Gravely Atlas JSV EFI 2016 Manuals

Gravely Atlas JSV EFI 2016 Manuals

Manuals and User Guides for Gravely Atlas JSV EFI 2016. We have 1 Gravely Atlas JSV EFI 2016 manual available for free PDF download: Service Manual

Gravely Atlas JSV EFI 2016 Service Manual

Gravely Atlas JSV EFI 2016 Service Manual (414 pages)

Brand: Gravely | Category: Offroad Vehicle | Size: 67 MB

Table of Contents

Chapter 1 1 General Information

9
- Table of Contents
  9
- Vehicle Identification
  10
- Gravely Identification Number
  10
- Engine Designation Number
  10
- Vehicle Identification Number (Vin) Designation
  10
- Vehicle and Engine Serial Number Locations
  11
- Vehicle Information
  12
- Special Tools Index
  12
- Specifications
  16
- 2016 Atlas Jsv3000 Efi Overview
  16
- 2016 Atlas Jsv3000 Efi Specifications
  17
- 2016 Atlas Jsv6000 Efi Overview
  18
- Misc. Specifications and Charts
  20
- Master Torque List
  20
- Conversion Table
  24
- Standard Bolt Torque Specification
  25
- Metric Bolt Torque Specification
  26
- Sae Tap / Drill Sizes
  27
- Metric Tap / Drill Sizes
  27
- Decimal Equivalents
  28
Chapter 2 Maintenance

29
- General Information - Maintenance
  31
- Service Notes - Maintenance
  31
- Torque Specifications - Maintenance
  31
- Service Specifications - Maintenance
  32
- Break-In Period
  33
- Maintenance Chart Key
  33
- Periodic Maintenance Chart
  33
- Periodic Maintenance Overview
  33
- Pre-Ride - 50 Hour Maintenance Interval
  34
- 50 - 500 Hour Maintenance Interval
  35
- Maintenance Quick Reference
  36
- Grease Lubrication Points
  38
- Lubricants, Maintenance and Service Products
  40
- Service Products and Lubricants
  40
- Frame, Nuts, Bolts, and Fasteners
  41
- General Vehicle Inspection and Maintenance
  41
- Pre-Ride / Daily Inspection
  41
- Shift Cable Inspection / Adjustment
  42
- Fuel Pump / Fuel Filters
  43
- Fuel System and Air Intake Maintenance
  43
- Fuel System Warning
  43
- Fuel Lines
  44
- Vent Line
  44
- Air Filter Service
  45
- Engine Intake Pre-Filter Screen Service
  45
- Engine Air Intake Exploded View
  46
- Engine Maintenance
  47
- Engine Oil Level
  47
- Engine Oil and Filter Change
  48
- Engine Crankcase Breather Hose Inspection
  49
- Engine Cylinder Leakdown Test
  49
- Valve Clearance Inspection
  50
- Exhaust - Spark Arrestor
  51
- Transmission and Front Gearcase Maintenance
  52
- Transmission Lubrication
  52
- Front Gearcase Lubrication
  53
- Coolant Level Inspection
  54
- Coolant Strength / Type
  54
- Cooling System Maintenance
  54
- Liquid Cooling System Overview
  54
- Cooling System Hoses
  55
- Coolant Drain / Fill
  56
- Radiator Inspection / Cleaning
  56
- Cvt / Final Drive / Wheel and Tire Maintenance
  57
- Cvt Drying
  57
- Cvt Intake Pre-Filter Service
  57
- Drive Shaft Boot Inspection
  58
- Wheel and Hub Torque Table
  58
- Tire Inspection
  59
- Tire Pressure
  59
- Wheel Installation
  59
- Wheel Removal
  59
- Battery Installation
  60
- Battery Maintenance
  60
- Battery Removal
  60
- Electrical and Ignition System Maintenance
  60
- Chassis / Engine Electrical Ground
  61
- Spark Plug Service
  61
- Steering Inspection
  62
- Steering Maintenance
  62
- Tie Rod End / Wheel Hub Inspection
  62
- Wheel Toe Alignment Inspection
  62
- Wheel Toe Adjustment
  63
- Shock Position Adjustment
  64
- Spring Pre-Load Adjustment
  64
- Suspension Inspection
  64
- Suspension Maintenance
  64
- Brake Fluid Inspection
  65
- Brake Hose and Fitting Inspection
  65
- Brake Pad / Disc Inspection
  65
- Brake System Maintenance
  65
Chapter 3 Engine / Cooling System

67
- General Information - Engine
  70
- Service Notes - Engine
  70
- Special Tools - Engine
  70
- Torque Specifications - Engine
  71
- Service Specifications - Engine
  72
- Engine Detail - Torque Values / Sequences / Assembly Notes
  74
- Main Engine Components - Torque Specification and Sequence
  74
- Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
  75
- Cylinder / Oil Filter / Oil Pump / Breather
  76
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
  77
- Spark Plug / Starter / Throttle Body / Valve Cover
  78
- Piston / Crankshaft / Balance Shaft
  79
- Cooling System Assembly View and Coolant Flow Diagram
  80
- Engine Cooling System Service
  80
- Cooling System Pressure Test
  81
- Cooling System Specifications
  81
- Radiator Cap Pressure Test
  81
- Radiator Fan Removal
  82
- Radiator Removal / Coolant Drain
  82
- Cooling System Bleeding Procedure
  83
- Thermostat Replacement
  83
- Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
  84
- Water Pump Mechanical Seal / Oil Seal Replacement
  85
- Accessible Engine Components
  92
- Engine Removal
  92
- Engine Service
  92
- Engine Installation
  94
- Engine Mounting and Torque Values
  97
- Engine Break-In Period
  98
- Engine Lubrication Specifications
  98
- Oil Pressure Test
  98
- Engine Oil Flow Chart
  99
- Setting Tdc (Top-Dead-Center)
  100
- Camshaft / Carrier Removal
  101
- Engine Disassembly / Inspection - Top End
  101
- Valve Cover Removal
  101
- Camshaft Sprocket Inspection
  102
- Camshaft Inspection
  103
- Exhaust Camshaft Decompression Mechanism
  103
- Cam Chain and Guide Service
  104
- Cylinder Head Removal
  104
- Cylinder Head Disassembly
  105
- Cylinder Head Inspection
  106
- Cylinder Head Warp Inspection
  106
- Valve Inspection
  107
- Combustion Chamber Cleaning
  108
- Valve Seat Reconditioning
  108
- Cylinder Removal
  110
- Cylinder Inspection
  111
- Piston Removal
  111
- Piston / Rod Inspection
  112
- Piston-To-Cylinder Clearance
  112
- Piston Ring Installed Gap
  113
- Cylinder Hone Selection / Honing Procedure
  114
- Honing to Oversize
  114
- Camshaft Installation / Timing
  115
- Camshaft Timing - Quick Reference
  118
- Valve Cover Installation
  119
- Engine Assembly - Top End
  120
- Piston Ring Installation
  120
- Cylinder Installation
  121
- Piston / Connecting Rod Assembly
  121
- Cylinder Head Assembly
  122
- Valve Sealing Test
  123
- Cylinder Head Installation
  124
- Valve Clearance Check / Adjustment
  125
- Intake Valve Lash - Tappet Selection Matrix
  128
- Exhaust Valve Lash - Tappet Selection Matrix
  129
- Crankcase Disassembly
  130
- Engine Disassembly / Inspection - Lower End
  130
- Flywheel / Stator Cover Removal
  130
- Starter One-Way Clutch Removal / Inspection
  131
- Stator Removal
  132
- Oil Pump Removal
  133
- Crankcase Breather Service
  135
- Oil Pump Assembly
  135
- Balance Shaft Removal / Inspection
  136
- Crankcase Separation
  136
- Crankshaft Removal
  137
- Crankshaft Inspection
  138
- Pto Side Crankcase Bearing Service
  138
- Mag Side Crankcase Bearing Service
  140
- Oil Pickup Assembly Inspection
  140
- Crankcase Inspection
  141
- Oil Pressure Regulator (Bypass) Valve Inspection
  141
- Crankcase Assembly - Pto Side
  142
- Engine Assembly - Lower End
  142
- Balance Shaft Installation / Timing
  143
- Final Crankcase Assembly
  144
- Flywheel Installation
  145
- Starter One-Way Clutch Installation
  145
- Stator / Stator Cover Installation
  147
- Engine Cooling System
  148
- Troubleshooting - Engine / Cooling System
  148
Chapter 4 Fuel System

151
- General Information - Fuel System
  153
- Service Notes - Fuel System
  153
- Special Tools - Fuel System
  153
- Service Specifications - Fuel System
  155
- Torque Specifications - Fuel System
  155
- Electronic Fuel Injection
  156
- Fuel System Component Locations
  156
- Fuel System Components
  156
- Fuel System Operation Overview
  158
- Initial Priming / Starting Procedure
  158
- Fuel Tank Exploded View
  159
- Fuel Tank Service
  159
- Fuel Line Removal / Installation
  160
- Fuel Tank Removal
  160
- Fuel Tank Installation
  161
- Fuel Pump Service
  162
- Fuel Pump Test
  162
- Fuel Sender Test
  162
- Operation Overview
  162
- Fuel Pump Replacement
  164
- Ecu Service
  167
- Electronic Control Unit (Ecu)
  167
- Operation Overview
  167
- Ecu Replacement
  168
- Electronic Throttle Control (Etc)
  169
- Etc Replacement
  169
- Etc Test
  169
- Operation Overview
  169
- Cps Test
  170
- Crankshaft Position Sensor (Cps)
  170
- Operation Overview
  170
- Cps Replacement
  171
- Operation Overview
  172
- T-Map Sensor Replacement
  172
- T-Map Sensor Test
  172
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  172
- Ect Sensor Test
  173
- Engine Coolant Temperature Sensor (Ect)
  173
- Operation Overview
  173
- Ect Sensor Replacement
  174
- Operation Overview
  175
- Pedal Position Sensor (Pps)
  175
- Pps Replacement
  175
- Pps Test
  175
- Fuel Injector Service
  176
- Fuel Injector Troubleshooting
  176
- Operation Overview
  176
- Fuel Injector Replacement
  177
- Fuel Injector Test
  177
- Fuel System Diagnostics
  179
- Instrument Cluster Trouble Code Display
  179
- Fuel System Troubleshooting
  183
- Diagnostic Software Version
  184
- Digital Wrench Operation
  184
- Digital Wrench® Diagnostic Software Overview
  184
- Ecu Replacement
  184
- Guided Diagnostic Available
  184
- Special Tools
  184
- Digital Wrench® - Diagnostic Connector
  185
- Digital Wrench® Communication Errors
  185
- Digital Wrench® Serial Number Location
  185
- Digital Wrench® Version and Update
  185
- Digital Wrench Updates
  186
- Digital Wrench® Feature Map
  188
- Engine Controller Reprogramming (Reflash)
  189
Chapter 5 Cvt System

193
- General Information - Cvt System
  194
- Service Notes - Cvt System
  194
- Special Tools - Cvt System
  194
- Service Specifications - Cvt System
  195
- Torque Specifications - Cvt System
  195
- Cvt Break-In (Drive Belt / Clutches)
  196
- Cvt System Overview
  196
- Drive Clutch Operation
  196
- Driven Clutch Operation
  196
- Maintenance / Inspection
  196
- Overheating / Diagnosis
  197
- Cvt Covers and Ducting Components
  198
- Cvt System Service
  198
- Cvt Disassembly
  199
- Cvt Assembly
  200
- Belt Removal
  201
- Drive Belt Service
  201
- Belt Inspection
  202
- Belt Installation
  202
- Drive Clutch Exploded View
  203
- Drive Clutch Service
  203
- Bearing Inspection
  204
- Clutch Disassembly
  204
- Drive Clutch Spring Inspection
  205
- Shift Weight Inspection
  205
- Button to Tower Clearance Inspection
  206
- Spider Removal
  206
- Clutch Inspection
  207
- Roller, Pin, and Thrust Washer Inspection
  207
- Bushing Service
  209
- Moveable Sheave Bushing Inspection
  209
- Clutch Assembly
  211
- Driven Clutch Service
  212
- Exploded View
  212
- Clutch Disassembly / Inspection
  213
- Clutch Assembly
  214
- Troubleshooting
  216
Chapter 6 Transmission

219
- General Information - Transmission
  220
- Service Notes - Transmission
  220
- Service Specifications - Transmission
  220
- Special Tools - Transmission
  220
- Torque Specifications - Transmission
  220
- Shift Lever Removal / Installation
  221
- Shift Lever Service
  221
- Shift Cable Adjustment
  222
- Shift Cable Inspection
  222
- Shift Cable Service
  222
- Transmission Removal
  223
- Transmission Installation
  226
- Transmission Mounting Torque Values
  230
- Differential Operation
  231
- Transmission Service
  231
- Transmission Disassembly
  232
- Gear Cluster Disassembly
  235
- Snorkel Shaft Removal / Disassembly
  236
- Planetary Differential Disassembly
  237
- Planetary Differential Bushing Replacement
  238
- Planetary Differential Assembly
  240
- Gear / Shaft / Bearing Inspection
  241
- Snorkel Gear Backlash Procedure
  242
- Transmission Assembly
  245
- Troubleshooting
  250
- Troubleshooting Checklist
  250
- Exploded View
  251
- Transmission Exploded View
  251
Chapter 7 Final Drive

253
- General Information - Final Drive
  254
- Service Notes - Final Drive
  254
- Service Specifications - Final Drive
  254
- Special Tools - Final Drive
  254
- Torque Specifications - Final Drive
  254
- Bearing Carrier Removal / Inspection
  255
- Front Bearing Carrier Service
  255
- Bearing Replacement
  256
- Bearing Carrier Installation
  257
- Front Drive Shaft Installation
  258
- Front Drive Shaft Removal
  258
- Front Drive Shaft Service
  258
- Front Propshaft Removal / Installation
  259
- Front Propshaft Removal / Installation - Crew
  259
- Front Propshaft Service
  259
- Propshaft U-Joint Disassembly
  261
- Propshaft U-Joint Service
  261
- Propshaft U-Joint Assembly
  262
- Front Gearcase Exploded View
  264
- Front Gearcase Service
  264
- All Wheel Drive Operation
  265
- Awd Diagnosis
  266
- Front Gearcase Removal
  267
- Front Gearcase Disassembly / Inspection
  268
- Front Gearcase Assembly
  271
- Front Gearcase Installation
  273
- Rear Drive Shaft Installation
  275
- Rear Drive Shaft Removal
  275
- Rear Drive Shaft Service
  275
- Drive Shaft / CV Joint Handling Tips
  276
- Drive Shaft Service
  276
- Outer CV Joint / Boot Replacement
  276
- Inner Plunging Joint / Boot Replacement
  278
- Drive Shaft Cutaway View
  281
Chapter 8 Body / Steering / Suspension

283
- General Information - Body / Steering / Suspension
  285
- Service Notes - Body / Steering / Suspension
  285
- Special Tools - Body / Steering / Suspension
  285
- Decal Replacement
  286
- Torque Specifications - Body / Steering / Suspension
  286
- Cab Frame
  287
- Cab Frame Assembly View - Jsv3000
  287
- Chassis Assembly Views
  289
- Main Frame / Frame Supports - Jsv3000
  289
- Body Components Assembly Views
  291
- Dash Panels / Glove Box
  291
- Hood / Front Fenders / Front Fascia
  292
- Floor / Rear Fenders / Skid Plate / Storage - Jsv3000
  293
- Seat Mounting / Seat Belts - Jsv3000
  296
- Rear Cargo Box Service
  298
- Tailgate / Cargo Box Panels Assembly View
  298
- Cargo Box Installation
  300
- Cargo Box Removal
  300
- Body Component Removal
  301
- Front Fascia Removal
  301
- Hood Removal
  301
- Lower Seat Base Removal
  301
- Dash Panels / Glove Box Removal
  302
- Front Fenders Removal
  302
- Rocker Panel Removal - Jsv3000
  303
- Rocker Panel Removal - Jsv6000
  304
- Front Floor Removal
  305
- Main Floor Removal
  305
- Rear Floor Removal - Jsv6000
  306
- Steering Assembly Service
  308
- Steering Assembly View
  308
- Steering Shaft Removal (Non-Eps)
  309
- Steering Wheel Removal (Non-Eps)
  309
- Steering Shaft Bearing Replacement
  310
- Assembly View
  311
- Front Lower A-Arm Installation
  312
- Front Lower A-Arm Removal
  312
- Front Upper A-Arm Installation
  313
- Front Upper A-Arm Removal
  313
- Ball Joint Removal
  314
- Ball Joint Service
  314
- Ball Joint Service Preparation
  314
- Ball Joint Installation
  315
- Exploded View
  317
- Rear Suspension Link and Axle Brace
  317
- Rear Upper Suspension Link Installation
  318
- Rear Upper Suspension Link Removal
  318
- Rear Lower Suspension Link Installation
  319
- Rear Lower Suspension Link Removal
  319
- Rear Axle Brace Removal
  320
- Rear Axle Bearing Replacement
  321
- Rear Axle Brace Installation
  322
- Shock / Spring Service
  323
- Shocks Assembly View
  323
- Shock Removal / Installation
  324
- Spring Replacement
  324
Chapter 9 Brake System

325
- General Information - Brake System
  327
- Service Notes - Brake System
  327
- Service Specifications - Brake System
  328
- Torque Specifications - Brake System
  328
- Brake System Assembly View
  329
- Brake System Service
  329
- Brake Bleeding / Fluid Change
  330
- Master Cylinder Installation
  332
- Master Cylinder Removal
  332
- Master Cylinder Service
  332
- Brake Pedal Removal
  333
- Foot Brake Pedal Service
  333
- Installation
  333
- Front Brake Pad Service
  334
- Pad Removal
  334
- Pad Assembly / Installation
  335
- Pad Inspection
  335
- Brake Burnishing Procedure
  336
- Caliper Assembly View
  337
- Front Caliper Service
  337
- Caliper Disassembly
  338
- Caliper Removal
  338
- Caliper Inspection
  339
- Caliper Assembly
  340
- Caliper Installation
  340
- Disc Inspection
  342
- Disc Runout
  342
- Front Brake Disc Service
  342
- Disc Replacement
  343
- Pad Inspection
  344
- Pad Removal
  344
- Rear Brake Pad Service
  344
- Brake Burnishing Procedure
  345
- Pad Installation
  345
- Caliper Assembly View
  346
- Caliper Removal
  346
- Rear Caliper Service
  346
- Caliper Disassembly
  347
- Caliper Assembly
  348
- Caliper Inspection
  348
- Caliper Installation
  349
- Rear Brake Disc Service
  351
Chapter 10 Electrical

355
- General Information - Electrical System
  357
- Service Notes - Electrical
  357
- Service Specifications - Electrical
  358
- Special Tools - Electrical
  358
- Torque Specifications - Electrical
  358
- Brake Light Switch
  359
- Headlamp Switch
  359
- Switches / Controls
  359
- Awd / 2Wd / Turf Switch
  360
- Ignition Key Switch
  360
- Transmission (Gear Position) Switch
  361
- Speed Sensor Location
  362
- Speed Sensor Testing
  362
- Vehicle Speed Sensor Service
  362
- Differential Solenoid Circuit Operation
  363
- Differential Solenoid Overview
  363
- Rear Diff Solenoid Service
  363
- Instrument Cluster Service
  364
- Overview
  364
- Rider Information Display
  365
- Information Display Area
  366
- Diagnostic Mode
  368
- Instrument Cluster Pinouts
  369
- Instrument Cluster Trouble Code Display
  369
- Instrument Cluster Removal
  374
- Instrument Cluster Installation
  375
- All Wheel Drive Coil Service
  376
- Diagnosing System Failures
  376
- Operation Overview
  376
- Headlight Adjustment
  377
- Headlight Bulb Replacement
  377
- Headlight Service
  377
- Headlight Housing Removal
  378
- Led Lamp Replacement
  379
- Tail Light / Brake Light Service
  379
- Fuel Sender Service
  380
- Testing
  380
- Cooling System Break-Out Diagram
  381
- Cooling System Service
  381
- Coolant Temperature Sensor
  382
- Fan Control Circuit Bypass Test
  382
- Fan Control Circuit Operation / Testing
  382
- Ignition Coil / Ht Lead Replacement
  383
- Ignition Coil Service
  383
- Ignition Coil Tests
  383
- Operation Overview
  383
- Fuse Box: Fuses / Relays / Circuit Break Service
  384
- Overview / Operation
  384
- Fuse Box Detail View
  385
- Relay Operation
  385
- Charging System "Break Even" Test
  387
- Charging System Service
  387
- Current Draw - Key off
  387
- Charging System Stator (Alternator) Tests
  388
- Regulator / Rectifier Operation
  389
- Stator (Alternator) Replacement
  389
- Charging System Testing Flow Chart
  391
- Battery Service
  392
- Battery Specifications
  392
- General Battery Information
  392
- Battery off Season Storage
  393
- Battery Terminal Block
  393
- Battery Testing
  393
- Load Test
  393
- Ocv - Open Circuit Voltage Test
  393
- Battery Charging Procedure
  394
- Starter Motor Removal
  395
- Starter System Service
  395
- Troubleshooting
  395
- Voltage Drop Test
  395
- Starter Motor Installation
  396
- Starter Solenoid Bench Test
  396
- Starter Solenoid Operation
  396
- Starting System Testing Flow Chart
  398

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