Polaris GENERAL 2016 Off-Road Vehicle Manuals

Polaris GENERAL 2016 Off-Road Vehicle Manuals

Manuals and User Guides for Polaris GENERAL 2016 Off-Road Vehicle. We have 1 Polaris GENERAL 2016 Off-Road Vehicle manual available for free PDF download: Service Manual

Polaris GENERAL 2016 Service Manual

Polaris GENERAL 2016 Service Manual (690 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 82 MB

Table of Contents

Chapter 1 1 General Information

7
- Table of Contents
  7
- General Information
  8
- Service Rules
  8
- Publication Part Numbers
  9
- Replacement Keys
  9
- Special Tools Website
  10
- Special Tools Index
  11
- Master Torque Table
  14
- Vehicle Identification
  20
- Vehicle Specifications
  21
- Misc Specifications and Charts
  39
  - Conversion Table
    39
  - Sae Tap / Drill Sizes
    40
  - Metric Tap / Drill Sizes
    40
  - Decimal Equivalents
    41
Maintenance Chapter 2 Maintenance 2

43
- Chapter 2
  45
- General Information - Maintenance
  45
- Maintenance
  45
- Service Notes - Maintenance
  45
- Special Tools - Maintenance
  45
- Torque Specifications - Maintenance
  45
- Service Specifications - Maintenance
  46
- Periodic Maintenance
  47
  - Periodic Maintenance Overview
    47
  - Break-In Period
    47
  - Maintenance Chart Key
    47
  - Pre-Ride Inspection
    48
  - Periodic Maintenance Chart
    50
  - Maintenance Quick Reference
    52
  - Grease Lubrication Points
    54
  - Maintenance Lubricants
    55
- General Vehicle Inspection and Maintenance
  56
- Engine Maintenance
  58
- Cooling System Maintenance
  63
  - Cooling System Overview
    63
  - Coolant Strength
    63
  - Coolant Level Inspection
    63
  - Cooling System Hoses
    64
  - Radiator Inspection / Cleaning
    65
  - Coolant Drain / Fill
    65
- Fuel System and Air Intake Maintenance
  66
  - Fuel Lines
    66
  - Fuel Pump / Fuel Filters
    67
  - Fuel Tank Vent Line
    68
  - Vent Line Termination Fitting
    68
  - Air Filter Service
    68
  - Intake Duct Drain Inspection
    69
- Pvt System Maintenance
  70
  - Pvt Drying
    70
- Transmission and Front Gearcase Maintenance
  71
  - Transmission Lubrication
    71
    
    Transmission Lubricant Level Check
    71
    
    Transmission Lubricant Change
    71
  - Front Gearcase Lubrication
    72
    
    Front Gearcase Fluid Level Check
    72
    
    Front Gearcase Fluid Change
    72
- Final Drive Maintenance
  73
  - Drive Shaft Boot Inspection
    73
  - Wheel Removal
    73
  - Wheel Installation
    73
  - Tire Inspection
    74
  - Tire Inspection (Intl)
    74
- Steering Maintenance
  75
  - Steering Inspection
    75
  - Steering Wheel Free-Play
    75
  - Tie Rod End / Wheel Hub Inspection
    76
  - Wheel Toe Alignment Inspection
    76
  - Wheel Toe Adjustment
    77
- Suspension Maintenance
  78
- Brake System Maintenance
  80
- Electrical Maintenance
  83
  - Battery Maintenance
    83
  - Battery Removal
    83
  - Battery Removal (Intl)
    84
  - Battery Installation
    84
  - Battery Installation (Intl)
    84
  - Engine / Chassis Electrical Ground
    85
  - Spark Plug Service
    85
  - Throttle Pedal Inspection
    86
Chapter 3 Engine / Cooling System

87
- General Information - Engine
  90
- Service Notes - Engine / Cooling System
  90
- Special Tools - Engine / Cooling System
  90
- Torque Specifications - Engine / Cooling System
  91
- Service Specifications - Engine / Cooling System
  92
- Assembly Views - Engine
  94
- Engine Service
  105
  - Engine Oil Level
    105
  - Engine Oil and Filter Change
    106
  - Engine Crankcase Breather Hose Inspection
    107
  - Engine Cylinder Leakdown Test
    107
  - Valve Clearance Inspection
    107
  - Top End Service (Engine in Chassis)
    109
  - Crankshaft Pto Seal Replacement
    110
  - Engine Removal
    112
  - Engine Installation
    115
  - Engine Break-In Period
    118
  - Oil Pressure Test
    118
  - Engine Oil Flow Chart
    120
- Engine Disassembly / Inspection - Top End
  121
  - Valve Cover Removal
    121
  - Camshaft Removal
    121
  - Camshaft Sprocket Inspection
    122
  - Camshaft / Camshaft Bore Inspection (1000)
    123
  - Cylinder Head Removal
    124
  - Cylinder Head Warp Inspection
    125
  - Cylinder Head Disassembly
    125
  - Valve Inspection
    126
  - Combustion Chamber Cleaning
    127
  - Valve Sealing Test
    128
  - Valve Seat Reconditioning (1000)
    128
- Engine Disassembly / Inspection - Bottom End
  131
  - Stator Cover Removal / Inspection
    131
  - Water Pump Housing Removal
    132
  - Flywheel Removal
    132
  - Starter One-Way Clutch Disassembly
    133
  - Crankcase Disassembly / Inspection
    134
  - Balance Shaft Removal / Inspection
    136
  - Crankshaft Removal / Inspection
    137
  - Crankcase Inspection
    139
  - Cylinder Inspection
    140
  - Cylinder / Piston Removal
    141
  - Piston Disassembly / Inspection (1000)
    141
  - Piston Ring Removal
    142
  - Piston Ring to Groove Clearance Inspection
    143
  - Piston Ring Installed Gap (1000)
    143
  - Piston-To-Cylinder Clearance
    144
  - Connecting Rod Inspection
    144
- Engine Assembly - Bottom End
  146
  - Bearing Selection Identification Letters and Numbers
    146
  - Connecting Rod Bearing Selection
    147
  - Crankshaft Main Bearing Selection
    147
  - Upper Crankcase Preparation
    148
  - Piston Ring Installation
    148
  - Piston / Connecting Rod Assembly
    150
  - Cylinder / Piston Installation
    151
  - Crankshaft Installation
    152
  - Balance Shaft Installation
    153
  - Lower Crankcase Preparation
    154
  - Crankcase Assembly
    154
  - Starter One-Way Clutch Assembly
    158
  - Flywheel Installation
    158
  - Stator Cover Installation
    159
- Engine Assembly - Top End
  160
  - Cylinder Head Assembly
    160
  - Cylinder Head Installation
    161
  - Camshaft Installation / Timing
    162
  - Camshaft Timing - Quick Reference
    166
  - Valve Clearance Adjustment
    167
  - Valve Cover Installation
    168
  - Intake Valve Lash - Tappet Selection Matrix
    169
  - Exhaust Valve Lash - Tappet Selection Matrix
    170
- Intake / Exhaust Service
  171
  - Intake Removal
    171
  - Intake Installation
    172
  - Exhaust Removal
    173
  - Exhaust Installation
    174
- Cooling System Service
  175
  - Cooling System Assembly View
    175
  - Engine Cooling System Specifications
    176
  - Cooling System Pressure Test
    176
  - Cooling System Pressure Cap Test
    177
  - Cooling System Hose Replacement
    177
  - Radiator Replacement
    178
  - Thermostat Replacement
    179
  - Cooling System Bleeding
    180
  - Water Pump Removal
    181
  - Water Pump Installation
    181
  - Water Pump Service
    183
- Troubleshooting - Engine / Cooling System
  186
  - Engine Cooling System
    186
Chapter 4 Fuel System

189
- General Information - Fuel System
  190
- Service Notes - Fuel System
  190
- Service Specifications - Fuel System
  191
- Special Tools - Fuel System
  191
- Torque Specifications - Fuel System
  191
- Assembly Views - Fuel System
  192
  - Fuel System Assembly View
    192
  - Evap Fuel System Assembly View
    193
  - Fuel Pump Assembly View
    194
- Evap System
  195
  - Evap System Overview
    195
  - Evap Conditions and Symptoms
    196
  - Carbon Canister Filter Replacement
    197
  - Carbon Canister Replacement
    197
  - Purge Valve Replacement
    198
  - Purge Valve Ohm Test
    198
- Fuel Lines
  199
  - Fuel Line Routing
    199
  - Fuel Line Routing - General 4
    207
  - Fuel Line Routing - General 4 (Evap Models)
    207
  - Vent Line Termination Fitting
    211
  - Fuel Line Quick Connect Removal
    211
- Fuel Injector
  213
  - Fuel Injector Operation Overview
    213
    
    Fuel Injector Overview
    213
    
    Fuel Injector O-Rings
    213
  - Fuel Injector Troubleshooting
    214
  - Fuel Injector Test
    214
  - Fuel Injector Replacement
    215
- Fuel Tank Service
  218
  - Fuel Line Replacement
    218
  - Fuel Tank Removal
    218
  - Fuel Tank Installation
    220
- Fuel Pump Service
  221
  - Fuel Pump Operation Overview
    221
  - Fuel Sender Test
    221
  - Fuel Pump Test
    221
  - Fuel Pump Replacement
    222
- Troubleshooting - Fuel System
  226
  - Fuel System Troubleshooting
    226
  - 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
    226
Chapter 5 Pvt System

227
- General Information - Pvt System
  229
- Service Notes - Pvt System
  229
- Special Tools - Pvt System
  229
- Service Specifications - Pvt System
  230
- Torque Specifications - Pvt System
  230
- Assembly Views - Pvt System
  231
  - Pvt Covers and Duct Components
    231
  - Drive Clutch Assembly View
    232
  - Driven Clutch Assembly View
    234
- Pvt System Overview
  235
  - Pvt System Operation Overview
    235
  - Drive Clutch Operation
    235
  - Driven Clutch Operation
    235
  - Pvt Break
    236
  - Pvt System Maintenance / Inspection
    236
  - Pvt System Overheating / Diagnosis
    237
- Pvt System Service
  238
  - Pvt Disassembly
    238
  - Pvt Assembly
    239
- Drive Belt Service
  241
  - Drive Belt Removal
    241
  - Drive Belt Inspection
    241
  - Drive Belt Installation
    242
- Drive Clutch Service
  243
  - Drive Clutch Disassembly / Inspection
    243
  - Needle Bearing Inspection
    244
  - Shift Weight Inspection
    245
  - Button to Tower Clearance Inspection
    245
  - Spider Removal
    246
  - Roller, Pin, and Thrust Washer Inspection
    246
  - Clutch Inspection
    247
  - Moveable Sheave Bushing Inspection
    248
  - Bushing Service
    248
  - Drive Clutch Assembly
    250
- Driven Clutch Service
  253
  - Driven Clutch Alignment Procedure
    253
  - Driven Clutch Disassembly
    253
  - Driven Clutch Assembly
    255
- Driven Clutch Disassembly
  257
- Driven Clutch Service (Intl)
  257
  - Driven Clutch Slider Inspection
    257
- Pvt System
  257
- Driven Clutch Assembly
  259
- Pvt System Troubleshooting
  261
- Troubleshooting - Pvt System
  261
Chapter 6 Transmission

263
- General Information - Transmission
  264
- Service Notes - Transmission
  264
- Service Specifications - Transmission
  264
- Special Tools - Transmission
  264
- Assembly Views - Transmission
  265
- Shift Cable Service
  270
  - Shift Lever Removal / Installation
    270
  - Shift Cable Inspection
    270
  - Shift Cable Adjustment
    271
- Transmission Service
  272
  - Transmission Removal
    272
  - Transmission Installation
    274
  - Transmission Mounting Torque Values
    278
  - Differential Operation
    279
  - Transmission Disassembly
    281
  - Gear Cluster Disassembly
    283
  - Snorkel Shaft Removal / Disassembly
    284
  - Planetary Differential Disassembly
    286
  - Planetary Differential Bushing Replacement
    287
  - Planetary Differential Assembly
    289
  - Bevel Differential Disassembly (2019)
    290
  - Bevel Differential Assembly (2019)
    290
  - Gear / Shaft / Bearing Inspection
    293
  - Snorkel Gear Backlash Procedure
    294
  - Transmission Assembly
    297
- Troubleshooting - Transmission
  302
Chapter 7 Final Drive

303
- General Information - Final Drive
  305
- Service Notes - Final Drive
  305
- Service Specifications - Final Drive
  305
- Special Tools - Final Drive
  305
- Torque Specifications - Final Drive
  305
- Assembly Views - Final Drive
  306
  - Propshaft Assembly View (2016-2017)
    306
  - Propshaft Assembly View (2018-2019)
    308
  - Drive Shaft Assembly View
    310
  - Drive Shaft Assembly View (Intl)
    311
  - Front Gearcase Assembly View
    313
  - Gearcase Vent Line
    314
- Propshaft Service
  315
  - Propshaft Removal (2016-2017)
    318
  - Propshaft Removal - General 4 (2017)
    319
  - Propshaft Removal (2018)
    319
  - U-Joint Disassembly
    321
  - U-Joint Assembly
    322
  - Propshaft Installation (2016-2017)
    327
  - Propshaft Installation - General 4 (2017)
    328
  - Propshaft Installation-General 4 (2018)
    328
- Drive Shaft Service
  331
  - Front Drive Shaft Removal
    331
  - Front Drive Shaft Installation
    332
  - Rear Drive Shaft Removal
    333
  - Rear Drive Shaft Installation
    334
  - Drive Shaft / CV Joint Handling Tips
    336
  - Outer CV Joint / Boot Replacement
    336
  - Inner Plunging Joint / Boot Replacement
    339
- Bearing Carrier Service
  342
  - Front Bearing Carrier Removal / Inspection
    342
  - Front Bearing Replacement
    343
    
    Bearing Removal
    343
    
    Bearing Installation
    343
  - Front Bearing Carrier Installation
    344
  - Rear Bearing Carrier Removal / Inspection
    345
  - Rear Bearing Replacement
    346
    
    Bearing Removal
    346
    
    Bearing Installation
    347
  - Rear Bearing Carrier Installation
    347
- Front Gearcase Service
  349
  - Front Gearcase Removal
    349
  - Front Gearcase Disassembly / Inspection
    351
  - Front Gearcase Assembly
    354
  - Front Gearcase Installation
    357
- Troubleshooting - Final Drive
  359
  - Final Drive Troubleshooting
    359
Chapter 8 Steering / Suspension

361
- General Information - Steering / Suspension
  363
- Service Notes - Steering / Suspension
  363
- Special Tools - Steering / Suspension
  363
- Torque Specifications - Steering / Suspension
  363
- Service Specifications - Steering / Suspensions
  364
- Assembly Views - Steering / Suspension
  365
  - Steering Assembly View
    365
  - Front Suspension Assembly View
    366
  - Rear Suspension Assembly View
    367
- Steering Assembly Service
  368
  - Steering Shaft Removal - Upper
    368
  - Steering Wheel Removal
    369
  - Power Steering Unit Removal
    369
  - Steering Shaft Removal - Lower
    370
  - Steering Shaft Bearing Replacement
    371
  - Steering Shaft Installation - Lower
    371
  - Power Steering Unit Installation
    372
  - Steering Shaft Installation - Upper
    373
  - Tie Rod End / Wheel Hub Inspection
    375
  - Steering Rack Removal
    375
  - Steering Rack Installation
    376
  - Wheel Toe Alignment Inspection
    376
  - Wheel Toe Adjustment
    377
  - Steering Wheel Free-Play
    378
  - Epas Operation Overview
    378
- Shock Service
  380
  - Shock Specifications
    380
  - Shock Specifications - General 4
    381
  - Shock Compression Adjustment
    382
  - Shock Removal
    382
  - Spring Replacement
    382
  - Spring Adjustment
    383
  - Spring Adjustment - General 4
    384
  - Shock Installation
    384
  - Shock Disassembly (Fox)
    385
    
    Eyelet-Mounted Rebound Adjuster
    391
    
    DX Bushing and Seal Style Eyelet
    392
  - Shock Assembly (Fox)
    393
    
    Eyelet-Mounted Rebound Adjuster
    394
    
    Assembly Continued
    395
  - Shock Disassembly (Walker Evans)
    402
  - Shock Assembly (Walker Evans)
    403
- Suspension Service
  405
  - Control Arm Installation - Front
    406
  - Control Arm Removal - Rear
    409
  - Control Arm Installation - Rear
    410
  - Stabilizer Bar Removal - Front
    413
  - Stabilizer Bar Installation - Front
    413
  - Stabilizer Bar Removal - Rear
    414
  - Stabilizer Bar Installation - Rear
    415
- Ball Joint Service
  416
  - Ball Joint Preparation
    416
  - Ball Joint Removal
    416
  - Ball Joint Installation
    416
- Troubleshooting - Steering / Service
  417
  - Epas Troubleshooting
    417
    
    Power Steering Non-Functional with Mil
    417
    
    Power Steering Non-Functional with Mil off
    418
  - Epas Troubleshooting Using Digital Wrench
    419
Chapter 9 Brake System

421
- General Information - Brake System
  423
- Service Notes - Brake System
  423
- Special Tools - Brake System
  423
- Torque Specifications - Brake System
  423
- Service Specifications - Brake System
  424
- Service Specifications - Brake System (Intl)
  425
- Antilock Brake System (Abs) (Intl)
  426
- Assembly Views - Brake System
  442
  - Brake System Assembly View
    442
  - Brake System Assembly View - General 4
    443
  - Line Routing and Retention
    444
  - General 4 Brake Line Routing and Retention
    447
  - Brake Line Routing and Retention (2019) General 4
    450
  - Brake Caliper Assembly View
    453
    
    Front Caliper
    453
    
    Rear Caliper
    454
- Brake System Service
  455
  - Brake System Operation Overview
    455
  - Brake Bleeding / Fluid Change
    455
  - Brake Burnishing Procedure
    456
- Master Cylinder Service
  457
  - Master Cylinder Removal
    457
  - Master Cylinder Installation
    457
- Brake Pedal Service
  458
  - Brake Pedal Removal
    458
  - Brake Pedal Installation
    458
- Front Pad Service
  459
  - Brake Pad Inspection
    460
  - Brake Pad Inspection (Intl)
    460
  - Brake Pad Installation - Front
    460
- Front Caliper Service
  462
  - Brake Caliper Removal - Front
    462
  - Brake Caliper Disassembly - Front
    462
  - Brake Caliper Inspection - Front
    463
  - Brake Caliper Assembly - Front
    464
  - Brake Caliper Installation - Front
    464
- Disc Service
  466
  - Brake Disc Runout
    466
  - Brake Disc Inspection
    466
  - Brake Disc Replacement
    466
- Rear Pad Service
  468
  - Brake Pad Removal - Rear
    468
  - Brake Pad Inspection
    469
  - Brake Pad Installation - Rear
    469
- Rear Caliper Service
  470
  - Brake Caliper Removal - Rear
    470
  - Break Caliper Disassembly - Rear
    470
  - Brake Caliper Inspection - Rear
    471
  - Brake Caliper Assembly - Rear
    471
  - Brake Caliper Installation - Rear
    472
- Parking Brake (Int
  473
  - Parking Brake Assembly View
    473
  - Parking Brake Inspection (Intl)
    474
  - Caliper Removal
    475
  - Caliper Installation
    475
  - Disc Inspection / Replacement
    475
- Troubleshooting - Brake System
  477
  - Brake System Troubleshooting
    477
    
    Brakes Squeal / Poor Brake Performance
    477
    
    Pedal Vibration
    477
    
    Caliper Overheats (Brakes Drag)
    477
    
    Brakes Lock
    477
Chapter 10 Body / Frame

479
- General Information - Body / Frame
  481
- Service Notes - Body / Frame
  481
- Special Tools - Body / Frame
  481
- Torque Specifications - Body / Frame
  481
- Assembly Views - Body / Frame
  482
  - Exterior Body Component Assembly View
    482
  - Exterior Body Component Assembly View - General 4
    483
  - Exterior Body Component Assembly View (Int
    484
  - Interior Body Component Assembly View
    485
  - Interior Body Component Assembly View - General 4
    486
  - Seat Assembly View
    487
  - Cargo Box Assembly View
    488
  - Door Assembly View
    489
  - Door Assembly View - General 4
    493
  - Rops Assembly View
    495
  - Rops Assembly View - General 4
    496
  - Frame Assembly View
    497
  - Frame Assembly View - General 4
    498
- Body Component Removal
  501
  - Roof Removal
    501
  - Audio System Removal
    501
  - Rear View Mirror Removal
    502
  - Door Removal
    502
  - Door Removal - General 4
    503
  - Seat Removal
    503
  - Hood Removal
    503
  - Front Bumper Removal
    504
  - Exterior Body Component Removal
    504
  - Exterior Body Component Removal - General 4
    509
  - Interior Body Component Removal
    516
  - Interior Body Component Removal - General 4
    516
  - Cargo Box Removal
    519
  - Decal Replacement
    520
- Body Component Installation
  521
- Exterior Body Component Installation
  528
- Exterior Body Component Installation - General
  531
- Front Bumper Installation
  533
- Hood Installation
  534
- Seat Installation
  534
- Door Installation
  535
- Door Installation - General 4
  536
- Door Cable Adjustment
  539
- Audio System Installation
  543
- Rear View Mirror Installation
  545
- Roof Installation
  546
- Frame Component Installation
  547
- Rops Removal
  547
- Rops Removal - General 4
  547
- Rops Installation
  548
- Rops Installation - General 4
  549
- Skid Plate Replacement
  551
- Skid Plate Replacement - General 4
  551
Chapter 11 Electrical

553
- Assembly Views
  558
- Harness Routing / Retention (2017-2018)
  558
- Harness Routing / Retention - General 4
  559
- Harness Routing / Retention Abs (2018 Intl)
  562
- Harness Routing / Retention Non-Abs (2018 Intl)
  564
- Harness Routing / Retention (2019)
  566
- Harness Routing / Retention 2019 - General 4
  568
- Harness Routing / Retention 2019 (Evap)
  570
- General Information - Electrical System
  572
- Electrical Diagnostics
  575
  - Electrical Service Notes
    575
  - Digital Multi-Meter (DMM) Notes
    575
  - Static and Dynamic Testing
    575
    
    Static Testing
    575
    
    Dynamic Testing
    575
  - Connector Probing Guidelines
    576
    
    Front Probing
    576
    
    Back Probing
    576
    
    Break out
    576
  - Testing Continuity/Resistance
    577
  - Testing for a Short to Ground
    577
  - Testing for a Short to Voltage
    578
  - Testing for Intermittent Conditions
    579
  - Testing Current Flow (Amperage)
    579
  - Testing Parasitic Draw
    579
  - Testing Voltage Drop
    580
- Instrument Cluster Service
  581
  - Instrument Cluster Overview
    581
  - Instrument Cluster Overview (Intl)
    582
  - Rider Information Display
    583
  - Rider Information Display (Intl)
    583
  - Information Display Area
    585
    
    Display Area Modes
    585
    
    Gauge Settings Menu
    586
    
    Backlight Color
    586
    
    Clock
    586
    
    Display Units
    586
    
    Trip Meter
    587
    
    Trip Time
    587
    
    Programmed Service Interval
    587
  - Instrument Cluster Pinouts (Intl)
    588
  - Instrument Cluster Replacement
    589
- Adjustable Speed Limiting Device (Asld) (Intl)
  590
  - Asld Overview (Intl)
    590
- Ride Command System
  591
  - Ride Command Overview
    591
  - Ride Command Troubleshooting
    593
- Electronic Control Unit (Ecu)
  595
  - Ecu Operation Overview
    595
  - Ecu Service
    595
  - Ecu Replacement
    595
  - Diagnostic Trouble Codes Overview
    596
  - Diagnostic Trouble Code List
    597
  - Abs Trouble Codes (Intl)
    601
  - Cylinder Misfire Detection
    604
- Battery Service
  605
  - Battery Specifications
    605
  - Battery Removal
    605
  - Battery Removal (Intl)
    605
  - Battery Installation
    606
  - Battery Installation (Intl)
    606
  - Battery Off-Season Storage
    606
  - Battery Testing
    607
  - Open Circuit Voltage (Ocv) Test
    607
  - Load Test
    607
  - Current Draw - Key off
    607
  - Battery Charging Procedure
    607
- Fuse / Relay Service
  609
- Charging System Service
  619
- Starting System Service
  623
  - Starting System Operation Overview
    623
  - Voltage Drop Test
    623
  - Starter Motor Removal
    623
  - Starter Motor Installation
    624
  - Starter Solenoid Service
    624
  - Starting System Troubleshooting
    625
- Ignition System Service
  626
  - Ignition System Operation Overview
    626
  - Ignition Coil / Ht Lead Replacement
    626
  - Ignition Coil Tests
    626
  - Spark Plug Service
    627
- Electronic Power-Assisted Steering
  628
  - Epas Operation Overview
    628
  - Epas System Diagnostics
    628
- Lighting System Service
  629
  - Headlight Adjustment
    629
  - Headlight Bulb Replacement
    629
  - Headlight Removal
    630
  - Headlight Installation
    630
  - Tail Light Replacement
    631
  - Dash Led Light
    631
- Winch Service
  632
  - Winch Replacement
    632
- Switch Service
  634
  - Brake Pressure Switch
    634
  - Headlight Switch
    635
  - Ignition (Key) Switch
    636
  - Awd / 2Wd Switch
    637
  - Awd / 2Wd / Turf Switch
    638
  - Transmission / Gear Position Switch
    638
  - Seat Belt Switch
    639
  - Winch Switch
    640
- Crankshaft Position Sensor (Cps)
  641
  - Cps Operation Overview
    641
  - Cps Test
    641
  - Cps Replacement
    642
- Electronic Throttle Control (Etc)
  643
  - Etc Operation Overview
    643
  - Etc Test
    643
  - Etc Replacement
    643
  - Etc Learn Procedure
    644
- Throttle Position Sensor (Tps)
  645
  - Tps Operation Overview
    645
  - Tps Test
    645
  - Tps Replacement
    645
- Heated Oxygen Sensor (O2)
  646
  - O2 Operation Overview
    646
  - O2 Test
    646
  - O2 Replacement
    646
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  647
  - T-Map Operation Overview
    647
  - T-Map Test
    647
  - T-Map Replacement
    647
- Engine Coolant Temperature (Ect) Sensor
  648
  - Ect Operation Overview
    648
  - Ect Test
    648
  - Ect Replacement
    648
- Vehicle Speed Sensor (Vss)
  649
  - Vss Operation Overview
    649
  - Vss Test
    649
  - Vss Replacement
    649
- Misc Electrical Service
  650
  - 12V Receptacle
    650
    
    Testing
    650
  - Terminal Block
    650
  - Pulse Bar
    651
  - Chassis Ground
    651
  - Diagnostic Plug
    651
- Digital Wrench
  652
- Breakout Diagrams
  661
  - Cooling System Breakout
    661
  - Starting System Breakout
    662
  - Unswitched Chassis Power Breakout
    663
  - Key-On Battery Power Breakout
    664
  - Awd Breakout
    665
- Vehicle Speed Sensor Breakout
  666
- Lights Breakout
  667
- Epas Breakout
  668
- Ride Command Breakout
  669

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