull Coil Circuit See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect the three-pin connector between the fuel solenoid and the wire harness (Figure 12-23, Page 12-29).
Page 228 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES – Starter solenoid. See the Kubota D722 diesel engine manual (CC P/N 103840201). – Wire continuity of wires w122, w121, w37, w48, w24, w125, w126, and w201. See Test Procedure 18 – Wire Continuity on page 12-31.
Page 229 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 31 – Fuel Level Sending Unit See General Warnings, Section 1, Page 1-2. WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure.
Page 230 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES TEST PROCEDURE 32 – Fuel Gauge See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. 1. Black(Jumper Wire From 6) 2. Blue 4. Orange 6. Black 7. White Figure 12-35 Fuel Gauge/Hour Meter Disable the vehicle.
Page 231 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 33 – Hour Meter See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels. With the key switch OFF, check the hour meter display. It is powered by an internal battery and should always be on, even with the engine off and the key removed.
Page 232 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1130 Figure 12-38 Light Switch Test TEST PROCEDURE 35 – Voltage at Headlight Socket See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Disable the vehicle.
Page 233 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 2101 Figure 12-39 Voltage At Headlight Socket Figure 12-40 Bed Lift Motor Wires TEST PROCEDURE 36 – Bed Lift Motor NOTE: Keep the battery connected during this test procedure. Ensure that the battery is fully-charged before performing this test procedure.
Page 234 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 2102 2103 Figure 12-41 Bed Lift Motor Voltage Reading with Switch Figure 12-42 Bed Lift Motor Voltage Reading with Switch in UP position in DOWN position TEST PROCEDURE 37 – Bed Lift Switch Remove the bed lift switch.
Page 235 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures BED LIFT SWITCH CONTINUITY Between Terminals Cont. when pushed DOWN Cont. when Cont. when pushed DOWN pushed UP Cont. when pushed UP Cont. when pushed DOWN Cont. when Cont. when pushed DOWN pushed UP Cont.
Page 237: Section 13 - Electrical Components: Gasoline Vehicles
SECTION 13 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. STARTER AND STARTER SOLENOID See General Warnings, Section 1, Page 1-2. Refer to the engine manual for testing, removal, disassembly, and installation procedures. See the Kawasaki FH680D engine manual (CC P/N 103351201).
Page 238: Relay Removal
ELECTRICAL COMPONENTS: GASO- Neutral Switch LINE VEHICLES RELAY REMOVAL Disable the vehicle. See Disabling the Vehicle on page 1-3. Remove the electrical component cover. Remove the relay from the multi-pin connector. RELAY INSTALLATION Insert the relay into the multi-pin connector. See following NOTE. NOTE: The relay contacts are keyed to ensure that the relay can only be installed in the correct orientation.
Page 239: Carburetor Solenoid
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Carburetor Solenoid CARBURETOR SOLENOID See General Warnings, Section 1, Page 1-2. The carburetor solenoid is located on the bottom of the carburetor. TESTING THE CARBURETOR SOLENOID See Test Procedure 27 – Carburetor Solenoid Circuit on page 11-30. CARBURETOR SOLENOID REMOVAL Disconnect battery and spark plug wire(s).
Page 240: Carburetor Heater
ELECTRICAL COMPONENTS: GASO- Carburetor Heater LINE VEHICLES CARBURETOR HEATER See General Warnings, Section 1, Page 1-2. The carburetor heater is located on top of the carburetor. CARBURETOR HEATER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 241: Voltage Regulator
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Voltage Regulator VOLTAGE REGULATOR See General Warnings, Section 1, Page 1-2. TESTING THE VOLTAGE REGULATOR See Test Procedure 20 – Voltage Regulator on page 11-27. VOLTAGE REGULATOR REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 242: Warning Lights
ELECTRICAL COMPONENTS: GASO- Warning Lights LINE VEHICLES WARNING LIGHTS See General Warnings, Section 1, Page 1-2. TESTING THE WARNING LIGHTS See Test Procedure 28 – Low Oil Warning Light Circuit on page 11-31. WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 243: Fuel Gauge/Hour Meter
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Fuel Gauge/Hour Meter 2131 Figure 13-6 Instrument Panel Electrical Components FUEL GAUGE/HOUR METER See General Warnings, Section 1, Page 1-2. TESTING THE FUEL GAUGE/HOUR METER See Test Procedure 31 – Fuel Gauge on page 11-34. Also see Test Procedure 32 – Hour Meter on page 11-35. With the key switch in the OFF position, the fuel gauge field is blank;...
Page 244: Fuel Gauge/Hour Meter Installation
ELECTRICAL COMPONENTS: GASO- Key Switch LINE VEHICLES FUEL GAUGE/HOUR METER INSTALLATION Install a new fuel gauge/hour meter (2) into the hole in the instrument panel until the flange seats against the instrument panel (Figure 13-6, Page 13-7). Force the mounting clip (3) onto the back of the fuel gauge/hour meter until fully seated. Connect the wires to the fuel gauge/hour meter.
Page 245: 12-Volt Accessory Receptacle
ELECTRICAL COMPONENTS: GASOLINE VEHICLES 12-Volt Accessory Receptacle 12-VOLT ACCESSORY RECEPTACLE See General Warnings, Section 1, Page 1-2. TESTING THE 12-VOLT ACCESSORY RECEPTACLE See Test Procedure 29 – 12-Volt Accessory Receptacle on page 11-32. 12-VOLT ACCESSORY RECEPTACLE REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 246: Bed Lift Switch
ELECTRICAL COMPONENTS: GASO- Bed Lift Switch LINE VEHICLES BED LIFT SWITCH TESTING THE BED LIFT SWITCH See Test Procedure 36 – Bed Lift Switch on page 11-39. BED LIFT SWITCH REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 247: Bed Lift Circuit Breaker Installation
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Light Switch BED LIFT CIRCUIT BREAKER INSTALLATION Install the circuit breaker in the reverse order of removal. LIGHT SWITCH See General Warnings, Section 1, Page 1-2. TESTING THE LIGHT SWITCH See Test Procedure 33 – Light Switch on page 11-35. LIGHT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 248: Fuse Removal
ELECTRICAL COMPONENTS: GASO- Reverse Warning Buzzer (If Equipped) LINE VEHICLES FUSE REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. Remove the electrical component cover (located near the battery) and remove the fuse from the fuse block. FUSE INSTALLATION Install the fuse.
Page 249: Reverse Warning Buzzer Installation
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Reverse Warning Buzzer Limit Switch (If Equipped) 2098 Figure 13-7 Reverse Warning Buzzer and Limit Switch REVERSE WARNING BUZZER INSTALLATION Install the reverse warning buzzer and secure it with two plastic rivets. Connect the black wire from the wire harness to the negative (–) terminal on the buzzer. Connect the red/white wire from the wire harness to the positive (+) terminal on the buzzer.
Page 250: Reverse Warning Buzzer Limit Switch Installation
ELECTRICAL COMPONENTS: GASO- Front Differential Limit Switch LINE VEHICLES 2141 2142 Figure 13-8 Reverse Warning Buzzer Limit Switch Figure 13-9 Reverse Warning Buzzer Limit Switch Adjustment Slot (Properly Adjusted) REVERSE WARNING BUZZER LIMIT SWITCH INSTALLATION Install the reverse warning buzzer limit switch in the reverse order of removal. Place the Forward/Reverse handle in the REVERSE position.
Page 251: Testing The Front Differential Limit Switch
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Front Differential Limit Switch TESTING THE FRONT DIFFERENTIAL LIMIT SWITCH See Test Procedure 17 – Front Differential Limit Switch on page 11-25. FRONT DIFFERENTIAL LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 252: Fuel Level Sending Unit
ELECTRICAL COMPONENTS: GASO- Fuel Level Sending Unit LINE VEHICLES FUEL LEVEL SENDING UNIT See General Warnings, Section 1, Page 1-2. Thoroughly test the fuel level sending unit before replacing the unit. TESTING THE FUEL LEVEL SENDING UNIT See Test Procedure 30 – Fuel Level Sending Unit on page 11-32. FUEL LEVEL SENDING UNIT REMOVAL See Fuel Level Sending Unit Removal on page 15-11.
Page 253: Oil Pressure Sensor
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Oil Pressure Sensor OIL PRESSURE SENSOR See General Warnings, Section 1, Page 1-2. Refer to the engine manual for additional testing, removal, disassembly, and installation procedures. See the Kawasaki FH680D engine manual (CC P/N 103351201). HEADLIGHTS See General Warnings, Section 1, Page 1-2.
Page 254: Wire Harness Diodes
ELECTRICAL COMPONENTS: GASO- Wire Harness Diodes LINE VEHICLES Attach the connector harness to the halogen bulb. The retaining tab should lock onto the halogen bulb (Figure 13-12, Page 13-17). From the front of vehicle, reach under the cowl and insert the bulb assembly into the headlight lens. Turn the bulb assembly counterclockwise one-quarter turn.
Page 255: Battery
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Battery BATTERY See General Warnings, Section 1, Page 1-2. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working around a battery. • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 256: Self-Discharge
ELECTRICAL COMPONENTS: GASO- Battery LINE VEHICLES Check the battery periodically to ensure that it is in a full state of charge. See Charging the Battery on page 13-21. Keep the battery hold-down clamp tight. See Vibration Damage on page 13-20. SELF-DISCHARGE Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery.
Page 257: Battery Removal
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Battery BATTERY REMOVAL See General Warnings on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. Remove the driver-side seat. Remove the battery hold-down located on the bottom of the battery. Remove the battery.
Page 258: Battery Storage
ELECTRICAL COMPONENTS: GASO- Battery LINE VEHICLES BATTERY STORAGE See General Warnings on page 1-2. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 13-19. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 259: Section 14 - Electrical Components: Diesel Vehicles
SECTION 14 – ELECTRICAL COMPONENTS: DIESEL VEHICLES DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. STARTER AND STARTER SOLENOID See General Warnings, Section 1, Page 1-2. Refer to the engine manual for testing, removal, disassembly, and installation procedures. See the Kubota D722 diesel engine manual (CC P/N 103840201).
Page 260: Relay Removal
Neutral Switch ELECTRICAL COMPONENTS: DIESEL VEHICLES RELAY REMOVAL Disable the vehicle. See Disabling the Vehicle on page 1-3. Remove the electrical component cover. Remove the relay from the multi-pin connector. RELAY INSTALLATION Insert the relay into the multi-pin connector. See following NOTE. NOTE: The relay contacts are keyed to ensure that the relay can only be installed in the correct orientation.
Page 261: Fuel Solenoid
ELECTRICAL COMPONENTS: DIESEL VEHICLES Fuel Solenoid FUEL SOLENOID See General Warnings, Section 1, Page 1-2. The fuel solenoid is mounted to the passenger-side of the engine block at the front of the injector pump. TESTING THE FUEL SOLENOID See Test Procedure 27 – Fuel Solenoid Pull Coil Circuit on page 12-37. See also Test Procedure 28 – Fuel Solenoid Hold Coil Circuit on page 12-37.
Page 262: 60-Amp Fusible Link
60-Amp Fusible Link ELECTRICAL COMPONENTS: DIESEL VEHICLES 60-AMP FUSIBLE LINK See General Warnings, Section 1, Page 1-2. TESTING THE 60-AMP FUSIBLE LINK See Test Procedure 22 – 60-Amp Fusible Link on page 12-33. The fusible link is a short length of special, high temperature insulated wire and should not be confused with standard wire.
Page 263: Warning Lights
ELECTRICAL COMPONENTS: DIESEL VEHICLES Warning Lights Push the fusible link wire assembly into the harness and secure with new wire ties. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. WARNING LIGHTS See General Warnings, Section 1, Page 1-2. TESTING THE WARNING LIGHTS See Test Procedure 23 –...
Page 264: Fuel Gauge/Hour Meter
Fuel Gauge/Hour Meter ELECTRICAL COMPONENTS: DIESEL VEHICLES 2131 Figure 14-6 Instrument Panel Electrical Components FUEL GAUGE/HOUR METER See General Warnings, Section 1, Page 1-2. TESTING THE FUEL GAUGE/HOUR METER See Test Procedure 32 – Fuel Gauge on page 12-40. Also see Test Procedure 33 – Hour Meter on page 12-41. With the key switch in the OFF position, the fuel gauge field is blank;...
Page 265: Fuel Gauge/Hour Meter Removal
ELECTRICAL COMPONENTS: DIESEL VEHICLES Key Switch FUEL GAUGE/HOUR METER REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Raise the hood. Disconnect the wires from the fuel gauge/hour meter (2) (Figure 14-6, Page 14-6). Remove the mounting clip (3) that secures the gauge/meter. Alternate pulling the lower and upper tabs away from the gauge housing to remove clip.
Page 266: 12-Volt Accessory Receptacle
12-Volt Accessory Receptacle ELECTRICAL COMPONENTS: DIESEL VEHICLES From under the hood, connect the multi-pin connector to the key switch. Lower and secure the hood. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 12-VOLT ACCESSORY RECEPTACLE See General Warnings, Section 1, Page 1-2.
Page 267: Bed Lift Switch
ELECTRICAL COMPONENTS: DIESEL VEHICLES Bed Lift Switch BED LIFT SWITCH TESTING THE BED LIFT SWITCH See Test Procedure 37 – Bed Lift Switch on page 12-44. BED LIFT SWITCH REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Raise the hood.
Page 268: Light Switch
Light Switch ELECTRICAL COMPONENTS: DIESEL VEHICLES LIGHT SWITCH See General Warnings, Section 1, Page 1-2. TESTING THE LIGHT SWITCH See Test Procedure 34 – Light Switch on page 12-41. LIGHT SWITCH REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Raise the hood.
Page 269: Fuse Installation
ELECTRICAL COMPONENTS: DIESEL VEHICLES Reverse Warning Buzzer (If Equipped) FUSE INSTALLATION Install the fuse. See following WARNING. WARNING • If a fuse is blown, determine the cause of the failure and make necessary repairs before installing a new fuse. Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the vehicle electrical system may occur.
Page 270: Reverse Warning Buzzer Installation
Reverse Warning Buzzer Limit Switch (If Equipped) ELECTRICAL COMPONENTS: DIESEL VEHICLES REVERSE WARNING BUZZER INSTALLATION Install the reverse warning buzzer and secure it with two plastic rivets. Connect the black wire from the wire harness to the negative (–) terminal on the buzzer. Connect the red/white wire from the wire harness to the positive (+) terminal on the buzzer.
Page 271: Front Differential Limit Switch Diesel
ELECTRICAL COMPONENTS: DIESEL VEHICLES Front Differential Limit Switch diesel Place the Forward/Reverse handle in the REVERSE position. Tighten the limit switch mounting screws so that they are snug, but the limit switch can still be rotated in the adjustment slot (Figure 14-8, Page 14-12). Rotate the limit switch so that the lobe on the Forward/Reverse handle activates the limit switch as shown (Figure 14-9, Page 14-12).
Page 272: Front Differential Limit Switch Installation
Fuel Level Sending Unit ELECTRICAL COMPONENTS: DIESEL VEHICLES 2133 2496 Figure 14-10 Front Differential Limit Switch Removal – Figure 14-11 Front Differential Limit Switch Removal – Through Early 2010 Model Year From Late 2010 Model Year FRONT DIFFERENTIAL LIMIT SWITCH INSTALLATION Install the front differential limit switch (1) in the reverse order of removal and tighten the nuts (2) to 4 in-lb (0.5 N·m) (Figure 14-10, Page 14-14) or (Figure 14-11, Page 14-14).
Page 273: Fuel Level Sending Unit Removal
ELECTRICAL COMPONENTS: DIESEL VEHICLES Alternator FUEL LEVEL SENDING UNIT REMOVAL See Fuel Level Sending Unit Removal on page 16-12. FUEL LEVEL SENDING UNIT INSTALLATION See Fuel Level Sending Unit Installation on page 16-13. ALTERNATOR See General Warnings, Section 1, Page 1-2. TESTING THE ALTERNATOR See Test Procedure 21 –...
Page 274: Alternator And V-Belt Installation
Alternator ELECTRICAL COMPONENTS: DIESEL VEHICLES Remove the belt shield and the alternator from the engine compartment. If necessary, remove the V-belt. 2145 2146 Figure 14-14 Belt Tension Adjustment Bolt Figure 14-15 Alternator Mounting Bolt ALTERNATOR AND V-BELT INSTALLATION Place the alternator and belt shield on the engine and insert the alternator mounting bolt through the shield and alternator and into the engine block (Figure 14-15, Page 14-16).
Page 275: Oil Pressure Sensor
ELECTRICAL COMPONENTS: DIESEL VEHICLES Oil Pressure Sensor OIL PRESSURE SENSOR See General Warnings, Section 1, Page 1-2. Refer to the engine manual for testing, removal, disassembly, and installation procedures. See the Kubota D722 diesel engine manual (CC P/N 103840201). HEADLIGHTS See General Warnings, Section 1, Page 1-2.
Page 276: Thermostat Switch
Thermostat Switch ELECTRICAL COMPONENTS: DIESEL VEHICLES Attach the connector harness to the halogen bulb. The retaining tab should lock onto the halogen bulb (Figure 14-16, Page 14-17). From the front of vehicle, reach under the cowl and insert the bulb assembly into the headlight lens. Turn the bulb assembly counterclockwise one-quarter turn.
Page 277: Thermostat Switch Installation
ELECTRICAL COMPONENTS: DIESEL VEHICLES THERMOSTAT SWITCH INSTALLATION Apply Loctite 567 Liquid Thread Sealer to the threads of the thermostat switch. See following CAUTION. CAUTION • Do not use any thread-sealing tape on the threads of the thermostat switch. The housing of the thermostat switch must make a good connection to the engine block.
Page 278: Fan Installation
Wire Harness Diodes ELECTRICAL COMPONENTS: DIESEL VEHICLES 2148 Figure 14-18 Fan and Shroud FAN INSTALLATION Correctly position the electric fan assembly on the fan shroud and secure with four lock-patch bolts. Tighten the hardware to 48 in-lb (5 N·m). See preceding NOTE. Connect the two-pin connector from the fan motor to the wire harness (Figure 14-18, Page 14-20).
Page 279: Wire Harness Diode Installation
ELECTRICAL COMPONENTS: DIESEL VEHICLES Battery WIRE HARNESS DIODE INSTALLATION Slide a piece of heatshrink tubing over one of the wire ends where the diode will be attached. Use in-line wire splicing connectors to install the new diode. Make sure to observe polarity and place the end of the diode with the silver stripe on the wire that was marked when the diode was removed.
Page 280: Testing The Battery
Battery ELECTRICAL COMPONENTS: DIESEL VEHICLES TESTING THE BATTERY See Test Procedure 1 – Battery on page 12-12. PREVENTIVE MAINTENANCE To keep the battery in good operating condition, remove corrosion immediately. Post connections should be clean and tight. Frayed or worn wires should be replaced. After all cables have been connected and properly tightened to 20 ft-lb (27.1 N·m), coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to prevent future corrosion.
Page 281: Battery Removal
ELECTRICAL COMPONENTS: DIESEL VEHICLES Battery NOTE: Contact your local water department for mineral content analysis. IMPURITY ALLOWABLE CONTENT (PARTS PER MILLION) Suspended matter Trace Total solids 100.0 Calcium and magnesium oxides 40.0 Iron Ammonia Organic matter 50.0 Nitrates 10.0 Nitrites Chloride BATTERY REMOVAL See General Warnings on page 1-2.
Page 282: Battery Installation
Battery ELECTRICAL COMPONENTS: DIESEL VEHICLES WARNING • If the charger must be stopped, disconnect the AC supply cord from the wall outlet before disconnecting the DC leads from the battery. Allow the battery to cool to room temperature and resume charging battery at a lower amp rate. BATTERY INSTALLATION See General Warnings on page 1-2.
Page 283 ELECTRICAL COMPONENTS: DIESEL VEHICLES Battery WARNING • Do not jump-start a dead battery with another battery and jumper cables. 2008-2012 All-Wheel Drive Maintenance and Service Manual Page 14-25...
Page 285: Section 15 - Gasoline Engine, Muffler, Fuel System, And Clutches
SECTION 15 – GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. GASOLINE ENGINE See General Warnings, Section 1, Page 1-2. This section contains information on removing and installing the Kawasaki gasoline engine. For complete instructions on engine disassembly, repair, rebuilding, and reassembly, refer to the engine manual.
Page 286 GASOLINE ENGINE, MUFFLER, FUEL Gasoline Engine SYSTEM, AND CLUTCHES 2149 Figure 15-1 Engine Removal and Installation Components Page 15-2 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 287: Engine Installation
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Gasoline Engine 12. Remove the accelerator cable. See Accelerator Cable Removal on page 15-19. 13. Remove the muffler. See Muffler Removal on page 15-6. 14. Remove the intermediate exhaust pipe. See Intermediate Pipe Removal on page 15-6. 15.
Page 288 GASOLINE ENGINE, MUFFLER, FUEL Gasoline Engine SYSTEM, AND CLUTCHES 2151 Figure 15-2 Secure Oil Adapter to Engine Loosely install new flange-head bolts (8) up through engine plate and into engine mounting base. See following NOTE. NOTE: Engine mounting bolts will be tightened after the engine and transmission are aligned, the clutch inner cover is installed, and the cover bolts are tightened to maintain the alignment.
Page 289: Oil Filter Hoses
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Gasoline Engine 21. Install the seat frame and lower rear ROPS (Roll Over Protection Structure) bars. See Seat Support Installation on page 4-10 and ROPS Installation on page 4-8. 22. Install the upper ROPS frame. See ROPS Installation, Section 4, Page 4-8. 23.
Page 290: Exhaust System
GASOLINE ENGINE, MUFFLER, FUEL Exhaust System SYSTEM, AND CLUTCHES Use new clamps when the hoses are replaced. Fill the engine with engine oil. See Engine Oil on page 10-8. EXHAUST SYSTEM MUFFLER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 291: Intermediate Pipe Installation
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Exhaust System WARNING • Always wear eye protection when springs are removed or installed. NOTE: Shift the end of the muffler inlet and intermediate pipe from side to side to relax and disconnect the springs. Remove the springs from the intermediate pipe and manifold pipe and remove the pipe.
Page 292: Fuel System
GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES FUEL SYSTEM REF. REF. ROUTING LENGTH FUEL LINE Solid Color Clear Fuel tank to fuel filter 24.3 inches (61.5 cm) Fuel filter to fuel pump 24.3 inches (61.5 cm) Vent tube (fuel tank) 22 inches (55.8 cm) 2155 Figure 15-5 Fuel System (without Carbon Canister)
Page 293 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System REF. LENGTH FUEL LINE DIAMETER ROUTING Ø SOLID COLOR CLEAR 5/16 in. (8 mm) Fuel tank to fuel filter (6) 24.3 inches (61.5 cm) 5/16 in. (8 mm) Fuel filter (6) to fuel pump 24.3 inches (61.5 cm) Molded Vent Tube (Fuel Tank to 3/16 in.
Page 294: Fuel Filter
GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES FUEL FILTER See General Warnings, Section 1, Page 1-2. One in-line filter (4) is installed between the fuel tank and the fuel pump (Figure 15-5, Page 15-8). Fuel filters, fuel lines, and the fuel tank vent should be inspected periodically for leaks and replaced when necessary. Filter changes should not exceed the recommended interval.
Page 295: Fuel Level Sending Unit
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System 1. Carburetor Ground Wire 2. Electric Heater 1454 Figure 15-7 Carburetor Ground Wire Carburetor Jetting The Kawasaki FH680D engine is equipped with a carburetor that has fixed jets. These fixed jets do not require adjustment.
Page 296 GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. Remove the passenger seat. See Seat Removal, Section 4, Page 4-9. Remove the rubber boot (8) from the center post on the fuel level sending unit. Remove the nut (9) from the center post and remove the orange wire (7) (Figure 15-8, Page 15-12).
Page 297 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System Fuel Level Sending Unit Installation DANGER • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. WARNING • Do not use electrically powered tools to remove or install the fuel level sending unit. Failure to heed this warning could result in a fire or explosion.
Page 298: Fuel Tank
GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES 2154 2156 Figure 15-9 Fuel Level Sending Unit Alignment Figure 15-10 Fuel Level Sending Unit Position Carefully thread each hex-head screw by hand, with the ring terminal on the black ground wire (6) under the screw head closest to the engine (Figure 15-8, Page 15-12).
Page 299 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure. Fuel Tank Removal Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 300 GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES 13. Remove the nut from the strap end below the passenger seat area. 14. Lift the strap end and remove the opposite end from the slotted bracket. 15. Remove the passenger side bed latch bracket from the frame. 16.
Page 301: Carbon Canister
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System 13. Ensure the fuel shut-off valve on top of the fuel tank is in the open (ON) position (Figure 15-14, Page 15-19). 14. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4.
Page 302: Fuel Shut-Off Valve
GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES 1646 Figure 15-13 Carbon Canister, Hoses and Routing FUEL SHUT-OFF VALVE See General Warnings, Section 1, Page 1-2. The fuel shut-off valve is located on top of the fuel tank. The fuel shut-off valve should always be turned to the closed (OFF) position during vehicle storage, towing or trailering, and maintenance and service (Figure 15-14, Page 15-19).
Page 303: Engine Control Linkages
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages 1. Fuel Shut-off Valve 2. Closed (OFF) 3. Open (ON) NOTE: When selecting valve position, ensure that it is fully opened or fully closed. Figure 15-14 Fuel Shut-off Valve ENGINE CONTROL LINKAGES ACCELERATOR CABLE See General Warnings, Section 1, Page 1-2.
Page 304 GASOLINE ENGINE, MUFFLER, FUEL Engine Control Linkages SYSTEM, AND CLUTCHES 1885 2159 Figure 15-15 Z-Shaped Cable End (Gasoline Vehicles) Figure 15-16 Accelerator Cable Pedal Bracket (Gasoline Vehicles) 2160 Figure 15-17 Accelerator Cable at Engine Remove the accelerator cable from the plastic retaining clips under the passenger side of the frame. Pull the cable at the dashboard to remove it from the engine compartment.
Page 305: Choke Cable
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages NOTE: Tie the nylon cord routed during removal to the engine end of the cable. Pull the nylon cord to help feed the cable back through the instrument panel area and engine compartment. Secure the cable to the plastic retaining clips under the passenger side of the frame.
Page 306: Engine Governor Arm
GASOLINE ENGINE, MUFFLER, FUEL Engine Control Linkages SYSTEM, AND CLUTCHES 2162 2163 Figure 15-19 Choke Cable on Engine Figure 15-20 Choke Cable Through Front Cover Choke Cable Installation Secure a new choke cable to the nylon cord outside of the instrument panel. At the engine compartment, pull the nylon cord until the choke cable reaches the engine.
Page 307: Engine Rpm Adjustment
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages 2503 Figure 15-21 Governor Arm Engine Governor Arm Removal and Installation Refer to the engine manual for additional testing, removal, disassembly, and installation procedures. See the Kawasaki FH680D engine manual (CC P/N 103351201). ENGINE RPM ADJUSTMENT Vehicle Creep New vehicles or vehicles with a new drive belt or clutches may crawl forward with the shifter in FORWARD and the...
Page 308 GASOLINE ENGINE, MUFFLER, FUEL Engine Control Linkages SYSTEM, AND CLUTCHES 1. Carburetor idle screw 2. Engine governed idle screw 3. High-speed RPM screw 2504 Figure 15-22 Overview of RPM Adjustment Screws Idle RPM Adjustment DANGER • Do not operate the engine in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison.
Page 309 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages Throttle lever (5) against carburetor idle screw (1) with no gap (A). 2505 2506 Figure 15-23 Carburetor Idle Screw Figure 15-24 Push Governor Arm Clockwise High-Speed RPM Adjustment DANGER • Do not operate the engine in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison.
Page 310: Air Intake System
GASOLINE ENGINE, MUFFLER, FUEL Air Intake System SYSTEM, AND CLUTCHES AIR INTAKE SYSTEM See General Warnings, Section 1, Page 1-2. AIR FILTER REPLACEMENT The air filter should be inspected periodically and replaced when necessary. Filter changes should not exceed the recommended interval.
Page 311: Air Canister Removal
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Air Intake System AIR CANISTER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. Remove the air filter cartridge. See Air Filter Removal on page 15-26. Remove the bottom (inlet) hose from the canister (Figure 15-29, Page 15-29).
Page 312: Air Filter Intake Hose Installation
GASOLINE ENGINE, MUFFLER, FUEL Air Intake System SYSTEM, AND CLUTCHES Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. Remove the hose from under the filter canister. Remove the hose from under the vehicle body on the frame. Slide the hose through the frame support bracket and remove the hose from the vehicle (Figure 15-27, Page 15-28).
Page 313: Air Filter Outlet Hose Removal
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Air Intake System 2168 2169 Figure 15-28 Air Port on Frame Figure 15-29 Air Filter Inlet Hose AIR FILTER OUTLET HOSE REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 314: Clutches
GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES CLUTCHES The following service tools are required to disassemble the clutches properly and are available from a service parts representative (Figure 15-30, Page 15-30)(Figure 15-31, Page 15-30)(Figure 15-32, Page 15-30): 1. Spider removal tool (CC P/N 102607501) 2.
Page 315: Clutch Troubleshooting
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches CLUTCH TROUBLESHOOTING See General Warnings, Section 1, Page 1-2. Use a tachometer during vehicle operation to determine if the engine begins to lose RPM when the vehicle climbs a steep hill. Check the engine RPM and governor adjustments. If these adjustments are within specifications, there is a clutch problem.
Page 316: Drive Clutch
GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES Rotate the driven clutch clockwise and roll the belt over the driven clutch sheaves and onto the clutch. Install the outer clutch cover. See Clutch Outer Cover Installation on page 15-41. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4.
Page 317 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches CAUTION • Do not lubricate the drive clutch. Lubricants attract dirt and dust, which interfere with proper clutch operation. • Use only a dry cloth and lightly wipe the shaft of the fixed face assembly (15) (Figure 15-35, Page 15-34).
Page 318 GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES 2173 Figure 15-35 Drive Clutch Components (Two-Weight) Page 15-34 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 319 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Drive Clutch Disassembly – Three-Weight Design Remove the six bolts (1) that secure the cover plate (2) to the moveable sheave (12) (Figure 15-37, Page 15-36). Remove the cover (2), spring (3) and spacer (4) from the clutch spider (5). Inspect the rollers (6), pins (7) and weights (11).
Page 320 GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES Screw, Hex Flange Head, 1/4–20x1.25 Roller Weight Cover Plate Pin, .375x1.375 12. Moveable Sheave Spring, Compression, 2.0 OD Black/Or Washer, Flat 13. Locknut, #10-24 Spacer, Clutch, 1.44x1.125x.15 Button, Torque Primary 14. Screw, Shoulder, Hex Socket, .25x2.5 Spider 10.
Page 321 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Drive Clutch Component Inspection – Two-Weight Design Use a feeler gauge to inspect the torque rollers (7) and replace the rollers if necessary (Figure 15-35, Page 15-34). 1.1. Use a pin driver to drive out the pin (8), which will release a pin (9) and allow the rollers (7) to slide out of the spider (6).
Page 322: Driven Clutch
GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES Pull the moveable sheave upward and start threading bolts (1) into holes. Use a crisscross pattern to continue tightening the bolts to 113 in-lb (12.7 N·m). Drive Clutch Installation – Both Designs Place the drive clutch assembly on the crankshaft taper.
Page 323 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches CAUTION • Do not hit or tap the clutch with a hammer. Do not pry the clutch. These actions will damage the clutch. Driven Clutch Disassembly The following service tools are required to disassemble and assemble the driven clutch. They are available from a service parts representative: •...
Page 324 GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES "X" "X" 2175 Figure 15-39 Driven Clutch Assembly Driven Clutch Assembly Place the fixed sheave (5) onto the spring compression base and note the location of the X so the X on the moveable sheave (4) can be aligned correctly (Figure 15-39, Page 15-40).
Page 325: Clutch Cover
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches NOTE: Ensure the hose contacts the canister and the clamp is installed tightly between the port bead and canister. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4.
Page 326 GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES Install the drive clutch. See Drive Clutch Installation – Both Designs on page 15-38. Install drive belt. See Drive Belt Installation on page 15-31. Install the clutch outer cover. See Clutch Outer Cover Installation on page 15-41. 10.
Page 327: Section 16 - Diesel Engine, Muffler, Fuel System, And Clutches
SECTION 16 – DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. DIESEL ENGINE See General Warnings, Section 1, Page 1-2. This section contains information on removing and installing the Kubota diesel engine. For complete instructions on engine disassembly, repair, rebuilding, and reassembly, refer to the engine manual.
Page 328 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Diesel Engine AND CLUTCHES 2177 2178 Figure 16-1 Disconnect Coolant Hoses, Fuel Lines, Figure 16-2 Disconnect Thermostat Switch, Starter Wires Accelerator Cable and Fuel Solenoid Valve Connector and Ground Wires 10. Remove the fuel return line (4) at the engine relief valve port and securely plug the fuel return line (Figure 16-1, Page 16-2).
Page 329: Engine Installation
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Diesel Engine 2179 2180 Figure 16-3 Driver Side Diesel Engine Mount Figure 16-4 Passenger Side Diesel Engine Mount 21. Remove the hardware securing manifold pipe to exhaust manifold and slide exhaust system as far to the rear as possible.
Page 330 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Diesel Engine AND CLUTCHES Install the clutch outer cover. See Clutch Outer Cover Installation on page 16-37. Using new gasket, slide exhaust system forward and secure the manifold pipe to the exhaust manifold. See Manifold Pipe Installation on page 16-6. Tighten the hardware that secures the muffler.
Page 331: Exhaust System
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Exhaust System EXHAUST SYSTEM MUFFLER REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Loosen the muffler spring suspension bracket bolts. Remove the two springs that secure the muffler inlet to the intermediate pipe (Figure 16-5, Page 16-5). See following NOTE.
Page 332: Manifold Pipe Removal
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Exhaust System AND CLUTCHES MANIFOLD PIPE REMOVAL Remove the three bolts and flange-head locknuts (Figure 16-6, Page 16-6). Separate the manifold pipe from the engine exhaust manifold. 2181 Figure 16-6 Diesel Manifold Pipe Flange MANIFOLD PIPE INSTALLATION Clean both the exhaust manifold and the manifold pipe flanges with a scraper or wire brush.
Page 333 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Exhaust System Secure the muffler inlet to the intermediate pipe with new springs. See following WARNING and NOTE. WARNING • Always wear eye protection when springs are removed or installed. NOTE: Shift the end of the muffler inlet and intermediate pipe from side to side to relax and connect the springs. Align the muffler with the intermediate pipe and tighten the muffler spring bracket hardware to 21 ft-lb (29 N·m).
Page 334: Fuel System
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES FUEL SYSTEM LENGTH FUEL LINE DIAMETER ROUTING Ø SOLID COLOR CLEAR 5/16 in. (8 mm) Fuel tank to water separator 23.0 in. (58.4 cm) 5/16 in. (8 mm) Water separator to fuel pump 13.0 in.
Page 335: Bleeding Air From Fuel System
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System WARNING • Make sure fuel lines are the correct length and are properly routed. Failure to heed this warning could result in damage to the fuel lines and fire. BLEEDING AIR FROM FUEL SYSTEM See General Warnings, Section 1, Page 1-2.
Page 336 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES 1452 Figure 16-9 Water Separator Drain Valve Place a drain pan under the fuel filter. Lift the passenger-side seat. Locate the valve on the underside of the filter. Turn the valve clockwise until water begins to stream from the filter (Figure 16-9, Page 16-10).
Page 337 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System NOTE: Dispose of water according to the environmental laws and regulations for your area. 2327 Figure 16-10 Fuel Filter with Water Separator Fuel Filter Removal See General Warnings, Section 1, Page 1-2. The fuel filter (8) also functions as a water separator.
Page 338: Fuel Pump
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES FUEL PUMP See General Warnings, Section 1, Page 1-2. Mechanical Fuel Pump Removal The mechanical fuel pump is located on the passenger side of the engine under the injector pump. It only operates when the engine is rotating.
Page 339 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System 2153 Figure 16-11 Fuel Level Sending Unit Removal Fuel Level Sending Unit Installation DANGER • Diesel fuel! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. WARNING •...
Page 340 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES 2154 Figure 16-12 Fuel Level Sending Unit Alignment Feed a new sending unit rheostat arm and float (4) into the fuel tank (Figure 16-11, Page 16-13). The rheostat arm and float should be positioned toward the passenger’s side surface of the fuel tank (Figure 16-13, Page 16-15). Align the flange identification mounting holes (1) directly over the corresponding mounting holes in the gasket and fuel tank (Figure 16-12, Page 16-14).
Page 341: Fuel Tank
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System CAUTION • Use only the existing screws or new plastic-thread screws made for plastics applications. Do not use sheet metal screws as replacement hardware. Use a crisscross pattern to tighten the hardware to 9 in-lb (1 N·m). If the hardware cannot be tightened to 9 in-lb (1 N·m), the fuel tank must be replaced.
Page 342 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES Remove the upper portion of the ROPS (Roll Over Protection Structure) frame. See ROPS Removal, Section 4, Page 4-6. Remove the seat frame. See Seat Support Removal, Section 4, Page 4-9. Disconnect the fuel feed line (1) from the fuel tank to the primary fuel filter and raise the end of the hose above the fuel tank.
Page 343 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System 13. Remove the passenger-side bed latch bracket from the frame. 14. Remove the fuel tank. Fuel Tank Storage or Disposal Remove the cap from the tank and thoroughly rinse it with water. The cap may be discarded or kept as a spare. Use a well-ventilated area and flush the fuel tank with water to remove any remaining fuel.
Page 344: Engine Control Linkages
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Engine Control Linkages AND CLUTCHES 16. Place the Forward/Reverse handle in NEUTRAL, turn the key switch to start the engine, and allow it to idle. See following DANGER. DANGER • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation.
Page 345: Engine Rpm Adjustment
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages 1885 2183 Figure 16-16 Accelerator Cable At Pedal (Z-Shaped Cable Figure 16-17 Accelerator Cable Anchor At Pedal (Diesel End) – Through Early 2010 Model Year Only) – Through Early 2010 Model Year 2362 Figure 16-18 Accelerator Cable At Pedal (Z-Shaped Cable End and Anchor) –...
Page 346 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Engine Control Linkages AND CLUTCHES Inspect the accelerator pedal and cable. See Section 5 – Accelerator and Brake Pedal Assemblies. Check idle and high-speed RPM. See Idle RPM Adjustment on page 16-20. See High-Speed RPM Adjustment on page 16-21.
Page 347 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages 2187 2188 Figure 16-21 Diesel Probe Fuel Line Clamp On Engine Figure 16-22 Diesel Probe Battery Cable Clamp Secure the fuel line probe clamp to the clean area of the fuel injector line (Figure 16-21, Page 16-21). Secure the negative (–) line clamp to the negative (–) battery post (Figure 16-22, Page 16-21).
Page 348: Air Intake System
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Air Intake System AND CLUTCHES NOTE: It is very important that the line be cleaned enough to expose the metal. Read the tachometer and diesel probe instructions before any RPM adjustments are made. Secure the fuel line clamp to the clean area of the fuel injector line (Figure 16-21, Page 16-21). Secure the negative (–) line clamp to the negative (–) battery post (Figure 16-22, Page 16-21).
Page 349: Air Canister Removal
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Air Intake System Figure 16-25 Air Filter Cartridge AIR CANISTER REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Remove the air filter cartridge. See Air Filter Removal on page 16-22. Remove the bottom (inlet) hose from the canister (Figure 16-29, Page 16-25).
Page 350: Air Filter Intake Hose Removal
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Air Intake System AND CLUTCHES AIR FILTER INTAKE HOSE REMOVAL The air filter intake hose fits between the driver-side frame and the inlet port on the air filter canister. The frame serves as a duct to draw air from a location at the top of the front of the vehicle. See following CAUTION. CAUTION •...
Page 351: Air Filter Outlet Hose Removal
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Air Intake System 2168 2169 Figure 16-28 Air Port on Frame Figure 16-29 Air Filter Inlet Hose AIR FILTER OUTLET HOSE REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Disconnect the air outlet hose from the air filter canister outlet port.
Page 352: Clutches
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES CLUTCHES The following service tools are required to disassemble the clutches properly and are available from a service parts representative (Figure 16-30, Page 16-26)(Figure 16-31, Page 16-26)(Figure 16-32, Page 16-26): 1. Spider removal tool (CC P/N 102607501) 2.
Page 353: Clutch Troubleshooting
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches CLUTCH TROUBLESHOOTING See General Warnings, Section 1, Page 1-2. Use a tachometer during vehicle operation to determine if the engine begins to lose RPM when the vehicle climbs a steep hill. Check the engine RPM. If engine speed is within manufacturer specifications, there is a clutch problem. See Engine RPM Adjustment on page 16-19.
Page 354: Drive Clutch
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES Drive Belt Installation Position the new belt on the drive clutch and then start the belt over the top of the driven clutch. Rotate the driven clutch clockwise and roll the belt over the driven clutch sheaves and onto the clutch. Install the clutch outer cover.
Page 355 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches CAUTION • Do not lubricate the drive clutch. Lubricants attract dirt and dust, which interfere with proper clutch operation. • Use only a dry cloth and lightly wipe the shaft of the fixed face assembly (15) (Figure 16-35, Page 16-30).
Page 356 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES 2173 Figure 16-35 Drive Clutch Components (Two-Weight) Page 16-30 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 357 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Drive Clutch Disassembly – Three-Weight Design Remove the six bolts (1) that secure the cover plate (2) to the moveable sheave (12) (Figure 16-37, Page 16-32). Remove the cover (2), spring (3) and spacer (4) from the clutch spider (5). Inspect the rollers (6), pins (7) and weights (11).
Page 358 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES Screw, Hex Flange Head, 1/4–20x1.25 Roller Weight Cover Plate Pin, .375x1.375 12. Moveable Sheave Spring, Compression, 2.0 OD Black/Or Washer, Flat 13. Locknut, #10-24 Spacer, Clutch, 1.44x1.125x.15 Button, Torque Primary 14. Screw, Shoulder, Hex Socket, .25x2.5 Spider 10.
Page 359 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Drive Clutch Component Inspection – Two-Weight Design Use a feeler gauge to inspect the torque rollers (7) and replace the rollers if necessary (Figure 16-35, Page 16-30). 1.1. Use a pin driver to drive out the pin (8), which will release a pin (9) and allow the rollers (7) to slide out of the spider (6).
Page 360: Driven Clutch
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES Pull the moveable sheave upward and start threading bolts (1) into holes. Use a crisscross pattern to continue tightening the bolts to 113 in-lb (12.7 N·m). Drive Clutch Installation – Both Designs Disconnect battery.
Page 361 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches CAUTION • Do not hit or tap the clutch with a hammer. Do not pry the clutch. These actions will damage the clutch. 2174 Figure 16-38 Driven Clutch Service Tools Driven Clutch Disassembly Place the driven clutch onto the Spring compression base (CC P/N 102603501) (1) (Figure 16-38, Page 16-35).
Page 362 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES "X" "X" 2175 Figure 16-39 Driven Clutch Assembly Driven Clutch Assembly Place the fixed sheave (5) onto the spring compression base and note the location of the X so that the X on the moveable sheave (4) can be aligned correctly (Figure 16-39, Page 16-36).
Page 363: Clutch Cover
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches NOTE: Ensure the hose is fully seated and the clamp is properly located and tightened. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Drive the vehicle and check for proper operation. CLUTCH COVER Clutch Outer Cover Removal Disconnect battery.
Page 364 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES 2191 2192 Figure 16-40 Diesel Inner Cover Assembly Figure 16-41 Diesel Inner Cover Spacer Clutch Inner Cover Installation Position the inner cover spacer on the engine block using the stud bolts for alignment (Figure 16-41, Page 16-38). Align the mounting holes in the inner cover with the transmission and engine bolt holes (Figure 16-40, Page 16-38).
Page 365: Section 17 - Drivetrain Components
SECTION 17 – DRIVETRAIN COMPONENTS DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. This section contains information on removing and installing the front differential, transmission, and rear differential. Refer to the appropriate sections for complete instructions on disassembly, repair, rebuilding, and reassembly. See , or . HALF SHAFTS HALF SHAFT REMOVAL Disconnect battery and spark plug wire(s) (gasoline vehicles only).
Page 366 Half Shafts DRIVETRAIN COMPONENTS 10. Position the caliper and discs on the top of the upper A-frame and secure them with a wire tie. See following CAUTION. CAUTION • Do not kink, twist, or damage the hydraulic brake lines. 11. Remove the two flanged bolts and square nuts from the camber adjustment bar (Figure 17-3, Page 17-2). 12.
Page 367: Half Shaft Installation
DRIVETRAIN COMPONENTS Half Shafts HALF SHAFT INSTALLATION Half shafts are assembled with CV joints and are available only as a complete assembly. If a half shaft is replaced because of wear, the manufacturer recommends that both half shafts be replaced. Apply a light coat of anti-seize compound to each end of the half shaft splines (Figure 17-6, Page 17-3).
Page 368: Front Differential
Front Differential DRIVETRAIN COMPONENTS FRONT DIFFERENTIAL FRONT DIFFERENTIAL REMOVAL See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s) (gasoline vehicles only). See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Loosen the lug nuts on both front wheels. Remove the rubber spindle nut covers from both front wheels.
Page 369: Front Differential Installation
DRIVETRAIN COMPONENTS Front Differential 2199 2200 Figure 17-9 Differential Clutch Connector Figure 17-10 Front Differential Plate Bolts FRONT DIFFERENTIAL INSTALLATION See General Warnings, Section 1, Page 1-2. NOTE: If the differential was removed or replaced from the differential plate, use new flange-head bolts and tighten the hardware to 30 ft-lb (41 N·m).
Page 370: Front Driveshaft
Front Driveshaft DRIVETRAIN COMPONENTS FRONT DRIVESHAFT FRONT DRIVESHAFT REMOVAL See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s) (gasoline vehicles only). See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Remove the roll pin from the differential pinion shaft and front driveshaft (Figure 17-7, Page 17-4). See following NOTE.
Page 371: Rear Receiver Hitch
DRIVETRAIN COMPONENTS Rear Receiver Hitch REAR RECEIVER HITCH REAR RECEIVER HITCH REMOVAL See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s) (gasoline vehicles only). See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Remove the hydraulic line T-bracket from the passenger side of the receiver hitch. Remove the hydraulic line from the rubber grommets and hitch frame.
Page 372: Rear Axle - 2008-2011 Models
Rear Axle – 2008-2011 Models DRIVETRAIN COMPONENTS REAR AXLE – 2008-2011 MODELS REAR AXLE REMOVAL Disconnect battery and spark plug wire(s) (gasoline vehicles only). See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Loosen the lug nuts on both rear wheels. Lift and support the rear of vehicle and remove the wheel(s).
Page 373: Rear Axle Installation
DRIVETRAIN COMPONENTS Rear Axle – 2008-2011 Models 11. Detach rear shock absorbers from axle. See Rear Shock Absorber Removal, Section 9, Page 9-1. 12. Remove the rear receiver hitch. See Rear Receiver Hitch Removal on page 17-7. 13. Remove the roll pin from the differential pinion shaft and rear driveshaft universal coupling. See following NOTE. NOTE: Use a 1/4-inch roll pin punch to drive out the roll pin.
Page 374 Rear Axle – 2008-2011 Models DRIVETRAIN COMPONENTS Secure the rear receiver hitch to the inside of the swing arms and axle at four locations with new bolts and washers. If new bolts are not available, clean existing bolts and add Loctite 2760 per instructions. Finger-tighten the hardware.
Page 375: Rear Axle - Starting 2012 Model Year
DRIVETRAIN COMPONENTS Rear Axle – Starting 2012 Model Year REAR AXLE – STARTING 2012 MODEL YEAR REAR AXLE REMOVAL Disconnect battery and spark plug wire(s) (gasoline vehicles only). See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Loosen the lug nuts on both rear wheels. Lift and support the rear of vehicle and remove the wheel(s).
Page 376: Rear Axle Installation
Rear Axle – Starting 2012 Model Year DRIVETRAIN COMPONENTS NOTE: Use a 1/4-inch roll pin punch to drive out the roll pin. 10. Remove the four bolts, washers, and flanged locknuts securing axle to trailing arms and lateral links. See Trailing Arms and Lateral Links –...
Page 377: Rear Driveshaft
DRIVETRAIN COMPONENTS Rear Driveshaft REAR DRIVESHAFT REAR DRIVESHAFT REMOVAL See General Warnings, Section 1, Page 1-2. Push the car to a position that enables easy access to the roll pin securing the rear driveshaft to the differential pinion shaft (Figure 17-7, Page 17-4). Chock the front wheels. Disconnect battery and spark plug wire(s) (gasoline vehicles only).
Page 378 Transmission DRIVETRAIN COMPONENTS Remove the drive belt. See Drive Belt Removal on page 15-31 (gasoline vehicles) or Drive Belt Removal on page 16-27 (diesel vehicles). Remove the drive clutch. See Drive Clutch Removal – Both Designs on page 15-32 (gasoline vehicles) or Drive Clutch Removal –...
Page 379: Transmission Installation
DRIVETRAIN COMPONENTS Transmission 2208 Figure 17-18 Transmission Base Mount TRANSMISSION INSTALLATION See General Warnings, Section 1, Page 1-2. Apply a light coat of anti-seize to the front splined shaft of the transmission. Ensure the base brackets are installed on the transmission and install the transmission on the engine mounting plate while sliding the splined shaft into the front driveshaft.
Page 380: Forward/Reverse Shifter Cable
Transmission DRIVETRAIN COMPONENTS 13. Install the clutch outer cover. See Clutch Outer Cover Installation on page 15-41 (gasoline vehicles) or Clutch Outer Cover Installation on page 16-37 (diesel vehicles). 2209 Figure 17-19 Lubrication Fill Plug and Vent Tube 14. Attach vent tube and check lubricant level of transmission (Figure 17-19, Page 17-16). See Periodic Maintenance, Section 10, Page 10-1.
Page 381 DRIVETRAIN COMPONENTS Transmission 2210 2211 Figure 17-20 Forward/Reverse Shifter Cable Ball Socket Figure 17-21 Forward/Reverse Shifter Cable Flanged Nuts At Shifter Handle Ball Stud At Shifter Handle Bracket NOTE: Note the positions of the flanged nuts on the cable. The nut farthest from the handle should be at the farthest end of the threaded portion of the cable.
Page 382: Forward/Reverse Shifter Handle
Transmission DRIVETRAIN COMPONENTS Forward/Reverse Shifter Cable Installation Secure a new cable to the transmission end of the nylon cord at the dash frame. Pull and route the cable from the dash frame to the transmission. See following NOTE. NOTE: If a nylon cord was not used to remove the cable, carefully feed the cable from behind the dash frame down between the splash guard and frame, under the vehicle body, and up to the transmission.
Page 383: Rear Differential And Axle Shafts
DRIVETRAIN COMPONENTS Rear Differential and Axle Shafts Shifter Handle Installation Secure the shifter handle with a new socket-head pivot shoulder bolt (CC P/N 102684601), nylon spacer, two large flat washers, and a new nylon locknut. Tighten the hardware to 40 in-lb (5 N·m) (Figure 17-20, Page 17-17).
Page 384: Rear Differential And Axle Shaft Installation
Rear Differential and Axle Shafts DRIVETRAIN COMPONENTS If replacing shaft, transfer washer (1) and retaining ring (2) from old shaft to new (Figure 17-24, Page 17-20). 2213 2214 Figure 17-23 Axle Shaft and Brake Rotor Figure 17-24 Axle Shaft Retaining Ring and Washer REAR DIFFERENTIAL AND AXLE SHAFT INSTALLATION Clean and lubricate the seals on each side of the differential with appropriate oil.
Page 385 DRIVETRAIN COMPONENTS Rear Differential and Axle Shafts Rear Wheel Bearing Removal Remove the axle tube (1) from the differential (Figure 17-25, Page 17-21). See Rear Differential and Axle Shaft Removal on page 17-19. Remove the retaining ring (2) that is in front of the bearing (3) (Figure 17-25, Page 17-21). Drive bearing from axle tube by applying force to the outer race.
Page 387: Section 18 - Radiator And Coolant System (Diesel)
SECTION 18 – RADIATOR AND COOLANT SYSTEM (DIESEL) DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. GENERAL INFORMATION See General Warnings, Section 1, Page 1-2. The diesel vehicle is equipped with a cooling system that includes a radiator, an electric radiator fan, a reservoir, and a circulating system.
Page 388 General Information RADIATOR AND COOLANT SYSTEM (DIESEL) Check the radiator for leaks or severe coil damage. Replace the radiator if damage has created a leak, or has caused flow restriction from crushed coils. Close both drain valves but leave the engine block coolant plug open. 10.
Page 389: Coolant Reservoir
RADIATOR AND COOLANT SYSTEM (DIESEL) Coolant Reservoir COOLANT RESERVOIR See General Warnings, Section 1, Page 1-2. COOLANT RESERVOIR REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Raise the hood and remove the reservoir cap. See following WARNING. WARNING •...
Page 390: Coolant Reservoir Installation
Radiator RADIATOR AND COOLANT SYSTEM (DIESEL) COOLANT RESERVOIR INSTALLATION Install reservoir, aligning holes in mounting tabs with holes in chassis, and secure with bolts. Tighten the hardware to 132 in-lb (15 N·m). Attach 5/8 inch hose to the bottom of reservoir and secure with clamp. Attach the two hoses to top of reservoir and secure with clamps.
Page 391: Radiator Installation
RADIATOR AND COOLANT SYSTEM (DIESEL) Radiator 1. Radiator Support Bracket 2. Flanged Bolts 3. Flanged Nut 4. Two-Pin Connector 2219 Figure 18-4 Radiator Bracket Attachment Push the splash guard toward the dash and carefully lift the radiator straight up to remove from vehicle. See following CAUTION.
Page 392: Coolant Pipe Weldment
Coolant Pipe Weldment RADIATOR AND COOLANT SYSTEM (DIESEL) WARNING • Coolant reservoir and radiator are pressurized. Remove caps slowly to relieve pressure. • Hot! Coolant system is pressurized. Do not remove radiator cap while engine is hot. 11. If necessary, remove reservoir cap and fill to the FULL mark. Replace cap. See preceding WARNING. 12.
Page 393: Fan
RADIATOR AND COOLANT SYSTEM (DIESEL) WARNING • Coolant reservoir and radiator are pressurized. Remove caps slowly to relieve pressure. • Hot! Coolant system is pressurized. Do not remove radiator cap while engine is hot. If necessary, remove reservoir cap and fill to the FULL mark. Replace cap. See preceding WARNING. 10.
Page 395: Section 19 - Hydraulic Attachment System
SECTION 19 – HYDRAULIC ATTACHMENT SYSTEM DANGER • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. • Always wear eye protection and protective clothing when working on and around hydraulic systems. • Remove jewelry and objects that might conduct electricity while working on power units. •...
Page 396: Attachment Interface
Attachment Interface HYDRAULIC ATTACHMENT SYSTEM Turn the key switch to the OFF position to shut off vehicle. Turn the key switch back to the ON position, but DO NOT start the utility vehicle engine. Keep the joystick ON/OFF switch set to ON. Relieve pressure in the desired circuit: 4.1.
Page 397: Removing And Installing The Attachment Arm Mechanism
HYDRAULIC ATTACHMENT SYSTEM Attachment Interface 2222 2223 Figure 19-3 Hand Lever Linkages and Pins Figure 19-4 Inspect Mount Mount NOTE: The following picture may not show your exact attachment but mounting frame inspections are the same. Inspect the pin mounts (1), mounting flange (2) and all welds for wear, damage and cracks (Figure 19-4, Page 19-3).
Page 398 Attachment Interface HYDRAULIC ATTACHMENT SYSTEM Lower the attachment arm to the ground and tilt the attachment interface forward (Figure 19-5, Page 19-3). Stop the engine, put the Forward/Reverse Handle in NEUTRAL, engage the park brake, unfasten your seat belt, and exit the vehicle. Remove the retaining ring (1) and pin (2) from the attachment interface cylinder rod end, and keep the retaining ring and pin for later use in this procedure (Figure 19-6, Page 19-3).
Page 399 HYDRAULIC ATTACHMENT SYSTEM Attachment Interface 2227 2228 Figure 19-9 Secure Attachment and Interface Cylinders Figure 19-10 Remove Attachment Arm Retaining Pins 2229 2230 Figure 19-11 Attachment Arm Pins and Retaining Rings Figure 19-12 Align the Vehicle to Attachment Arms Attachment Arm Installation Align the vehicle with the attachment arms (Figure 19-12, Page 19-5).
Page 400 Attachment Interface HYDRAULIC ATTACHMENT SYSTEM WARNING • Do not have hands in the area of the cylinders when extending or retracting the cylinders. Remove the two retaining rings (4 and 7) and pins (3 and 6) that secure the two cylinders (1 and 5) to the mount (2) (Figure 19-14, Page 19-6).
Page 401 HYDRAULIC ATTACHMENT SYSTEM Attachment Interface 12. Raise the attachment arm (1) and align it with the cylinder (2). Install the pin (3) and retaining ring (4) (Figure 19-16, Page 19-6). 13. Raise the attachment interface and align it with the cylinder. Install the pin (2) and the retaining ring (1) (Figure 19-17, Page 19-7).
Page 402: Electrical
Electrical HYDRAULIC ATTACHMENT SYSTEM ELECTRICAL Diode 2 Diode 3 WD1027864C-L Figure 19-18 Wiring Diagram for Hydraulic Attachment System Vehicles (Front) Page 19-8 2008-2012 All-Wheel Drive Maintenance and Service Manual...
Page 403 HYDRAULIC ATTACHMENT SYSTEM Electrical Diode 4 WD1027864C-R Figure 19-19 Wiring Diagram for Hydraulic Attachment System Vehicles (Rear) 2008-2012 All-Wheel Drive Maintenance and Service Manual Page 19-9...
Page 404: Joystick
Electrical HYDRAULIC ATTACHMENT SYSTEM JOYSTICK See General Warnings, Section 1, Page 1-2. Bottom View (Wire Harness Removed For Clarity) B. AUX SWITCH: 8 - Pin Connector (6 Wires) ON-OFF Switch A. FLOAT SWITCH: 8 - Pin Connector (4 Wires) Removed For Clarity 1.
Page 405 HYDRAULIC ATTACHMENT SYSTEM Electrical If a switch does not work as stated in step 2, replace switch. If a switch does work as stated in step 2 and the joystick still does not work, check the following items: – Fuse –...
Page 406: Joystick On/Off Switch
Electrical HYDRAULIC ATTACHMENT SYSTEM Ensure the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Unplug harness from the eight switches under joystick (Figure 19-22, Page 19-11). Remove four nuts and screws securing joystick to control box cover. Joystick Installation Insert joystick into control box cover and secure with the four nuts and screws previously removed.
Page 407: Attachment Arm Float Switch
HYDRAULIC ATTACHMENT SYSTEM Electrical – Continuity from the 14-gauge red wire (w08) at the Accessory Relay to the 16-gauge orange/black wire (w10) at the ON/OFF switch. – Continuity from the 16-gauge orange wire (w81) at the ON/OFF switch to any 18-gauge orange wire at the joystick.
Page 408 Electrical HYDRAULIC ATTACHMENT SYSTEM Check switch light. 3.1. Without inserting switch into control box cover, reconnect switch to harness. 3.2. Remove light green wire (w34) from motor solenoid and cover its ring terminal to prevent a short. 3.3. Reconnect the battery cables, positive (+) cable first, and turn the key switch ON. 3.4.
Page 409: Auxiliary Hydraulic Switch
HYDRAULIC ATTACHMENT SYSTEM Electrical AUXILIARY HYDRAULIC SWITCH See General Warnings, Section 1, Page 1-2. A. Extend Position B. Retract Position C. Alignment Notches Terminals: 1. #18 Gray w1 2. #18 Red/White w82 3. #18 Gray w57 4. #18 Green w22 5. #18 Orange w12 6. #18 Yellow w23 2241 Figure 19-25 Auxiliary Hydraulic Switch Test (Rear View) Testing the Auxiliary Switch...
Page 410: Relays
Electrical HYDRAULIC ATTACHMENT SYSTEM Unplug harness from switch (Figure 19-22, Page 19-11). Note orientation of alignment notches (Figure 19-25, Page 19-15). Squeeze tabs at each end of switch and push switch out the top of the control box cover. Auxiliary Switch Installation Orient alignment notches and insert switch into control box cover until fully seated (Figure 19-25, Page 19-15).
Page 411 HYDRAULIC ATTACHMENT SYSTEM Electrical Locate and pull or pry the relay out of the multi-pin connector to remove (Figure 19-22, Page 19-11). Float Relay 1 and 2 Installation Insert the relay into the multi-pin connector. See following NOTE. NOTE: The relay contacts are keyed to ensure that the relay can only be installed in the correct orientation. If the relay is not easy to insert, rotate the relay until the correct contact orientation is obtained.
Page 412: Solenoid
Electrical HYDRAULIC ATTACHMENT SYSTEM SOLENOID 1. Light Green (w34) – Positive [+] Terminal of Coil 2. Red – from Circuit Breaker 3. Copper Strap to Motor 4. Purple – Negative [–] Terminal of Coil 2246 Figure 19-30 Solenoid Wiring and Testing Testing the Solenoid Test for continuity between the two small coil terminals (light green wire and purple wire) (Figure 19-30, Page 19-18).
Page 413: Control Valves
HYDRAULIC ATTACHMENT SYSTEM Electrical Set the joystick ON/OFF switch to OFF. Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Disconnect wires from each post of circuit breaker. Remove hardware securing breaker to chassis and remove breaker. Circuit Breaker Installation Attach breaker to chassis with screws and tighten to 75 in-lb (8.5 N·m).
Page 414 Electrical HYDRAULIC ATTACHMENT SYSTEM – The continuity of the control valve coil. – A bent valve stem. Replace valve. – Any debris in the valve cartridge. – Check for debris by energizing the valve without starting the motor and listening for the valve to shift (a definite “Click”...
Page 415: Hoses
HYDRAULIC ATTACHMENT SYSTEM Hoses If the valve does not shift, check and repair (if necessary) the following items: – The valve “hot” wire and ground wire (Figure 19-19, Page 19-9). – The switch controlling the valves. See Electrical on page 19-8. –...
Page 416: Hose Removal
Hoses HYDRAULIC ATTACHMENT SYSTEM 1. Red Hose At Pump 2. White Hose At Pump 3. White Hose At Quick Connect Fittings 4. Red Hose At Quick Connect Fittings 2251 Figure 19-35 Auxiliary Circuit Hoses HOSE REMOVAL Relieve pressure in hydraulic system. See Relieving Hydraulic System Pressure on page 19-1. Set the joystick ON/OFF switch to OFF, remove driver seat and disable vehicle.
Page 417: Quick Connect Fittings (Auxiliary Hydraulic Circuit Only)
HYDRAULIC ATTACHMENT SYSTEM Quick Connect Fittings (Auxiliary Hydraulic Circuit only) QUICK CONNECT FITTINGS (AUXILIARY HYDRAULIC CIRCUIT ONLY) 2252 Figure 19-36 Quick Connect Fitting Removal QUICK CONNECT REMOVAL Relieve pressure in hydraulic system. See Relieving Hydraulic System Pressure on page 19-1. Set the joystick ON/OFF switch to OFF, remove driver seat and disable vehicle.
Page 418: Cylinders
Cylinders HYDRAULIC ATTACHMENT SYSTEM CYLINDERS 1. Pivot Pin 2. Retaining Pin 3. Cylinder (Lift and Lower) 4. Cylinder (Tilt Up and Tilt Down) 5. Green 6. Blue 7. Pink 8. No Color 9. Wire Ties 2253 Figure 19-37 Cylinders and Hoses VEHICLE MOUNTED CYLINDERS Vehicle Mounted Cylinder Removal Relieve pressure in hydraulic system.
Page 419: Auxiliary Cylinder (Optional)
HYDRAULIC ATTACHMENT SYSTEM Cylinders Vehicle Mounted Cylinder Installation If installing a used cylinder, clean inside the attachment ends first. Otherwise, orient cylinder, align attachment ends and secure with pivot pin(s) and retaining pin(s). Match and connect hoses to fittings (Figure 19-37, Page 19-24). Tighten fittings to 22 ft-lb (30 N·m). Lubricate attachment ends.
Page 420 Cylinders HYDRAULIC ATTACHMENT SYSTEM Remove retaining pin (1) from the base end of the hydraulic cylinder (Figure 19-40, Page 19-26). Remove pivot pin (2) (Figure 19-41, Page 19-26) from the base end of the hydraulic cylinder and remove cylinder. 2256 2257 Figure 19-40 Remove Retaining Pin Figure 19-41 Remove Pivot Pin...
Page 421: Cylinder Disassembly
HYDRAULIC ATTACHMENT SYSTEM Cylinders CYLINDER DISASSEMBLY Parts Identification NOTE: The drawing may not show your hydraulic cylinder exactly as it appears, but the internal assembly is the same. 1. Case 5. O-ring 9. Head 2. Nut 6. O-ring 10. Oil Seal 3.
Page 422 Cylinders HYDRAULIC ATTACHMENT SYSTEM WARNING • Wear safety glasses to prevent eye injury when any of the following conditions exist: – Fluids are under pressure. – Flying debris or loose material is present. – Engine is running. – Tools are being used CAUTION •...
Page 423 HYDRAULIC ATTACHMENT SYSTEM Cylinders 2259 2260 Figure 19-43 Loosen the Head Figure 19-44 Remove Rod Assembly 2261 2262 Figure 19-45 Remove Nut from Piston Figure 19-46 Pull Components from Rod 10. If the head has a seal, remove the seal from the head (Figure 19-47, Page 19-29). 11.
Page 424: Cylinder Assembly
Cylinders HYDRAULIC ATTACHMENT SYSTEM 2265 2266 Figure 19-49 Remove Wiper Seal Figure 19-50 Remove Oil Seal 14. Remove the piston seal from the piston (Figure 19-51, Page 19-30). 15. Remove the O-ring from the piston (Figure 19-52, Page 19-30). 2267 2268 Figure 19-51 Remove Piston Seal Figure 19-52 Remove Piston O-ring...
Page 425 HYDRAULIC ATTACHMENT SYSTEM Cylinders WARNING – Engine is running. – Tools are being used. Install the O-ring on the piston (Figure 19-53, Page 19-31). NOTE: Do not overstretch the seal. Install the seal on the tool and stretch it until it fits the piston (Figure 19-54, Page 19-31). Allow the O-ring to stretch for 30 seconds before removing it from the tool.
Page 426 Cylinders HYDRAULIC ATTACHMENT SYSTEM 2271 2272 Figure 19-55 Install Piston Seal Figure 19-56 Compress Piston Seal Install the oil seal on the rod seal tool (Figure 19-57, Page 19-32). NOTE: The O-ring side of the oil seal goes toward the inside of the cylinder. Install the oil seal in the head (Figure 19-58, Page 19-32).
Page 427 HYDRAULIC ATTACHMENT SYSTEM Cylinders 2275 2276 Figure 19-59 Install Wiper Seal Figure 19-60 Install Back-up Washer Install the O-ring next to the back-up ring as shown (Figure 19-61, Page 19-33). 10. If a seal was removed from the head, use the following procedure to install a new seal. 11.
Page 428 Cylinders HYDRAULIC ATTACHMENT SYSTEM 2279 2280 Figure 19-63 Compress Seal Figure 19-64 Install Head on Rod 2281 2282 Figure 19-65 Install Cushioned Piston (If Equipped) Figure 19-66 Install Cushion Sleeve (If Equipped) and Piston 16. Install and tighten nut to 150-185 ft-lb (203-251 N·m) torque (Figure 19-67, Page 19-35). 17.
Page 429 HYDRAULIC ATTACHMENT SYSTEM Cylinders 2283 2284 Figure 19-67 Install and Tighten Piston Nut Figure 19-68 Lubricate Seal 20. Put oil on the Teflon seal on the piston (Figure 19-69, Page 19-35). 21. Install the rod assembly in the cylinder case (Figure 19-70, Page 19-35). 22.
Page 430: Cylinder Bushings (If Equipped)
Cylinders HYDRAULIC ATTACHMENT SYSTEM CYLINDER BUSHINGS (IF EQUIPPED) Removal and Installation WARNING • Wear safety glasses to prevent eye injury when any of the following conditions exist: – Fluids are under pressure. – Flying debris or loose material is present. –...
Page 431: Angle Frame Bushings
HYDRAULIC ATTACHMENT SYSTEM Angle Frame Bushings 2291 2292 Figure 19-75 Remove Bushings from Rod End Figure 19-76 Apply LOCTITE and Install Bushings Into Rod End ANGLE FRAME BUSHINGS SNOW BLADE ANGLE FRAME Removal and Installation WARNING • Wear safety glasses to prevent eye injury when any of the following conditions exist: –...
Page 432: Whisk Broom Angle Frame
Angle Frame Bushings HYDRAULIC ATTACHMENT SYSTEM 2293 2294 Figure 19-77 Remove Snow Blade Angle Pivot Bushings Figure 19-78 Apply LOCTITE and Install Angle Pivot Bushings Remove the four bushings (1) (Figure 19-79, Page 19-38) from both ends of the angle frame. Apply LOCTITE 271 (Red) to the bushings before installing them into the angle frame (Figure 19-80, Page 19-38).
Page 433: Front Mount
HYDRAULIC ATTACHMENT SYSTEM Front Mount Remove the two bushings (1) (Figure 19-81, Page 19-38) from both sides of the angle frame. Apply LOCTITE 271 (Red) to the bushing before installing them into the angle frame. Install the two bushings (1) (Figure 19-82, Page 19-38) on both sides of the angle frame. FRONT MOUNT FRONT MOUNT REMOVAL Front Mount Not Shown For Clarity...
Page 434: Front Mount Installation
Hydraulic Pump Assembly HYDRAULIC ATTACHMENT SYSTEM CAUTION • When repairing hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
Page 435: Fluid Level Inspection
HYDRAULIC ATTACHMENT SYSTEM Hydraulic Pump Assembly WARNING – Engine is running. – Tools are being used. CAUTION • When repairing hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
Page 436: Pump Assembly
Hydraulic Pump Assembly HYDRAULIC ATTACHMENT SYSTEM PUMP ASSEMBLY WARNING • Wear safety glasses to prevent eye injury when any of the following conditions exist: – Fluids are under pressure. – Flying debris or loose material is present. – Engine is running. –...
Page 437 HYDRAULIC ATTACHMENT SYSTEM Hydraulic Pump Assembly 2303 2304 Figure 19-87 Park Brake Cable Bolt Figure 19-88 Cover Edge of Heat Shield Remove bolt securing the passenger side park brake cable to the chassis, at the air filter, and move cable forward (Figure 19-87, Page 19-43).
Page 438: Reservoir
Hydraulic Pump Assembly HYDRAULIC ATTACHMENT SYSTEM CAUTION • Use care to avoid damaging the hoses and wires when moving them around the heat shield. 13. Remove two bolts securing pump assembly to cradle and remove cradle (Figure 19-90, Page 19-43). 14.
Page 439: Motor
HYDRAULIC ATTACHMENT SYSTEM Hydraulic Pump Assembly Wipe/rinse the pump clean. Clean and inspect reservoir o-ring. Replace if necessary. Lubricate o-ring with new fluid and install reservoir, being careful not to pinch or deform the o-ring. Tighten clamp to 57 in-lb (6.3 N·m). Install pump assembly.
Page 440: Pump
Hydraulic Pump Assembly HYDRAULIC ATTACHMENT SYSTEM 2311 2312 Figure 19-95 Align Slot In Armature Figure 19-96 Driveshaft PUMP Pump Removal See Pump Assembly Removal on page 19-42. Pump Installation See Instructions for Installing Modular Pump on Existing Unit following page 19-46. PRIMING THE PUMP Fill reservoir to the Maximum Fluid Level line.
Page 441 Monarch Hydraulics, Inc. Instructions for Installing Modular Pump on Existing Unit IMPORTANT: (See Figure #1) IMPORTANT: (See Figure #2) See Figure #3) IMPORTANT: Do not over tighten! Figure 1 Figure 2 Figure 3 Install (4) Screws Through Pump And Into Base. Drive Shaft Torque (4) Screws To 140-160 Inch Lbs.
Page 443 INDEX 12-volt accessory receptacle (diesel vehicles) installation ............7-16 testing ............12-38 removal ............7-16 12-volt accessory receptacle (gasoline vehicles) ball joint, upper testing .............11-32 installation ............7-14 removal ............7-14 battery (diesel vehicles) ........14-21 charging ..........14-23–14-24 hydrometer test ..........12-13 a-arm, lower installation ............
Page 444 INDEX see drive belt ........15-31, 16-27 brake disc belt, seat installation ............. 6-20 see seat belt ..........4-10–4-12 removal ............6-19 body, front brake pad, front components ............4-3 installation ............. 6-18 removal .............. 4-4 removal ............6-17 repair..............4-2 bushings box bed angle frame.............
Page 445 INDEX installation ............16-38 removal ............16-27 removal ............16-37 drive belt (gasoline vehicles) clutch inner cover (gasoline vehicles) inspection ............15-31 installation ............15-41 installation ............15-31 removal ............15-41 removal ............15-31 clutch outer cover (diesel vehicles) drive clutch (diesel vehicles)........ 16-26 installation ............
Page 446 INDEX RPM adjustment..........15-23 fuel gauge/hour meter (gasoline vehicles) RPM adjustment, high-speed ......15-25 fuel gauge circuit testing ........11-34 engine governor arm hour meter circuit testing........11-35 see governor arm, engine ...... 15-22–15-23 installation ............13-8 exhaust system (diesel vehicles) operation ............13-7 intermediate pipe removal ............
Page 447 INDEX testing .............11-14 removal ............15-27 ground wire, carburetor ........15-10 jetting, carburetor (gasoline vehicles) ....15-11 half shaft joystick (hydraulic attachment vehicles) removal ............17-1 installation ............19-12 handle, forward/reverse shifter removal ............19-11 installation ............17-19 testing ............19-10 removal ............17-18 headlight (diesel vehicles) bulb installation ...........
Page 448 INDEX removal ............19-45 installation ............. 6-31 muffler removal ............6-30 see also exhaust system......15-6, 16-5 equalizer muffler (diesel vehicles) installation ............. 6-32 installation ............16-6 removal ............6-32 removal ............16-5 park brake (cable only system) muffler (gasoline vehicles) cable, front installation ............
Page 449 INDEX 4 link ............17-11 RPM adjustment (gasoline vehicles) swingarm............17-8 high-speed............15-25 rear driveshaft idle ..............15-24 installation ............17-13 removal ............17-13 rear wheel bearing see wheel bearing ........... 17-21 seat receiver hitch adjustment ............4-9 installation ............17-7 installation ............
Page 450 INDEX installation ............. 7-16 switch, float removal ............7-16 installation ............19-14 ball joint, upper removal ............19-14 installation ............. 7-14 testing ............19-13 removal ............7-14 switch, joystick ON/OFF rack and pinion installation ............19-13 assembly............7-9 removal ............19-13 disassembly ............
Page 451 INDEX 20 voltage regulator..........11-27 diode troubleshooting guide (gasoline 21 ignition spark ..........11-27 vehicles) ............11-20 22 engine kill circuit ..........11-28 troubleshooting guide (diesel vehi- 23 grounded kill wire.........11-28 cles) ............... 12-1 24 key switch (engine kill circuit)......11-29 troubleshooting guide (gasoline 25 reverse buzzer limit switch ......11-29 vehicles) ............
Page 453 5. If you are reviewing a Kit Instruction, were all indicated parts included in your kit? Yes / No Your Comments and Suggestions: Please send a copy of this page to: Fax: (706) 228-2662 or Thank You! E-mail: Tech_Pubs@clubcar.com Club Car’s Technical Publications Department 2008-2012 All-Wheel Drive Maintenance and Service Manual...

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