Related Manuals for Toro 700 EFI
Summarization of Contents
General Information
General Specifications
Lists key technical specifications like tire size, capacities, and electrical details.
Cylinder, Piston, and Rings (500)
Provides specifications for the cylinder, piston, and rings for the 500cc model.
Cylinder, Piston, and Rings (700)
Provides specifications for the cylinder, piston, and rings for the 700cc model.
Valves and Guides (500)
Lists specifications for valves and guides for the 500cc model.
Valves and Guides (700)
Lists specifications for valves and guides for the 700cc model.
Torque Specifications
Crankshaft (500)
Torque specifications for the 500cc model crankshaft and connecting rod.
Crankshaft (700)
Torque specifications for the 700cc model crankshaft and connecting rod.
Camshaft and Cylinder Head (500)
Torque specs for camshaft and cylinder head components of the 500cc model.
Camshaft and Cylinder Head (700)
Torque specs for camshaft and cylinder head components of the 700cc model.
Exhaust Components
Torque specifications for exhaust system parts.
Brake Components
Torque specifications for brake system components.
Electrical Components
Torque specifications for electrical component fasteners.
Drive Train Components
Torque specifications for drive train parts.
Steering Components
Torque specifications for steering system components.
Chassis/ROPS Assembly
Torque specifications for chassis and ROPS assembly fasteners.
Suspension Components
Torque specifications for suspension system components.
Engine/Transmission (500)
Torque values for engine and transmission components on the 500cc model.
Engine/Transmission (700)
Torque values for engine and transmission components on the 700cc model.
Gasoline - Oil - Lubricant
Recommended Gasoline
Specifies the recommended octane and type of gasoline.
Recommended Engine/Transmission Oil
Specifies the recommended engine and transmission oil type and grade.
Recommended Front Differential/Rear Drive Lubricant
Specifies the recommended lubricant for the front and rear drive systems.
Filling Gas Tank
Instructions and warnings for safely filling the fuel tank.
Periodic Maintenance
Periodic Maintenance Chart
A chart outlining maintenance tasks and their frequency.
Front Differential - Rear Drive Lubricant
Checking Lubricant
Procedure for checking the lubricant level in differentials.
Changing Lubricant
Procedure for changing the lubricant in differentials.
Headlight/Taillight-Brakelight
Headlight Bulb Replacement
Procedure for replacing the headlight bulb.
Taillight/Brakelight Bulb Replacement
Procedure for replacing the taillight/brakelight bulb.
Checking/Adjusting Headlight Aim
Steps for checking and adjusting headlight aim.
Shift Lever
Checking Shift Cable Adjustment
Steps to check the shift cable for proper gear selection.
Adjusting Shift Cable
Detailed instructions for adjusting the shift cable.
Hydraulic Brake System
Checking/Bleeding
Procedure for checking brake fluid level and bleeding the system.
Inspecting Hoses
Inspecting hydraulic brake hoses for damage.
Checking/Replacing Brake Pads
Brake Disc Inspection
Instructions for measuring and replacing brake discs.
Burnishing Brake Pads
Procedure for burnishing new brake pads for optimal performance.
Steering/Frame/Controls
Steering Wheel
Procedures for removing, inspecting, and installing the steering wheel.
Tie Rods
Procedures for removing, installing, and inspecting tie rods.
Steering Knuckles
Removing and Disassembling
Procedures for removing and disassembling steering knuckles.
Cleaning and Inspecting
Cleaning and inspecting steering knuckle components.
Assembling and Installing
Procedures for assembling and installing steering knuckles.
Accelerator Pedal
Removing
Procedures for removing the accelerator pedal.
Installing
Procedures for installing the accelerator pedal.
Shift Lever
Removing
Procedures for removing the shift lever.
Installing
Procedures for installing the shift lever.
Shift Cable
Removing
Procedures for removing the shift cable.
Installing
Procedures for installing the shift cable.
Front Bumper Assembly
Removing
Procedures for removing the front bumper.
Cleaning and Inspecting
Cleaning and inspecting front bumper components.
Installing
Procedures for installing the front bumper.
Hood
Removing
Procedures for removing the vehicle hood.
Installing
Procedures for installing the vehicle hood.
Fenders
Removing
Procedures for removing fenders.
Installing
Procedures for installing fenders.
Floor
Removing
Procedures for removing the floor components.
Installing
Procedures for installing the floor components.
Dashboard
Removing
Procedures for removing the dashboard assembly.
Installing
Procedures for installing the dashboard assembly.
Belly Panel
Removing
Procedures for removing the belly panel.
Installing
Procedures for installing the belly panel.
Exhaust System
Removing Muffler
Procedures for removing the muffler.
Inspecting Muffler
Inspection of the muffler for damage.
Installing Muffler
Procedures for installing the muffler.
Cargo Box
Removing
Procedures for removing the cargo box.
Cleaning and Inspecting
Cleaning and inspecting cargo box components.
Installing
Procedures for installing the cargo box.
Taillight Assembly
Removing
Procedures for removing the taillight assembly.
Inspecting
Inspection of the taillight assembly.
Installing
Procedures for installing the taillight assembly.
Seat
Removing/Installing
Procedures for removing and installing the seat.
Troubleshooting
Problem: Handling too heavy or stiff
Identifies causes and solutions for stiff steering.
Problem: Steering oscillation
Identifies causes and solutions for steering oscillation.
Problem: Steering pulling to one side
Identifies causes and solutions for steering pulling issues.
Problem: Steering impaired
Identifies causes and solutions for general steering impairment.
Problem: Tire wear rapid or uneven
Identifies causes and solutions for rapid or uneven tire wear.
Problem: Steering noise
Identifies causes and solutions for steering noise.
Problem: Rear wheel oscillation
Identifies causes and solutions for rear wheel oscillation.
Troubleshooting
Problem: Engine will not start or is hard to start (Compression too low)
Diagnoses and fixes for low compression issues.
Problem: Engine will not start or is hard to start (No spark)
Diagnoses and fixes for ignition system (no spark) issues.
Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)
Diagnoses and fixes for fuel delivery problems.
Problem: Engine stalls easily
Diagnoses and fixes for engine stalling.
Problem: Engine noisy (Excessive valve chatter)
Diagnoses and fixes for noisy valves (chatter).
Problem: Engine noisy (Noise seems to come from piston)
Diagnoses and fixes for piston-related engine noise.
Problem: Engine noisy (Noise seems to come from timing chain)
Diagnoses and fixes for timing chain noise.
Problem: Engine noisy (Noise seems to come from crankshaft)
Diagnoses and fixes for crankshaft-related engine noise.
Problem: Engine noisy (Noise seems to come from transmission)
Diagnoses and fixes for transmission noise.
Troubleshooting
Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Diagnoses and fixes for secondary bevel gear/driven shaft noise.
Problem: Engine idles poorly
Diagnoses and fixes for poor engine idling.
Problem: Engine runs poorly at high speed
Diagnoses and fixes for poor performance at high speeds.
Problem: Exhaust smoke dirty or heavy
Diagnoses and fixes for excessive or discolored exhaust smoke.
Problem: Engine lacks power
Diagnoses and fixes for engine power loss.
Problem: Engine overheats
Diagnoses and fixes for engine overheating issues.
Servicing Engine (500)
Top-Side Components
Procedures for servicing the top-side engine components.
Removing Top-Side Components
Steps to remove top-side engine parts.
Servicing Top-Side Components
Detailed service procedures for top-side engine parts.
Installing Top-Side Components
Steps for reinstalling top-side engine components.
Left-Side Components
Procedures for servicing left-side engine components.
Removing Left-Side Components
Steps to remove left-side engine parts.
Servicing Left-Side Components
Detailed service procedures for left-side engine parts.
Installing Left-Side Components
Steps for reinstalling left-side engine components.
Right-Side Components
Procedures for servicing right-side engine components.
Removing Right-Side Components
Steps to remove right-side engine parts.
Servicing Right-Side Components
Detailed service procedures for right-side engine parts.
Installing Right-Side Components
Steps for reinstalling right-side engine components.
Center Crankcase Components
Procedures for servicing center crankcase components.
Separating Crankcase Halves
Steps to separate the crankcase halves.
Disassembling Crankcase Half
Procedures for disassembling a crankcase half.
Servicing Center Crankcase Components
Detailed service procedures for center crankcase components.
Assembling Crankcase Half
Steps for assembling a crankcase half.
Joining Crankcase Halves
Procedures for joining the crankcase halves.
Top-Side Components
Removing Top-Side Components
Steps to remove top-side engine parts.
Top-Side Components
Removing Top-Side Components
Steps to remove top-side engine parts.
Top-Side Components
Removing Top-Side Components
Steps to remove top-side engine parts.
Servicing Top-Side Components
Valve Assembly
Inspection of valve seats, stems, faces, and ends.
Cleaning/Inspecting Cylinder Head Cover
Procedures for cleaning and inspecting the cylinder head cover.
Servicing Valves/Valve Guides/Valve Seats
Installing Valves
Step-by-step guide for installing valves.
Piston Assembly
Inspecting Piston
Inspection points for piston cracks, seizure, and blow-by.
Removing Piston Rings
Procedure for removing piston rings in sequence.
Cylinder/Cylinder Head Assembly
Cleaning/Inspecting Cylinder Head
Procedures for cleaning and inspecting the cylinder head.
Installing Top-Side Components
A. Piston
Procedure for installing the piston onto the connecting rod.
B. Cylinder
Procedure for installing the cylinder over the piston.
Top-Side Components
Top-Side Components
General notes on installing top-side components.
Left-Side Components
Removing Left-Side Components
Steps to remove left-side engine parts.
Left-Side Components
D. Rotor/Flywheel
Procedures for removing and installing the rotor/flywheel.
E. Starter Clutch/Gear
Procedures for removing and installing the starter clutch and gear.
F. Starter Motor
Procedures for removing and installing the starter motor.
Servicing Left-Side Components
Inspecting Starter Clutch/Gear
Inspection of the starter clutch and gear for wear or damage.
Replacing Starter Clutch Assembly
Procedure for replacing the starter clutch assembly.
Installing Left-Side Components
A. Starter Clutch/Gear
Installation of the starter clutch and gear.
B. Rotor/Flywheel
Installation of the rotor and flywheel.
Installing Left-Side Components
C. Magneto Cover
Installation of the magneto cover.
D. Water Pump
Installation of the water pump.
Installing Left-Side Components
Installing Left-Side Components
General notes on installing left-side components.
Right-Side Components
Removing Right-Side Components
Steps to remove right-side engine parts.
Right-Side Components
D. Centrifugal Clutch Assembly
Procedures for removing and installing the centrifugal clutch assembly.
E. Oil Pump Drive Gear
Procedures for removing and installing the oil pump drive gear.
F. Oil Pump Driven Gear
Procedures for removing and installing the oil pump driven gear.
Installing Right-Side Components
A. Oil Strainer/Oil Pump
Steps for installing the oil strainer and oil pump.
Servicing Right-Side Components
Inspecting Centrifugal Clutch Shoe
Inspection of centrifugal clutch shoes for wear or damage.
Inspecting Centrifugal Clutch Housing
Inspection of the centrifugal clutch housing for damage.
Inspecting Primary One-Way Drive
Inspection of the primary one-way drive mechanism.
Inspecting Oil Pump
Inspection of the oil pump for damage.
Installing Right-Side Components
B. Clutch Cover
Installation of the clutch cover.
C. Fixed Drive Face
Installation of the fixed drive face.
D. Movable Drive Face
Installation of the movable drive face.
Center Crankcase Components
Separating Crankcase Halves
Steps to separate the crankcase halves.
Disassembling Crankcase Half
Procedures for disassembling a crankcase half.
Disassembling Crankcase Half
1. Remove the secondary driven shaft assembly (A)
Procedure for removing the secondary driven shaft assembly.
2. Remove the reverse idler gear assembly (F)
Procedure for removing the reverse idler gear assembly.
3. Remove the shift shaft (H)
Procedure for removing the shift shaft.
4. Remove the gear shift shaft (G)
Procedure for removing the gear shift shaft.
Servicing Center Crankcase Components
Secondary Gears
Information on secondary gears.
Checking Backlash
Procedure for checking secondary gear backlash.
Correcting Backlash
Procedure for correcting secondary gear backlash.
Crankshaft Assembly
Measuring Connecting Rod (Small End Inside Diameter)
Procedure to measure connecting rod small end inside diameter.
Measuring Connecting Rod (Small End Deflection)
Procedure to measure connecting rod small end deflection.
Countershaft
Disassembling
Steps to disassemble the countershaft.
Countershaft
Assembling
Steps to assemble the countershaft.
Installing Engine/Transmission
Servicing Engine (700)
Details the procedures for servicing the 700cc engine.
Top-Side Components
Procedures for servicing the top-side engine components.
Removing Top-Side Components
Steps to remove top-side engine parts.
Top-Side Components
Removing Top-Side Components
Steps to remove top-side engine parts.
Top-Side Components
Removing Top-Side Components
Steps to remove top-side engine parts.
Top-Side Components
Removing Top-Side Components
Steps to remove top-side engine parts.
Servicing Top-Side Components
Valve Assembly
Inspection of valve seats, stems, faces, and ends.
Cleaning/Inspecting Valve Cover
Procedures for cleaning and inspecting the valve cover.
Servicing Valves/Valve Guides/Valve Seats
Installing Valves
Step-by-step guide for installing valves.
Piston Assembly
Inspecting Piston
Inspection points for piston cracks, seizure, and blow-by.
Removing Piston Rings
Procedure for removing piston rings in sequence.
Cylinder/Cylinder Head Assembly
Cleaning/Inspecting Cylinder Head
Procedures for cleaning and inspecting the cylinder head.
Installing Top-Side Components
A. Piston
Procedure for installing the piston onto the connecting rod.
B. Cylinder
Procedure for installing the cylinder over the piston.
Top-Side Components
Removing Top-Side Components
Steps to remove top-side engine parts.
Left-Side Components
Removing Left-Side Components
Steps to remove left-side engine parts.
Left-Side Components
D. Rotor/Flywheel
Procedures for removing and installing the rotor/flywheel.
E. Starter Clutch/Gear
Procedures for removing and installing the starter clutch and gear.
Servicing Left-Side Components
Inspecting Starter Clutch/Gear
Inspection of the starter clutch and gear for wear or damage.
Replacing Starter Clutch Assembly
Procedure for replacing the starter clutch assembly.
Right-Side Components
Removing Right-Side Components
Steps to remove right-side engine parts.
Right-Side Components
A. V-Belt Cover
Procedures for removing and installing the V-belt cover.
B. Driven Pulley
Procedures for removing and installing the driven pulley.
C. Clutch Cover
Procedures for removing and installing the clutch cover.
D. Oil Pump
Procedures for removing and installing the oil pump.
Right-Side Components
KEY
Key to identify components in the illustration.
8. Remove the one-way clutch (D)
Procedure for removing the one-way clutch.
9. Using a hydraulic press, remove the clutch housing assembly
Procedure for removing the clutch housing assembly.
Right-Side Components
10. Remove the two cap screws securing the gear position switch
Procedure for removing the gear position switch.
11. Remove the nut (left-hand threads) securing the clutch shoe assembly (C)
Procedure for removing the clutch shoe assembly nut.
12. Remove the cap screw securing the oil pump drive gear (B)
Procedure for removing the oil pump drive gear.
13. Using an impact wrench, remove the cap screws securing the final drive carrier bearing housing (E)
Procedure for removing the final drive carrier bearing housing.
14. Remove the snap ring securing the oil pump driven gear (A)
Procedure for removing the oil pump driven gear.
Servicing Right-Side Components
Inspecting Centrifugal Clutch Shoe
Inspection of centrifugal clutch shoes for wear or damage.
Inspecting Clutch Housing
Inspection of the clutch housing for damage.
Inspecting Primary One-Way Drive
Inspection of the primary one-way drive mechanism.
Inspecting Oil Pump
Inspection of the oil pump for damage.
Center Crankcase Components
Separating Crankcase Halves
Steps to separate the crankcase halves.
Disassembling Crankcase Half
Procedures for disassembling a crankcase half.
Disassembling Crankcase Half
5. Remove the countershaft assembly (D)
Procedure for removing the countershaft assembly.
6. Using a rubber mallet, tap on the crankcase to remove the driveshaft
Procedure for removing the driveshaft.
7. Note the timing marks on the crank balancer assembly (B) gear and crankshaft (C) gear
Notes on timing marks for crank balancer and crankshaft gears.
Center Crankcase Components
KEY
Key to identify components in the illustration.
1. Remove the secondary driven shaft assembly (A)
Procedure for removing the secondary driven shaft assembly.
2. Remove the reverse idler gear assembly (F)
Procedure for removing the reverse idler gear assembly.
3. Remove the shift shaft (H)
Procedure for removing the shift shaft.
4. Remove the gear shift shaft (G)
Procedure for removing the gear shift shaft.
Servicing Center Crankcase Components
Secondary Gears
Information on secondary gears.
Checking Backlash
Procedure for checking secondary gear backlash.
Correcting Backlash
Procedure for correcting secondary gear backlash.
Crankshaft Assembly
Measuring Connecting Rod (Small End Inside Diameter)
Procedure to measure connecting rod small end inside diameter.
Measuring Connecting Rod (Small End Deflection)
Procedure to measure connecting rod small end deflection.
Countershaft
Disassembling
Steps to disassemble the countershaft.
Countershaft
Assembling
Steps to assemble the countershaft.
Fuel/Lubrication/Cooling
Troubleshooting
Troubleshooting common issues with fuel, lubrication, and cooling.
Throttle Body
Procedures for removing and installing the throttle body.
Throttle Body
Removing
Steps to remove the throttle body.
Installing
Steps to install the throttle body.
Gas Tank
Removing
Steps to remove the gas tank.
Cleaning and Inspecting
Cleaning and inspecting gas tank components.
Installing
Steps to install the gas tank.
Gas Tank
Installing
Steps to install the gas tank.
Oil Filter/Oil Pump
Removing/Disassembling
Steps for removing and disassembling the oil pump.
Radiator
Removing
Steps to remove the radiator.
Cleaning and Inspecting
Cleaning and inspecting radiator components.
Thermostat
Removing
Steps to remove the thermostat.
Thermostat
Removing
Steps to remove the thermostat.
Inspecting
Inspection and testing of the thermostat.
Installing
Steps to install the thermostat.
Troubleshooting
Problem: Starting impaired
Diagnoses and fixes for starting issues.
Problem: Idling or low speed impaired
Diagnoses and fixes for poor idling or low speed performance.
Problem: Medium or high speed impaired
Diagnoses and fixes for high speed performance issues.
Electrical System
Testing Electrical Components
General guidelines for testing electrical components.
Battery
Information on battery location, maintenance, and troubleshooting.
Charging/Maintenance Charging
Procedures for charging and maintaining the battery.
Accessory Receptacle/Connector
Testing voltage at the accessory receptacle/connector.
Brakelight Switch
Voltage (Wiring Harness Connector)
Procedure to test brakelight switch voltage.
Resistance (Switch Connector)
Procedure to test brakelight switch resistance.
Ignition Coil
Voltage (Primary Side)
Testing the primary coil voltage.
Starter Motor
Removing
Procedures for removing the starter motor.
Installing
Procedures for installing the starter motor.
Testing Voltage
Procedures for testing the starter motor voltage.
Drive Select Switch
Resistance
Procedures for testing drive select switch resistance.
Voltage
Procedures for testing drive select switch voltage.
Reverse Override Switch
Voltage
Procedures for testing the reverse override switch voltage.
Front Drive Actuator
Removing
Steps to remove the front drive actuator.
Installing
Steps to install the front drive actuator.
Ignition Switch
Voltage
Procedures for testing ignition switch voltage.
Headlight Switch
Voltage
Procedure to test headlight switch voltage.
EFI Sensors/Components
Crankshaft Position (CKP) Sensor
Procedures for testing CKP sensor resistance and AC voltage.
EFI Sensors/Components
Oxygen (O2) Sensor
Procedures for testing the O2 sensor.
Diagnostic Trouble Codes (DTC)
Explanation of diagnostic trouble codes and how they are displayed.
Code List
A list of fault codes, descriptions, possible causes, and recovery methods.
Troubleshooting
Problem: Spark absent or weak
Diagnoses and fixes for weak or absent spark.
Problem: Spark plug fouled with carbon
Diagnoses and fixes for carbon-fouled spark plugs.
Problem: Spark plug electrodes overheat or burn
Diagnoses and fixes for overheated or burned spark plug electrodes.
Problem: Battery does not charge
Diagnoses and fixes for battery charging issues.
Problem: Battery charges, but charging rate is below the specification
Diagnoses and fixes for low battery charging rates.
Problem: Magneto overcharges
Diagnoses and fixes for magneto overcharging.
Problem: Charging unstable
Diagnoses and fixes for unstable battery charging.
Problem: Starter does not engage
Diagnoses and fixes for starter engagement issues.
Problem: Battery “sulfation”
Diagnoses and fixes for battery sulfation.
Problem: Battery discharges too rapidly
Diagnoses and fixes for rapid battery discharge.
Problem: Battery polarity reversed
Diagnoses and fixes for reversed battery polarity.
Fuel Pump/Fuel Level Sensor
Testing
Steps for testing fuel pump pressure and operation.
Regulator/Rectifier
Testing Voltage
Procedure to test regulator/rectifier voltage output at varying RPM.
Headlights
Voltage
Procedure to test headlight voltage.
Taillight-Brakelight
Voltage (Taillight)
Procedure to test taillight voltage.
Voltage (Brakelight)
Procedure to test brakelight voltage.
Tilt Sensor
Supply Voltage
Procedure to test tilt sensor supply voltage.
Tilt Sensor
Output Voltage
Procedure to test tilt sensor output voltage.
EFI Sensors/Components
Crankshaft Position (CKP) Sensor
Procedures for testing CKP sensor resistance and AC voltage.
Throttle Position Sensor (TPS)
Testing
Procedures for testing and adjusting the TPS.
EFI Diagnostic System
Digital Gauge
Instructions for navigating the digital gauge diagnostic modes.
Troubleshooting
Problem: Spark absent or weak
Diagnoses and fixes for weak or absent spark.
Problem: Spark plug fouled with carbon
Diagnoses and fixes for carbon-fouled spark plugs.
Problem: Spark plug electrodes overheat or burn
Diagnoses and fixes for overheated or burned spark plug electrodes.
Problem: Battery does not charge
Diagnoses and fixes for battery charging issues.
Problem: Battery charges, but charging rate is below the specification
Diagnoses and fixes for low battery charging rates.
Problem: Magneto overcharges
Diagnoses and fixes for magneto overcharging.
Problem: Charging unstable
Diagnoses and fixes for unstable battery charging.
Problem: Starter does not engage
Diagnoses and fixes for starter engagement issues.
Problem: Battery “sulfation”
Diagnoses and fixes for battery sulfation.
Problem: Battery discharges too rapidly
Diagnoses and fixes for rapid battery discharge.
Problem: Battery polarity reversed
Diagnoses and fixes for reversed battery polarity.
Troubleshooting
Code List
A list of fault codes, descriptions, possible causes, and recovery methods.
Troubleshooting
Problem: Spark absent or weak
Diagnoses and fixes for weak or absent spark.
Problem: Spark plug fouled with carbon
Diagnoses and fixes for carbon-fouled spark plugs.
Problem: Spark plug electrodes overheat or burn
Diagnoses and fixes for overheated or burned spark plug electrodes.
Problem: Battery does not charge
Diagnoses and fixes for battery charging issues.
Problem: Battery charges, but charging rate is below the specification
Diagnoses and fixes for low battery charging rates.
Problem: Magneto overcharges
Diagnoses and fixes for magneto overcharging.
Problem: Charging unstable
Diagnoses and fixes for unstable battery charging.
Problem: Starter does not engage
Diagnoses and fixes for starter engagement issues.
Problem: Battery “sulfation”
Diagnoses and fixes for battery sulfation.
Problem: Battery discharges too rapidly
Diagnoses and fixes for rapid battery discharge.
Problem: Battery polarity reversed
Diagnoses and fixes for reversed battery polarity.
Drive System
Front Drive Actuator
Information on the front drive actuator's operation, removal, and installation.
Removing
Steps to remove the front drive actuator.
Front Drive Actuator
Removing
Steps to remove the front drive actuator.
Installing
Steps to install the front drive actuator.
Front Differential
Removing
Steps to remove the front differential.
Shimming Procedure/Shim Selection
Backlash
Procedure for setting backlash.
Drive Axles
Removing Rear Drive Axle
Steps to remove the rear drive axle.
Installing Wheels
Procedure for installing wheels and tightening lug nuts.
Installing Front Drive Axle
Procedure for installing the front drive axle.
Cleaning and Inspecting Axles
Disassembling Axles
Procedures for disassembling axles.
Assembling Axles
Procedures for assembling axles.
Rear Gear Case
Removing
Steps to remove the rear gear case.
Ring Gear/Thrust Button
Removing
Procedures for removing the ring gear and thrust button.
Inspecting
Inspection of ring gear, thrust button, and bearings.
Installing/Shimming
Procedure for installing and shimming the thrust button and ring gear.
Rear Drive Input Shaft/Housing
Removing/Disassembling
Procedures for removing and disassembling the rear drive input shaft housing.
Cleaning and Inspecting
Cleaning and inspecting input shaft housing components.
Assembling/Installing
Procedures for assembling and installing the input housing.
Hub
Removing
Procedures for removing the wheel hub.
Installing
Procedures for installing the wheel hub.
Hydraulic Brake Caliper
Removing/Disassembling
Procedures for removing and disassembling the hydraulic brake caliper.
Hydraulic Brake Caliper
Cleaning and Inspecting
Cleaning and inspecting caliper components.
Assembling/Installing
Procedures for assembling and installing the brake caliper.
Master Cylinder Assembly
Removing
Procedures for removing the master cylinder.
Inspecting
Inspection of the master cylinder components.
Installing
Procedures for installing the master cylinder.
Universal Joints
Removing
Procedures for removing universal joints.
Universal Joints
Installing
Procedures for installing universal joints.
Troubleshooting Drive System
Problem: Power not transmitted from engine to wheels
Identifies causes and solutions for power loss to wheels.
Problem: Power not transmitted from engine to either front wheel
Identifies causes and solutions for power loss to front wheels.
Troubleshooting Brake System
Problem: Braking poor
Identifies causes and solutions for poor braking performance.
Problem: Brake pedal travel excessive
Identifies causes and solutions for excessive brake pedal travel.
Problem: Brake fluid leaking
Identifies causes and solutions for brake fluid leaks.
Problem: Brake pedal spongy
Identifies causes and solutions for a spongy brake pedal.
Suspension
Shock Absorbers
Inspection points for shock absorber components.
Removing
Steps to remove shock absorbers.
Installing
Steps to install shock absorbers.
Front A-Arms
Removing
Steps to remove the front A-arms.
Front A-Arms
Removing
Steps to remove the front A-arms.
Cleaning and Inspecting
Cleaning and inspecting A-arm components.
INSTALLING
Installing A-Arm Assemblies
Procedures for installing A-arm assemblies.
Wheels and Tires
Tire Size
Information on recommended tire sizes and types.
Tire Inflation Pressure
Recommended tire inflation pressure for front and rear tires.
Removing
Procedures for removing wheels.
Cleaning and Inspecting
Cleaning and inspecting wheels and tires.
Installing
Procedures for installing wheels.
Troubleshooting
Problem: Suspension too soft
Identifies causes and solutions for soft suspension.
Problem: Suspension too stiff
Identifies causes and solutions for stiff suspension.
Problem: Suspension noisy
Identifies causes and solutions for noisy suspension.
Problem: Vehicle pulling or steering erratic
Identifies causes and solutions for vehicle pulling or erratic steering.
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