John Deere Trail Buck Utility ATV 500, 650, 650EX and 650EXT TM2160 Technical Manual
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John Deere Trail Buck Utility ATV 500, 650, 650EX and 650EXT TM2160 Technical Manual
LANGUAGE:ENGLISH
PAGES:312
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
John Deere Trail Buck Utility ATV 500, 650, 650EX and 650EXT TM2160 Technical Manual
This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows:
• Table of Contents
• Specifications and Information
• Identification Numbers
• Tools and Materials
• Component Location
• Schematics and Harnesses
• Theory of Operation
• Operation and Diagnostics
• Diagnostics
• Tests and Adjustments
• Repair
• Other
NOTE: Depending on the particular section or system being covered, not all of the above groups may be used. The bleed tabs for the pages of each section will align with the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section through the last section. We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us.
TABLE OF CONTENTS:
John Deere Trail Buck Utility ATV 500, 650, 650EX and 650EXT TM2160 Technical Manual
TM2160 500, 650, 650EX and 650EXT Trail Buck Utility ATV............. 1 Introduction..................................................... 3 Safety........................................................... 5 Recognize Safety Information................................. 5 Understand Signal Words...................................... 5 Replace Safety Signs......................................... 5 Handle Fluids Safely - Avoid Fires........................... 5 Use Care In Handling and Servicing Batteries................. 5 Prevent Battery Explosions................................... 6 Prevent Acid Burns........................................... 6 Wear Protective Clothing..................................... 6 Service Machines Safely...................................... 6 Use Proper Tools............................................. 6 Park Machine Safely.......................................... 6 Support Machine Properly and Use Proper Lifting Equipment.... 7 Work In Clean Area........................................... 7 Using High Pressure Washers.................................. 7 Illuminate Work Area Safely.................................. 7 Work In Ventilated Area...................................... 7 Warning: California Proposition 65 Warning................... 7 Remove Paint Before Welding or Heating....................... 7 Service Tires Safely......................................... 7 Service Cooling System Safely................................ 8 Handle Chemical Products Safely.............................. 8 Dispose of Waste Properly.................................... 8 Live With Safety............................................. 8 Specifications................................................... 9 Table of Contents............................................ 9 Fastener Torques............................................. 11 Metric Fastener Torque Values............................ 11 Inch Fastener Torque Values.............................. 12 General Information.......................................... 13 Gasoline................................................. 13 Gasoline Storage......................................... 13 4 - Cycle Gasoline Engine Oil............................ 14 Break-In Engine Oil - 4-Cycle Gasoline................... 14 Hydrostatic Transmission and Hydraulic Oil............... 15 Gear Case Oil............................................ 16 Gear Transmission Grease................................. 16 Alternative Lubricants................................... 16 Synthetic Lubricants..................................... 17 Lubricant Storage........................................ 17 Mixing of Lubricants..................................... 17 Oil Filters.............................................. 17 Coolant Specifications....................................... 17 Gasoline Engine Coolant.................................. 17 Gasoline Engine Coolant Drain Interval................... 18 Specifications - Trail Buck.................................. 19 Engine Specifications - 500.............................. 19 Engine Specifications - 650.............................. 19 Engine Specifications - 500 and 650...................... 19 Electrical Specifications................................ 22 Carburation Specifications............................... 23 Cooling Specifications................................... 23 Drive Train Specifications............................... 24 Steering Control Specifications.......................... 24 Suspension Specifications................................ 24 Brakes Specifications.................................... 24 Tires and Wheels Specifications.......................... 25 Dimension Specifications................................. 25 Capacities Specifications................................ 25 Torque Specifications.................................... 26 Engine........................................................... 29 Table of Contents............................................ 29 Specifications............................................... 31 Engine Specifications - 500.............................. 31 Engine Specifications - 650.............................. 31 Engine Specifications - 500 and 650...................... 31 Required Tools........................................... 34 Recommended Tools........................................ 35 Diagnostics.................................................. 36 Cooling System........................................... 36 Magneto System........................................... 36 Lubrication.............................................. 37 Cylinder and Head........................................ 39 Gearbox.................................................. 40 CVT...................................................... 41 Engine General........................................... 44 Tests and Adjustments........................................ 48 Leak Test................................................ 48 Repair....................................................... 51 Component Location....................................... 51 Engine Removal........................................... 51 Engine Installation...................................... 55 Anti-Vibration System.................................... 56 Exhaust System........................................... 56 Shifting System.......................................... 58 Fuel Circuit................................................. 59 Fuel System Components................................... 59 General.................................................. 60 Fuel Lines............................................... 60 Fuel System Pressurization............................... 60 Fuel Gauge............................................... 60 Fuel Tank Draining....................................... 61 Fuel Tank Strainer....................................... 61 Fuel Valve............................................... 62 Fuel Tank................................................ 63 Carburetor................................................... 65 Carburetor Components.................................... 65 Carburetor............................................... 66 Throttle Cable........................................... 69 Choke Cable.............................................. 71 Fuel Pump................................................ 72 Fuel Circuit................................................. 74 Air Intake Components.................................... 74 Air Filter............................................... 75 Air Filter Cleaning/Draining............................. 75 Air Filter Box........................................... 75 Rear Air Intake Adaptor.................................. 76 Cooling System............................................... 77 Engine Side Components................................... 77 Vehicle Side Components.................................. 78 General.................................................. 78 Coolant Level............................................ 79 Cooling System Leak Test................................. 79 Draining The System...................................... 80 Coolant Replacement...................................... 80 Thermostat............................................... 81 Water Temperature Switch................................. 82 Water Pump Housing....................................... 82 Water Pump Impeller...................................... 83 Water Pump Shaft......................................... 84 Radiator Cap............................................. 86 Radiator................................................. 86 Coolant Tank............................................. 87 Cooling Fan.............................................. 87 Outlet Deflector......................................... 88 Temperature Sender....................................... 88 Ignition and Charging System................................. 89 Charging Components...................................... 89 General.................................................. 89 Magneto Housing Cover.................................... 90 Seal..................................................... 94 Bearing.................................................. 95 Stator and Trigger Coil.................................. 95 Vehicle Speed Sensor (VSS)............................... 96 Rotor.................................................... 97 Oil System................................................... 98 Oil System Components.................................... 98 General.................................................. 98 Engine Oil Pressure Test................................. 99 Oil Change............................................... 99 Oil Strainer.............................................101 Engine Oil Pressure Regulator............................102 Oil Pump.................................................103 Cylinder and Head............................................108 Cylinder Head Components.................................108 Piston and Rings Components..............................109 General..................................................109 Spark Plug...............................................110 Thermostat...............................................110 Valve Cover..............................................110 Rocker Arm...............................................111 Chain Tensioner..........................................114 Breather.................................................115 Decompressor.............................................116 Camshaft Timing Gear.....................................118 Timing Chain.............................................120 Cylinder Head............................................120 Camshaft.................................................122 Valve Spring.............................................124 Valve....................................................125 Valve Guide Procedure....................................127 Cylinder.................................................129 Piston...................................................131 Piston Rings.............................................134 Crankshaft and Balancer......................................136 Crankshaft and Balancer Components.......................136 Crankcase Components.....................................137 General..................................................137 Crankshaft Locking Procedure.............................138 Timing Chain.............................................139 Chain Tensioner Guide....................................139 Crankcase................................................140 Balancer Shaft...........................................145 Crankshaft...............................................146 Transmission - 650...........................................152 Output Shaft and Transmission Components.................152 Crankcase Components.....................................153 General..................................................153 Oil Seals................................................154 Output Shaft.............................................155 Crankcase................................................159 Gearbox..................................................165 Shifting Indicator Switch................................174 Starter Drive Pinion.....................................175 CVT Assembly - 500...........................................177 Clutch Assembly Components...............................177 General..................................................177 Belt Replacement.........................................178 Drive Pulley.............................................179 Driven Pulley............................................186 Electrical.......................................................193 Table of Contents............................................193 General Information..........................................195 Reading Electrical Schematics............................195 Theory of Operation Information..........................196 Diagnostic Information...................................196 Wire Color Abbreviation Chart............................196 Common Circuit Tests.....................................197 Conductors for 12 Volt Circuits..........................197 Specifications...............................................198 Electrical Specifications................................198 Required Tools...........................................198 Recommended Tools........................................199 Schematics and Harnesses.....................................200 Component Location.......................................200 Trail Buck Main Schematic................................201 Components Overview..........................................204 General Operation Information............................204 Charging System..........................................204 Starting System..........................................204 Ignition System..........................................204 Gauges/Accessories.......................................205 General Testing/Troubleshooting Information..............205 Fuses Location...........................................206 Servicing Packard Connectors.............................206 Servicing Deutsch Connectors.............................206 Identification Of Major Connector Pins...................208 Testing Overview.............................................209 Testing Procedure........................................209 Battery Overview.............................................211 Battery..................................................211 Battery Testing..........................................211 Battery Removal..........................................212 Battery Cleaning.........................................212 Battery Inspection.......................................212 Battery Storage..........................................212 Activation Of A New Battery..............................213 Tips For Charging A Used Battery.........................214 Charging 2 or More Batteries at a Time...................215 Battery Installation.....................................215 Troubleshooting..............................................216 Starting System Troubleshooting..........................216 Tests and Adjustments........................................217 Starting System Tests....................................217 Electric Starter.........................................218 Ignition System..............................................221 Ignition System Testing Procedure........................221 Troubleshooting..........................................222 Ignition System Test.....................................223 Ignition Timing..........................................225 Spark Plug...............................................225 NGK Spark Plug Symbol Explanation........................227 12-Volt Auxiliary Power Outlet...........................227 12-Volt Power Outlet.....................................228 Headlamp.................................................228 Taillight................................................229 Ignition Switch..........................................229 Indicator Lights.........................................229 Electronic Module........................................230 Speedometer..............................................230 Winch....................................................231 Winch Control Switch.....................................231 Tests........................................................232 12-Volt Auxiliary Power Outlet...........................232 12-Volt Power Outlet.....................................232 Cooling Fan Operation Test...............................233 Headlamp.................................................233 Multi-Function Switch....................................233 Indicator Lights.........................................233 Winch Control Switch.....................................234 Drive Train......................................................235 Table of Contents............................................235 Specifications...............................................237 Required Tools...........................................237 Recommended Tools........................................237 Repair.......................................................238 Front Drive Shaft........................................238 Front Differential.......................................239 Front Propeller Shaft....................................246 Wheel Hub................................................246 Knuckle..................................................247 Wheel Bearing............................................247 Front Drive..................................................248 Front Drive Components...................................248 Rear Axle....................................................249 Rear Axle Components.....................................249 General..................................................250 Rear Differential Oil Level..............................250 Rear Differential Oil Replacement........................250 Rear Axle Assembly.......................................251 RH Axle..................................................251 LH Axle..................................................252 Rear Propeller Shaft.....................................252 Rear Hub.................................................253 Wheel Bearing............................................253 Rear Differential........................................253 Rear Differential Disassembly............................255 Steering.........................................................259 Table of Contents............................................259 Specifications...............................................261 Steering Control Specifications..........................261 Recommended Tools........................................261 Component Location...........................................262 Steering System..........................................262 Repair.......................................................263 General..................................................263 Handlebar Grip...........................................263 Handlebar................................................263 Steering Column..........................................263 Tie-Rod..................................................264 Steering Column Bearing..................................264 Multi-Function Switch....................................265 Throttle Handle Housing..................................265 LH Brake Handle..........................................266 RH Master Cylinder.......................................266 Suspension.......................................................267 Table of Contents............................................267 Specifications...............................................269 Suspension Specifications................................269 Recommended Tools........................................269 Component Location...........................................270 Swing Arm................................................270 Repair.......................................................271 General..................................................271 Rear Shock...............................................271 Swing Arm................................................272 Hydraulic Brakes.................................................275 Table of Contents............................................275 Specifications...............................................277 Brakes Specifications....................................277 Recommended Tools........................................277 Component Location...........................................278 Front Brakes.............................................278 Rear Brake...............................................279 Repair.......................................................280 General..................................................280 Hydraulic Brakes System..................................280 Parking Brake............................................280 Brake Fluid..............................................280 Master Cylinder..........................................282 Caliper..................................................284 Brake Pads...............................................285 Brake Disc...............................................286 Brake Lever..............................................287 Brake Pedal..............................................287 Brake Cable..............................................288 Brake Hoses..............................................289 Brake Light Switch.......................................290 Body / Frame.....................................................293 Table of Contents............................................293 Repair.......................................................295 Body Parts...............................................295 Seat.....................................................298 General..................................................299 Seat.....................................................299 Steering Cover...........................................299 Console..................................................300 Front Skid Plate/Bumper/ Luggage Rack....................300 Front Fender/Mudguard/ Facia.............................301 Inner Fender.............................................302 Engine Side Panel........................................303 Foot Rest................................................304 Rear Luggage Rack/Rear Bumper............................304 Rear Fender/Rear Fender Cover............................305 Rear Mudguard/Facia......................................306 Engine Skid Plate........................................306 Arm Protector............................................306 Latch Lever/Latch Base/Spring............................306 Seat Adjustment..........................................307 Seat Cover Replacement...................................307 Storage Cover Latch......................................308 Seat Cleaning............................................308 Decals Replacement.......................................308 Hitch/Trailer Ball.......................................308 Plastic Maintenance......................................308 Plastic Repair...........................................309 Body and Frame...............................................310 Body.....................................................310 General..................................................311 Footrest Support.........................................311 Removable Brace..........................................311 Rear Frame Extension.....................................311 Frame....................................................312
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⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
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