John Deere Trail Buck Utility ATV 500, 650, 650EX and 650EXT TM2160 Technical Manual – PDF Download

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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

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PAGES:312
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JOHN DEERE TRAIL BUCK UTILITY ATV 500, 650, 650EX AND 650EXT TM2160 TECHNICAL MANUAL – PDF DOWNLOAD:

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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 not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]