Manual de Servicio 3400XL

Service Manual
Dealer Copy -- Not for Resale
Utility Vehicle
S/N B3FK11001 & Above
S/N B3FM11001 & Above
7255694enUS (04-18) (D) Printed in U.S.A. ©2018 Bobcat Company. All rights reserved.
D
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing the utility vehicle. Read
and understand the Operation & Maintenance Manual and signs (decals) on
WARNING utility vehicle. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after adjustments,
repairs or service. Untrained operators and failure to follow instructions can
cause injury or death. W-2859-0510
Safety Alert Symbol: This symbol with a warning statement, CORRECT

means: “Warning, be alert! Your safety is involved!”
Carefully read the message that follows.
P-90216
Never service the utility vehicle
without instructions.
CORRECT WRONG WRONG

NA13240 NA13267 NA13244
Cleaning and maintenance are Have good ventilation when Never modify equipment or add
required daily. welding or grinding painted parts. attachments and accessories not
Wear dust mask when grinding approved by Bobcat Company.
painted parts. Toxic dust and gas
can be produced.
Avoid exhaust fume leaks which
can kill without warning. Exhaust
system must be tightly sealed.
WRONG WRONG WRONG
NA5183 NA13238 B-6589
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust utility exhaust. lighted tobacco away from
vehicle with the engine running Wear eye protection to guard batteries.
unless instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Never fill fuel tank with engine and flying debris when engines Wear protective clothing. If acid
running, while smoking or when are running or tools are used. contacts body, flush well with
near open flame. Use eye protection approved for water. For eye contact, flush well
type of welding. and get immediate medical
Keep access doors closed attention.
except for service.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation &
Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.
MSW41-1017
3 of 481 1-1 3400, 3400XL Service Manual


CONTENTS
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Utility Vehicle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

UTILITY VEHICLE IDENTIFICATION (3400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
UTILITY VEHICLE IDENTIFICATION (3400XL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16


FOREWORD
This manual is for the Utility Vehicle mechanic. It provides necessary servicing and adjustment
procedures for the Utility Vehicle and its component parts and systems. Refer to the for operating
instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the Vehicle has had service or repair:
1. Check that the ROPS is in 9. Check for correct function of
good condition and is not indicator lamps.
modified.
2. Check that ROPS mounting 10. Check all machine fluid

hardware is tightened and is levels. (3450 only).
Bobcat approved.
3. The operator and passenger 11. Inspect for fluid, oil or

seat belts must be correctly hydraulic fluid leaks (3450
installed, functional and in only).

good condition.
ANALYSIS
4. Safety signs (decals) must be 12. Lubricate the machine.
legible and in the correct
location.
5. Foot pedals must return to 13. Check the condition of the

neutral. battery and cables.
6. Check for correct function of 14. Inspect the air cleaner for
the head lights and tail lights. damage or leaks. Check the
condition of the element.
7. The parking brake must 15. Check the electrical charging

function correctly. system.
8. RapidLink must function 16. Check tires for wear and

correctly and be in good pressure. Use only approved
condition (3450 only). tires.
FW UV-0617 SM

17. Inspect for loose or broken 20. Check for correct function of
parts or connections. the Start Interlock System
before the machine is
returned to the customer.
18. Check for any field 21. Check function or condition of

modification not completed. all equipped options and
accessories.
19. Operate the vehicle and 22. Recommend to the owner

check all functions. that all necessary corrections
be made before the machine
is returned to service.

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW UV-0617 SM

SAFETY INSTRUCTIONS The following publications provide information on the safe
use and maintenance of the Bobcat utility vehicle and
Safety Alert Symbol attachments:
• The Delivery Report is used to assure that complete

This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the vehicle is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the vehicle or attachment contains operating
information as well as routine maintenance and
WARNING service procedures. It is a part of the vehicle and can

be stored in a container provided on the vehicle.
Replacement Operation & Maintenance Manuals can
Operator must have instructions before operating the be ordered from your Bobcat dealer.
utility vehicle. Untrained operators can cause injury
or death. • Safety signs (decals) instruct on the safe operation
W-2855-0510 and care of your Bobcat utility vehicle or attachment.
The signs and their locations are shown in the
Operation & Maintenance Manual. Replacement
signs are available from your Bobcat dealer.
IMPORTANT • An Operator’s Handbook fastened to the operator

cab. It’s brief instructions are convenient to the

This notice identifies procedures which must be operator. The handbook is available from your dealer
followed to avoid damage to the utility vehicle. in an English edition or one of many other languages.
I-2317-0510 See your Bobcat dealer for more information on
translated versions.
• The Service Manual and Parts Manual are available

from your dealer for use by mechanics to do shop-
type service and repair work.
DANGER
• The Utility Vehicle Operator Training Course is
The signal word DANGER on the utility vehicle and in available through your local dealer or at Bobcat.com/
the manuals indicates a hazardous situation which, if training or Bobcat.com. This course is intended to
not avoided, will result in death or serious injury. provide rules and practices of correct operation of the
D-1022-0510 utility vehicle. The course is available in English and
Spanish versions.
• The Utility Vehicle Safety Video is available from your

Bobcat dealer or at Bobcat.com/training or
WARNING Bobcat.com.
The signal word WARNING on the utility vehicle and

in the manuals indicates a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.
W-2856-0510
SI UV-1016 SM

SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner / operator review the

recommended uses of the product when delivered. If the
owner / operator will be using the utility vehicle for a
different application(s) he or she must ask the dealer for
recommendations on the new use.
Cutting or drilling concrete containing sand or rock

containing quartz may result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL) to
silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
means to control dust. Silica dust can cause lung disease
and is known to the state of California to cause cancer.
Call Before You Dig

Dial 811 (USA Only)

1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI UV-1016 SM

FIRE PREVENTION Fueling
Maintenance Stop the engine and let it cool before adding fuel. No
The utility vehicle and some attachments and smoking! Do not refuel a utility vehicle near open flames
accessories have components that are at high or sparks. Fill the fuel tank outdoors.
temperatures under normal operating conditions. The
primary source of high temperatures is the engine and Ultra Low Sulfur Diesel (ULSD) poses a greater static
exhaust system. The electrical system, if damaged or ignition hazard than earlier diesel formulations with
incorrectly maintained, can be a source of arcs or sparks. higher Sulfur content. Avoid death or serious injury from
fire or explosion. Consult with your fuel or fuel system
Flammable debris (leaves, straw, etc.) must be removed supplier to ensure the delivery system is in compliance
regularly. If flammable debris is allowed to accumulate, it with fueling standards for proper grounding and bonding
can cause a fire hazard. Clean often to avoid this practices.
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Starting
The operator’s area, engine compartment and engine Use the procedure in the Operation & Maintenance
cooling system must be inspected every day and cleaned Manual for connecting the battery and for jump starting.

if necessary to prevent fire hazards and overheating.
Spark Arrester Exhaust System
All fuels, most lubricants and some coolants mixtures are The spark arrester exhaust system is designed to control
flammable. Flammable fluids that are leaking or spilled the emission of hot particles from the engine and exhaust
onto hot surfaces or onto electrical components can system, but the muffler and the exhaust gases are still
cause a fire. hot.
Operation Check the spark arrester exhaust system regularly to
make sure it is maintained and working properly. Use the
Do not use the utility vehicle where exhaust, arcs, sparks
procedure in the Operation & Maintenance Manual for
or hot components can contact flammable material,
cleaning the spark arrester muffler
explosive dust or gases. Do not park this vehicle near
open flames or pilot lights.
Welding And Grinding
Electrical
Always clean the utility vehicle attachments and
accessories, disconnect the battery, and disconnect the
wiring from the Bobcat controllers before welding. Cover
fuel tank, rubber hoses, battery and all other flammable
parts. Keep a fire extinguisher near the utility vehicle
when welding.
Have good ventilation when grinding or welding painted

Check all electrical wiring and connections for damage.
parts. Wear dust mask when grinding painted parts.
Keep the battery terminals clean and tight. Repair or
Toxic dust or gas can be produced.
replace any damaged part or wires that are loose or
frayed.
Dust generated from repairing nonmetallic parts such as
hoods, fenders or covers can be flammable or explosive.
Battery gas can explode and cause serious injury. Use
Repair such components in a well ventilated area away
the procedure in the Operation & Maintenance Manual
from open flames or sparks.
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI UV-1016 SM

FIRE PREVENTION (CONT’D)
Fire Extinguishers
Know where fire extinguishers and first aid kits are

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI UV-1016 SM

SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the utility vehicle when Figure 3
requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Utility Vehicle Serial Number
Figure 1
P113548
The engine serial number is located on top of the engine

cover (Item 1) [Figure 3].

P-97863
The utility vehicle serial number plate is located on the

frame, under the passenger seat by the battery (Item 1)
[Figure 1].
Figure 2
Module 2 - Production
Sequence (Series)
Module 1 - Model / Engine

Combination P-90175
Explanation of utility vehicle Serial Number [Figure 2]:
1. The four digit Model / Engine Combination Module

number identifies the model number and engine
combination.
2. The five digit Production Sequence Number identifies

the order which the utility vehicle is produced.

DELIVERY REPORT
Figure 4
B-16315
The delivery report [Figure 4] contains a list of items that

must be explained or shown to the owner or operator by
the dealer when the Bobcat utility vehicle is delivered.
The delivery report must be reviewed and signed by the

owner or operator and the dealer.

UTILITY VEHICLE IDENTIFICATION (3400)
HEAD RESTS
GRAB HANDLE
STORAGE BIN
(LOCATED UNDER SEATS)
HIP RESTRAINT (2)

FRONT LIGHTS
TIRES
OPERATOR AND [1] ROPS / OPS STRUCTURE

PASSENGER SEATS
WITH SEAT BELTS (3)
CARGO BOX
OPERATION &
MAINTENANCE MANUAL
STORAGE COMPARTMENT
TAILGATE
RECEIVER TAIL LIGHTS /

NA5881
HITCH BRAKE LIGHTS (2) NA5882
[1] ROPS - Roll-Over Protective Structure, per OSHA 1928.53: 2006.

OPS - Occupant Protective Structure per ANSI/OPEI B71.9-2012.

UTILITY VEHICLE IDENTIFICATION (3400XL)
STORAGE BINS
(LOCATED UNDER SEATS) HEAD RESTS
GRAB HANDLE
HIP RESTRAINT (4)

TIRES
FRONT LIGHTS
OPERATOR AND [1] ROPS / OPS STRUCTURE

PASSENGER SEATS
WITH SEAT BELTS
OPERATION &
CARGO BOX MAINTENANCE MANUAL
STORAGE
COMPARTMENT
TAILGATE
GRAB HANDLE
TAIL LIGHTS /
RECEIVER BRAKE LIGHTS (2) NA9393
HITCH
NA9394
[1] ROPS - Roll-Over Protective Structure, per OSHA 1928.53: 2006.

OPS - Occupant Protective Structure per ANSI/OPEI B71.9-2012.

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE UTILITY VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
ROLLOVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
TRANSPORTING THE UTILITY VEHICLE ON A TRAILER . . . . . . . . . . . . . . . . . . . . . 10-30-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
TOWING THE UTILITY VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Pre-Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-2

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-3
Filling A Portable Fuel Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-3
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
CONTINUOUS VARIABLE TRANSMISSION (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

CVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
CVT Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2

GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Adding Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking Front Gearcase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Front Gearcase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Adding Front Gearcase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Removing And Replacing Front Gearcase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Tire Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Axle And Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Wheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

UTILITY VEHICLE STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . 10-140-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE . . . . . . . . . . . . . . 10-150-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
LUBRICATING THE UTILITY VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

LIFTING AND BLOCKING THE UTILITY VEHICLE Figure 10-10-1
Procedure
For service work under the utility vehicle, or to remove

the wheels, always support the utility vehicle with
jackstands or blocks of adequate capacity for weight of
utility vehicle. (See Performance on Page SPEC-10-5.)
Always park the utility vehicle on a flat level surface.
Stop the engine and put the gear selector in PARK.
1 1
If removing wheel(s), loosen the wheel nuts slightly
before lifting the vehicle.
P113795
WARNING Place the jackstands (Item 1) [Figure 10-10-1] under the

frame at the front of the utility vehicle.
AVOID INJURY OR DEATH NOTE: When lifting the utility vehicle, place the jack
Instructions are necessary before operating or under front frame [Figure 10-10-1].
servicing machine. Read and understand the

Operation & Maintenance Manual, Operator’s Figure 10-10-2
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
1 1
P113796
Place the jackstands (Item 1) [Figure 10-10-2] under the

rear frame of the utility vehicle.
NOTE: When lifting the utility vehicle, place the jack

under the rear frame [Figure 10-10-2].
21 of 481 10-10-1 3400, 3400XL Service Manual


ROLLOVER PROTECTIVE STRUCTURE (ROPS) Figure 10-20-2
3400 STANDARD
Description
Figure 10-20-1
1 1
1 1
P113790
P113789
Figure 10-20-3
The utility vehicle has a Roll-Over Protective Structure 3400XL

(ROPS) / Occupant Protective Structure (OPS) to provide 1
protection from rollover [Figure 10-20-1]. The seat belts

must be worn for ROPS / OPS protection. 1 1
1
Check the ROPS / OPS, mounting and hardware for
damage. Never modify the ROPS / OPS. Replace the
ROPS / OPS and hardware if damaged.
ROPS - Roll-Over Protective Structure per OSHA

1928.53: 2006 1
1 1
OPS - Occupant Protective Structure per ANSI/OPEI
B71.9-2012.
P113791
WARNING Make sure all ROPS mounting hardware [Figure 10-20-

2], [Figure 10-20-3] is tight (both sides).
AVOID INJURY OR DEATH NOTE: For 3400 Standard machine, there are 8
Never modify ROPS by welding, grinding, drilling locations on each side (16 total) to check the
holes or adding attachments unless instructed to do torque. For the 3400XL, there are 14 locations
so by Bobcat Company. Changes to the ROPS can on each side (28 total) to check the torque.
cause loss of operator protection from rollover and
result in injury or death. The correct torque for ROPS tube to ROPS tube
W-2596-0510 mounting hardware (Item 1) [Figure 10-20-2] and
[Figure 10-20-3] is 48 N•m (36 ft-lb).
NOTE: The side panels (behind the seat(s) will need

to be removed to access the lower hardware
on the ROPS structures.


TRANSPORTING THE UTILITY VEHICLE ON A Figure 10-30-2
TRAILER
Loading And Unloading
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can 1
break and cause personal injury.
W-2058-0807
P-97400
Be sure the transport and towing vehicles are of It may be necessary to remove items installed in the
adequate size and capacity for the weight of utility receiver hitch (Item 1) [Figure 10-30-2] before loading or
vehicle. (See Performance on Page SPEC-10-5.) unloading to prevent them from hitting the ground.
Figure 10-30-1

SUPPORT P113486
The Utility Vehicle can be loaded or unloaded forward or

backward [Figure 10-30-1].
The rear of the trailer must be blocked or supported
[Figure 10-30-1] when loading or unloading to prevent
the front end of the trailer from raising up.

TRANSPORTING THE UTILITY VEHICLE ON A
TRAILER (CONT’D)
Fastening
Use the following procedure to fasten the utility vehicle to

the transport vehicle to prevent it from moving during
turns, sudden stops or when going up and down slopes.
Put the gear selector to PARK, stop the engine and

remove the key.
Figure 10-30-3
2 2

P-97878
Fasten the front of utility vehicle using the front tie down
point (Item 1) [Figure 10-30-3].
If equipped with the front receiver hitch, connect chains

to front receiver hitch loops (Item 2) [Figure 10-30-3].
Figure 10-30-4
P-97696
Fasten the rear of utility vehicle using the receiver hitch

safety chain loops (Item 1) [Figure 10-30-4] as the tie
down point.
Use chain binders to tighten the chains and then safely tie
the chain binder levers to prevent loosening.

TOWING THE UTILITY VEHICLE
Procedure
The utility vehicle can be towed using the following
procedure.
• Connect a strap or chain to the front tow loop for
towing forward. Connect the strap or the chain to the
receiver hitch to tow in the reverse direction. (Only
tow for a short distance in the reverse direction.)
• Have an operator in the utility vehicle, with the seat

belt fastened, for steering and applying the brakes
while towing.
• Place the gear selector in NEUTRAL.

• Tow vehicle at a slow speed.
The towing strap (chain or cable) must be rated at one

and one-half times the weight of the utility vehicle. (See
Performance on Page SPEC-10-5.)


SERVICE SCHEDULE
Maintenance Intervals
Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early
failures.
WARNING
The service schedule is a guide for correct maintenance
of the Bobcat product. AVOID INJURY OR DEATH
Instructions are necessary before operating or
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
Daily (Before Starting The Utility Vehicle)
• Engine Oil - Check level and add as needed. (Run the engine briefly before checking the engine oil.) (See NOTE [2])

• Brake Fluid - Check level and add as needed. (See NOTE [2])
• Fuel - Check level and add as needed.
• Engine Cooling System - Check coolant level COLD and add premixed coolant as needed.
• Brake System and Pedal Travel - Insure proper operation. (See NOTE [2])
• Throttle - Insure proper operation.
• Tires - Check for wear, damage and correct tire pressure. (See NOTE [2])
• ROPS / OPS and Seat Belt - Check the condition of the ROPS / OPS and mounting hardware. Check the condition
of seat belts. Clean or replace seat belt retractors as needed.
• Front and Rear Suspension and Steering - Inspect for broken parts, loose hardware and free operation. (See NOTE
[2])
• Safety Signs (Decals) - Check for damaged or missing signs (decals). Replace any signs that are damaged or
missing.
• Frame Fasteners - Inspect and ensure tightness.
• Head Lights, Tail Lights, Indicator Lights and Switches - Check for proper operation and apply dielectric grease
when a lamp is replaced.
• Wheel Nuts - Check for loose wheel nuts and tighten to correct torque. See TIRE MAINTENANCE in this Manual.
(See NOTE [5])
• Engine Air Filter - Inspect, clean and replace filter as needed. Check for leaks and damaged components. (See
NOTE [2 and 3])
• CVT - Ensure proper operation. (See NOTE [2 and 3])
Every 10 Hours
• Engine Air Pre-Filter Screen - Inspect and clean. Replace if damaged. (See NOTE [2 and 3])
Every 25 Hours
• Battery - Check cables, connections, clean and test.

• Front Differential Lubricant - Check lubricant level; add as needed. (See NOTE [1 and 2])
• Transmission Lubricant - Check lubricant level; add as needed. (See NOTE [1 and 2])
• Engine Breather Filter - Inspect. Replace if necessary or at the same time as the engine air filter. (See NOTE [2 and
3])
• Engine Oil and Filter - Service at first month or 25 hours (whichever comes first), then as scheduled. Replace oil and
filter.
SS UV 3400G-1017

SERVICE SCHEDULE (CONT’D)
Maintenance Intervals (Cont’d)
Every 50 Hours
• Brake Pad Wear - Inspect. Replace if necessary. (See NOTE [2])

• Shift Linkage - Inspect, lubricate and adjust.
• Front Prop Shaft Yoke - Locate the fitting(s) and grease (3 pumps maximum). (See NOTE [2])
• Throttle Cable - Inspect for damage. Adjust or replace as necessary. (See NOTE [3])
• Air Intake System - Inspect all air intake lines and throttle body flange for leaks and repair if necessary. (See NOTE
[3])
Every 100 Hours
• Fuel System - Check for leaks at tank cap, lines and throttle body. (See NOTE [4])
• Radiator - Check for leaks and clean external surfaces.
• Cooling Hoses, Engine Mounts, Exhaust Pipe and Muffler - Inspect for damage or leaks (if applicable) Replace
components if necessary.
• Engine Oil and Filter - Replace oil and filter. Clean oil tank screen. See specification section for proper synthetic oil
requirements. (See NOTE [2])
• Front Differential Lubricant - Replace the fluid. (See NOTE [1 and 2])
• Transmission Lubricant - Replace the fluid. (See NOTE [1 and 2])
• Spark Plug - Inspect condition and gap. Replace if necessary. (See NOTE [3])

• Wiring - Inspect for wear and routing. Apply dielectric grease to connectors subjected to water, mud, etc.
• Clutches (Drive and Driven), and Drive Belt - Inspect for damage or wear. Clean with compressed air only. Replace
worn parts as needed. (See NOTE [2])
• Front and Rear Suspension and Steering - Inspect for steering freeplay and suspension wear. (See NOTE [2])
• Front Wheel Bearings - Inspect. Replace as needed.
Every 200 Hours
• Toe Adjust – Inspect front axle toe adjustment. Adjust if necessary and when parts are replaced.
• Brake Fluid - replace the fluid. (Change every 200 hours or two years, whichever comes first)
Every 24 Months
• Coolant - Replace the coolant.
Every 300 Hours or Every 36 Months
• Spark Arrestor Muffler - Empty the spark chamber.
[1] Change yearly

[2] Perform these procedures more often for vehicles subject to severe use.
[3] Emission Control System service.
[4] Replace lines every two years.
[5] The wheel nuts must be checked and torqued after the first eight hours of operation of a new machine and after the first
eight hours of operation when the wheel(s) have been removed for service.
SS UV 3400G-1017
30 of 481 -2 3400, 3400XL Service Manual

AIR CLEANER SERVICE
Pre-Filter Element
For the correct service interval of the pre-filter element,

(See SERVICE SCHEDULE on Page 10-50-1.)
The intake air pre-filter is located in the panel on the left
rear ROPS / OPS post. The pre-filter traps larger
particles before the air reaches the main engine air filter.
The filter is part of the left panel and can not be replaced
individually. If the filter is damaged, the left panel must be
replaced.
Figure 10-60-1

1
P113792
Carefully wipe all dirt and debris from the surface of the
pre-filter (Item 1) [Figure 10-60-1] and then clean the
filter with warm soapy water. Do not pressure wash the
pre-filter or damage to the pre-filter may occur.
IMPORTANT
High water pressure may damage components.
Bobcat recommends washing the vehicle by hand or
with a garden hose, using mild soap.
I-2299-0510

AIR CLEANER SERVICE (CON’D) Figure 10-60-4
Replacing Filter Element
Raise the cargo box.
For the correct service interval of the air cleaner, (See

SERVICE SCHEDULE on Page 10-50-1.)
Check the air intake hose(s), the filter element and the air
cleaner housing for cracks, tears or damage. Check to 1
make sure all connections are tight.
Figure 10-60-2 P113494
Clean the inside of the filter housing (Item 1) [Figure 10-

1 60-4] with a damp cloth. (Do not use compressed air.)
Install the new filter element (Item 1) [Figure 10-60-3].
Install the cover (Item 2) and engage the two retaining

clamps (Item 1) [Figure 10-60-2].
NOTE: Make sure the evacuator valve (Item 3) [Figure

1 10-60-2] is pointed down, as shown, after the
2 cover is installed.
3
P113492
Open the two retaining clamps (Item 1) and remove and

clean the cover (Item 2) [Figure 10-60-2].
Figure 10-60-3
P113493
Rotate the element to aid in removing the filter element

(Item 1) [Figure 10-60-3].

ENGINE COOLING SYSTEM
Checking Level
Follow the service interval for checking the coolant IMPORTANT

level. (See SERVICE SCHEDULE on Page 10-50-1.)
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
WARNING Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.
AVOID INJURY
Stop the engine and allow to cool before adding
Too little antifreeze reduces the additives which
coolant or you can be burned.
W-2106-0907
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Figure 10-70-1 Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
1 I-2124-0497
WARNING

MAXIMUM
AVOID BURNS
MINIMUM Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203
P-97708
Ethylene Glycol
The coolant recovery tank (Item 1) [Figure 10-70-1] is
located under the front cover. Mix new coolant in a separate container. (See Fluid And
Capacities on Page SPEC-10-7.)
The coolant level in the recovery tank must be between
the marks on the tank when the engine is cool [Figure The correct mixture of coolant to provide a -37°C (-34°F)
10-70-1]. freeze protection is 4 L ethylene glycol mixed with 4 L of
water OR 1 U.S. gal ethylene glycol mixed with 1 U.S. gal
NOTE: The cooling system is factory filled with of water.
ethylene glycol coolant (yellow color). DO
NOT mix ethylene glycol with propylene Add premixed coolant, 50% water and 50% ethylene
glycol. glycol to the coolant recovery tank until the coolant level
NOTE: When adding or servicing the coolant, the reaches the lower marker on the tank [Figure 10-70-1].
factory filled ethylene glycol coolant (yellow (Mixture of up to 60% ethylene glycol, 40% water is
color) can be intermixed with the Bobcat acceptable.)
coolant (green color).
Use a refractometer to check the condition of ethylene
glycol in your cooling system.

ENGINE COOLING SYSTEM (CONT’D) Figure 10-70-2
Cleaning
WARNING 1
AVOID INJURY
Use safety goggles when using air or water under
pressure. Do not use cold water to clean a hot
engine.
W-2064-0907
Check the cooling system every day to prevent over- P-97860

heating, loss of performance or engine damage.
Figure 10-70-3
Do not obstruct or deflect air flow through the radiator by
installing unauthorized accessories in front of the radiator
or behind the cooling fan. Interference with the radiator
air flow can lead to overheating and consequent engine
damage.

IMPORTANT 1
Do not use a pressure washer to clean the radiator.

High pressure can damage the fins.
I-2318-0710
P113499
Remove the front cover. (See Front Access Cover

Removal And Installation on Page 30-30-1.)
Use low air or water pressure to remove debris in the

area of the radiator (Item 1) [Figure 10-70-2] and
[Figure 10-70-3].
Check the cooling system for leaks.
Reinstall the front cover.

Removing And Replacing Coolant
Follow the service interval for replacing the coolant. (See

SERVICE SCHEDULE on Page 10-50-1.)
1
Remove the front cover. (See Front Access Cover
Removal And Installation on Page 30-30-1.) 2
WARNING
P113499
AVOID INJURY
Stop the engine and allow to cool before adding Open the radiator cap (Item 3) [Figure 10-70-5].
coolant or you can be burned.
W-2106-0907
Figure 10-70-6
WARNING

AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned. 1
W-2070-1203
P113500
Figure 10-70-4
At the bottom of the radiator, remove the lower radiator
1 hose (Item 1) [Figure 10-70-6] and drain the coolant into
2 a container.
Reinstall the lower radiator hose (Item 1) [Figure 10-70-

6].
Dispose of the used coolant in an environmentally safe

manner.
MAXIMUM
Add premixed coolant to the radiator until it is full. Install
the cap (Item 1) [Figure 10-70-4].
Add premixed coolant to the coolant recovery tank until it

is at the full mark. Install the vented plug (Item 2) and the
P-97708 cap (Item 1) [Figure 10-70-4].
Put the gear selector in PARK and start the engine. Allow
Remove the cap (Item 1) and the vented plug (Item 2) the engine to run until it is at operating temperature.
[Figure 10-70-4] from the coolant recovery tank.
Stop the engine and check the coolant level. Add
premixed coolant to the recovery tank as needed.
Remove the hose (Item 2) [Figure 10-70-4] from the
coolant recovery tank where it attaches to the radiator.
Reinstall the front cover.
Drain the coolant into a container.
NOTE: Some coolant level drop is normal after the
Reconnect the hose (Item 2) [Figure 10-70-4]. coolant system has been drained and refilled.
The system will need to purge any air that was
trapped in the system. Observe the coolant
levels and maintain as recommended by
adding coolant to recovery tank.

ENGINE COOLING SYSTEM (CONT’D)
Removing And Replacing Coolant (Cont’d)
WARNING
HOT PRESSURIZED FLUID CAN CAUSE
SERIOUS BURNS
• Never open hot.
• OPEN SLOWLY.
W-2755-0908
Figure 10-70-7

P113554
To bleed air from the cooling system, do the following:
Move the gear selector lever to Park and start the engine.
At the engine thermostat housing, slowly loosen the plug

(Item 1) [Figure 10-70-7] (Do not remove the plug, just
loosen the plug) and allow any air to escape by the plug
threads. When coolant, free of air bubbles is visible,
tighten the plug.
Stop the engine and check the coolant level. Add

premixed coolant to the recovery tank as needed.
NOTE: Some coolant level drop is normal after the

coolant system has been drained and refilled.
The system will need to purge any air that was
trapped in the system. Observe the coolant
levels and maintain as recommended by
adding coolant to recovery tank.

FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
At a minimum, low sulfur diesel fuel must be used in this
machine. Low sulfur is defined as 500 mg/kg (500 ppm) • Biodiesel blend fuel is an excellent medium for
sulfur maximum. microbial growth and contamination which can cause
corrosion and plugging of fuel system components.
Ultra low sulfur diesel fuel may also be used in this
machine. Ultra low sulfur is defined as 15 mg/kg (15 ppm)
• Use of biodiesel blend fuel may result in premature
sulfur maximum.
failure of fuel system components, such as plugged
U.S. Standard (ASTM D975) fuel filters and deteriorated fuel lines.
Use only clean, high quality diesel fuel, Grade Number • Shorter maintenance intervals may be required, such
2-D or Grade Number 1-D. as cleaning the fuel system and replacing fuel filters
and fuel lines.
The following is one suggested blending guideline that
should prevent fuel gelling during cold temperatures: • Using biodiesel blended fuels containing more than
five percent biodiesel can affect engine life and cause
TEMPERATURE GRADE 2-D GRADE 1-D deterioration of hoses, tubelines, injectors, injector
pump and seals.

Above -9°C (+15°F) 100% 0%
Down to -21°C (-5°F) 50% 50% Apply the following guidelines if biodiesel blend fuel is
Below -21°C (-5°F) 0% 100% used:
NOTE: Biodiesel blend fuel may also be used in this • Ensure the fuel tank is as full as possible at all times
machine. Biodiesel blend fuel must contain to prevent moisture from collecting in the fuel tank.
no more than five percent biodiesel mixed
with ultra low sulfur petroleum based diesel. • Ensure that the fuel tank cap is securely tightened.
This biodiesel blend fuel is commonly
marketed as B5 blended diesel fuel. B5 • Biodiesel blend fuel can damage painted surfaces,
blended diesel fuel must meet ASTM remove all spilled fuel from painted surfaces
specifications. immediately.
E.U. Standard (EN590) • Drain all water from the fuel filter daily before
operating the machine.
Use only clean, high quality diesel fuel that meets the
specifications listed below: • Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Low sulfur diesel fuel defined as 500 mg/kg (500 ppm)
sulfur maximum • Before vehicle storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer and
• Diesel fuel with cetane number of 51.0 and above. run the engine for at least 30 minutes.
Clean, high quality diesel fuel that meets the EN590
NOTE: Biodiesel blend fuel does not have long term
specification may also be used.
stability and should not be stored for more
NOTE: Biodiesel blend fuel may also be used in this than three months.
machine. Biodiesel blend fuel must contain
no more than seven percent biodiesel mixed
with ultra low sulfur petroleum based diesel.
This biodiesel blend fuel is commonly
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.

FUEL SYSTEM (CONT’D) Fuel Filter
Filling The Fuel Tank Remove water from, or replace the fuel filter at the
correct interval. (See SERVICE SCHEDULE on Page 10-
50-1.)
WARNING Figure 10-80-2
AVOID INJURY OR DEATH

Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
2
Figure 10-80-1
1 1
P113527

Removing Water:
The fuel filter is located under the cargo box, on the left
side of the engine.

P113495A
Loosen the drain (Item 1) [Figure 10-80-2] at the bottom
of the filter element to remove water from the filter. Close
Remove the fill cap (Item 1) [Figure 10-80-1]. the drain.
Use a clean, approved safety container to add fuel of the Replacing Element:
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO Remove the filter element (Item 2) [Figure 10-80-2].
SMOKING!
NOTE: Be sure the filter gasket is removed with the
Install and tighten the fuel cap (Item 1) [Figure 10-80-1]. old fuel filter.
Clean the area around the filter housing.
Put clean oil on the seal of the new filter element.
Install the fuel filter, and hand tighten until the gasket
contacts the surface, then an additional 1/2 - 3/4 turn.
Remove air from the fuel system. (See Removing Air

From The Fuel System on Page 10-80-3.)

FUEL SYSTEM (CONT’D) Filling A Portable Fuel Container
Removing Air From The Fuel System Static electric spark can explosively ignite gasoline
vapors when filling ungrounded portable containers.
Always put the container ON THE GROUND before

WARNING filling.
Keep the nozzle in contact with container while filling.

Always clean up spilled fuel or oil. Keep heat, flames,
NEVER fill container in the cargo box or on the utility
sparks or lighted tobacco away from fuel and oil.
vehicle.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
After replacing the filter element or when the fuel tank

WARNING
has run out of fuel, air must be removed from the fuel
system before starting the engine. FIRE AND EXPLOSION CAN CAUSE
SERIOUS INJURY OR DEATH
Be sure the engine is cool. Static electric spark can explosively ignite gasoline
vapors when filling ungrounded portable containers.
• ALWAYS place the container ON THE GROUND
before filling.

Figure 10-80-3
• Keep the nozzle in contact with container while
filling.
• NEVER fill container in the cargo box, storage
bins or on the machine.
W-2801-0709
1
P113527
With the gear selector in PARK, turn the key to the ON

position. Do Not start the engine.
The fuel pump will start pumping fuel with the key in the
ON position (10 - 15 seconds) and will force air out of the
fuel system.
At times it may be necessary to open the valve (Item 1)

[Figure 10-80-3] on the fuel filter housing until fuel
comes from the valve with no air bubbles.
Start the engine.
Repeat until the engine starts.


ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-90-2

Figure 10-90-1
ENGINE OIL
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
CRANKCASE)
1
2
TEMPERATURE RANGE ANTICIPATED BEFORE

P113551 NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CJ-4 OR BETTER, OR ACEA
E9 OR BETTER)
Check the engine oil level every day. [1] Bobcat Synthetic Oil – 5W-40
NOTE; The engine oil should be checked COLD or

allow sufficient time for the oil to drain back Bobcat engine oils are recommended for use in this
into the oil pan to prevent overfilling. machine. If Bobcat engine oil is not available, use a good
quality engine oil that meets API Service Classification of
Park the utility vehicle on a flat and level surface, put the CJ-4 or better, or ACEA E9 or better [Figure 10-90-2].
gear selector lever in Park and stop the engine.
The engine oil dipstick (Item 1) [Figure 10-90-1] is

located under the cargo box on the back side of the
engine.
WARNING
Raise the cargo box. AVOID INJURY OR DEATH
Remove the dipstick (Item 1) [Figure 10-90-1] and wipe sparks or lighted tobacco away from fuel and oil.
dry with a clean cloth. Reinstall the dipstick. Remove the Failure to use care around combustibles can cause
dipstick and check the oil level. Keep the oil level between explosion or fire.
the marks on the dipstick. W-2103-0508
If oil needs to be added, remove the fill cap (Item 2)

[Figure 10-90-1] and add oil until it is at the full mark on
the dipstick. Do not over fill. Install and tighten the fill cap.
NOTE: Rising oil levels between checks in cool

weather driving can indicate moisture
collecting in the oil pan. If the oil level is over
the full mark, change the oil.

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-4
Removing And Replacing Oil And Filter
Follow the service interval for replacing the engine oil and
filter. (See SERVICE SCHEDULE on Page 10-50-1.)
Run the engine until it is at operating temperature.
Position the utility vehicle on a flat and level surface.

Place the gear selector in PARK and stop the engine.
Raise the cargo box. 1

Clean the engine oil pan around the drain plug and clean
the engine around the oil filter. P113553
Figure 10-90-3
The engine oil filter is located on the front side of the
engine. Remove the oil filter (Item 1) [Figure 10-90-4]
and clean the filter housing surface.
Use a genuine Bobcat filter only.

1 Put clean oil on the new filter gasket, install the filter and
hand tighten until the gasket contacts the surface, then
an additional 1/2 turn.
WARNING
P113552
The engine oil drain plug is located on the bottom of the sparks or lighted tobacco away from fuel and oil.
oil pan (Item 1) [Figure 10-90-3]. Access the drain plug Failure to use care around combustibles can cause
through the hole in the belly pan. explosion or fire.
W-2103-0508
Remove the drain plug (Item 1) [Figure 10-90-3]. Drain
the oil into a container and recycle or dispose of used oil
in an environmentally safe manner.
Reinstall the drain plug and tighten to 40 N•m (30 ft-lb).

ENGINE LUBRICATION SYSTEM (CONT’D)
Removing And Replacing Oil And Filter (Cont’d)
Figure 10-90-5
2
1
P113551
Remove the fill cap (Item 1) [Figure 10-90-5].

Put the correct quantity of oil in the engine. (See Fluid
And Capacities on Page SPEC-10-7.)
Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.
NOTE: The engine oil should be checked COLD or

allow sufficient time for the oil to drain back
into the oil pan to prevent overfilling.
Remove the dipstick (Item 2) [Figure 10-90-5] and check

the oil level. (See Checking And Adding Engine Oil on
Page 10-90-1.)
Add oil as needed to keep the level between the marks

on the dipstick.
Install the dipstick.


CONTINUOUS VARIABLE TRANSMISSION (CVT) CVT Drying
There may be some instances when water is accidentally

ingested into the CVT system. Use the following
WARNING instructions to remove the water before operating.
Figure 10-100-1
AVOID SERIOUS INJURY OR DEATH
Failure to comply with the instructions in this
warning can result in serious injury or death.
Do not modify any component of the CVT system.

Doing so may reduce its strength so that a failure
may occur at a high speed. The CVT system has been
precision balanced. Any modification will cause the
system to be out of balance, creating vibration and
1
additional loads on components.
The CVT system rotates at high speeds, creating

large amounts of force on clutch components.
Extensive engineering and testing has been
conducted to ensure safety of this product. However, P113509
as an owner, you have the following responsibilities
to make sure this system remains safe:

1. Position the vehicle on a flat level surface. Put the
• Always follow all recommended maintenance gear selector in PARK. Stop the engine and exit the
procedures. See your Bobcat dealer as outlined vehicle.
in the owners manuals.
• The CVT system is intended for use on the 2. Remove the drain plug (Item 1) [Figure 10-100-1]
Bobcat product only. Do not install it on any other from the bottom of the clutch cover and allow the
product. water to drain completely. Reinstall the drain plug.
• Always make sure the CVT housing is secured in
place during operation. 3. Apply the brakes and start the engine.
W-2865-0510
4. With the gear selector in PARK, apply varying throttle
for 10 - 15 seconds to expel moisture and air dry the
belt and clutches. Do not hold the throttle wide open
for more than 10 seconds.
5. Allow the engine rpm to settle to idle speed. Apply the

brakes and shift the gear selector to low.
6. Test the belt for slippage. If the belt slips, repeat the
above steps.
7. If the belt continues to slip, take the vehicle to your

dealer for service as soon as possible.

CONTINUOUS VARIABLE TRANSMISSION (CVT)
(CONT’D)
CVT Filter
The CVT system use air flow to help cool the clutches
and drive belt.
Follow the service interval for cleaning and changing the

CVT filter. (See SERVICE SCHEDULE on Page 10-50-
1.)
The filter is part of the right panel and can not be

replaced individually. If the filter is damaged, the right
panel must be replaced.
Figure 10-100-2

1
P113793
Park the vehicle on a flat and level surface. Engage the

park brake and stop the engine.
Carefully wipe all dirt and debris from the surface of the
filter (Item 1) [Figure 10-100-2] and then clean the filter
with warm soapy water. Do not pressure wash the pre-
filter or damage to the pre-filter may occur.
IMPORTANT
High water pressure may damage components.
Bobcat recommends washing the vehicle by hand or
with a garden hose, using mild soap.
I-2299-0510

GEARCASE The drain plug (Item 1) [Figure 10-110-2] is located on
the bottom the transmission and can be accessed though
Checking Transmission Fluid a hole in the bottom cover plate.
Follow the service interval for checking the transmission To check the fluid level, remove the plug (Item 1) [Figure
fluid level. (See SERVICE SCHEDULE on Page 10-50- 10-110-1]. The fluid level is correct when at the bottom
1.) edge of the fill plug.
Use only recommended fluid in the transmission. (See Transmission Fluid

Fluid And Capacities on Page SPEC-10-7.)
For the correct fluid information, (See Fluid And
Put the utility vehicle on a flat and level surface. Capacities on Page SPEC-10-7.)
Move the gear selector to Park, stop the engine and exit Adding Transmission Fluid
the vehicle. (See STOPPING THE ENGINE AND
LEAVING THE UTILITY VEHICLE on Page 10-150-1.) Thoroughly clean the area around the fill / check plug
before removal.
Figure 10-110-1
If needed, remove the fill / check plug (Item 1) [Figure
10-110-1]. Use a long neck, flexible funnel and add fluid
until it is at the bottom edge of the plug opening.
Reinstall the plug and tighten to 16 N•m (12 ft-lb) torque.

1 Removing And Replacing Transmission Fluid
Replace transmission fluid at the correct service interval.

(See SERVICE SCHEDULE on Page 10-50-1.) and (See
Replace the fluid if it becomes contaminated.
P113794
Install a container under the drain plug (Item 1) [Figure
10-110-2].
Figure 10-110-2 Remove the drain plug (Item 1) [Figure 10-110-2].

Dispose of the used fluid in an environmentally safe
manner.
Reinstall the drain plug (Item 1) [Figure 10-110-2] and

tighten to 16 N•m (12 ft-lb) torque.
Remove the fill / check plug (Item 1) [Figure 10-110-1].

Use a long neck, flexible funnel and add fluid until it is at
1 the bottom edge of the plug opening.
Reinstall the fill / check plug (Item 1) [Figure 10-110-1]

and tighten to 16 N•m (12 ft-lb) torque.
P113512
Thoroughly clean the area around the plugs before

removal.
The fill / check plug (Item 1) [Figure 10-110-1] is located
on the side of the transmission.

GEARCASE (CONT’D) Figure 10-110-3
Removing And Replacing Transmission Fluid

(Cont’d)
WARNING
sparks or lighted tobacco away from fuel and oil. 1
explosion or fire.
W-2103-0508
P97864
Start the engine and operate the utility vehicle.

Figure 10-110-4
Stop the engine and check for leaks.
Check fluid level and add as needed.
Checking Front Gearcase Fluid

Follow the service interval for checking the front
gearcase fluid level. (See SERVICE SCHEDULE on 1
Page 10-50-1.)
Use only recommended fluid in the front gearcase. (See

Put the utility vehicle on a flat and level surface.

P113513
Move the gear selector lever to Park, stop the engine and
exit the vehicle. (See STOPPING THE ENGINE AND
LEAVING THE UTILITY VEHICLE on Page 10-150-1.) The fill / check plug (Item 1) [Figure 10-110-3] is located
on the right front edge of the gearcase and drain plug
(Item 2) [Figure 10-110-4] is located on the bottom of the
gearcase.
Thoroughly clean the area around the fill / check plug

before removal.
To check the fluid level, remove the plug (Item 1) [Figure

10-110-3]. The fluid level is correct when at the bottom
edge of the fill plug.

GEARCASE (CONT’D) Removing And Replacing Front Gearcase Fluid
Front Gearcase Fluid Replace front gearcase fluid at the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.)
For the correct fluid information, (See Fluid And
Capacities on Page SPEC-10-7.) Replace the fluid if it becomes contaminated.
Adding Front Gearcase Fluid Raise the front of the vehicle and install jackstands.
Thoroughly clean the area around the fill / check plug Install a funnel and a container under the drain plug (Item
before removal. 2) [Figure 10-110-4]. (See Fluid And Capacities on Page
If needed, remove the fill / check plug (Item 1) [Figure SPEC-10-7.)
10-110-1]. Use a long neck, flexible funnel and add fluid
until it is at the bottom edge of the plug opening. Remove the drain plug (Item 2) [Figure 10-110-4].
Dispose of the used fluid in an environmentally safe
Reinstall the plug and tighten to 11 -13 N•m (8 - 10 ft-lb) manner.
torque.
Reinstall the drain plug (Item 2) [Figure 10-110-4] and
tighten to 15 N•m (11 ft-lb) torque.
Remove jackstands and lower the vehicle to the ground

before adding fluid to make sure the fluid level is correct.
Thoroughly clean the area around the fill / check plug

before removal.
Remove the fill / check plug (Item 1) [Figure 10-110-3]

and add fluid until it is at the bottom edge of the plug
opening.
Reinstall the fill / check plug (Item 1) [Figure 10-110-3]

and tighten to 11 -13 N•m (8 - 10 ft-lb) torque.
WARNING
sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
Start the engine and operate the utility vehicle.
Stop the engine and check for leaks.

Check fluid level and add as needed.


TIRE MAINTENANCE Axle And Wheel Nut Torque
Tires NOTE: The wheel nuts must be checked and torqued

after the first eight hours of operation of a new
machine and after the first eight hours of
operation when wheel(s) have been removed
WARNING for service.
Check the wheel nut torque at the correct service

Operating this vehicle with worn tires, improperly
inflated tires, non-standard tires or improperly
Do not lubricate the studs or lug nuts.
installed tires will affect vehicle handling and could
cause an accident resulting in serious injury or
Tighten the wheel nuts to the correct torque. (See Tires
death. Always follow all tire maintenance procedures
on Page SPEC-10-8.)
outlined in this manual and on the safety signs
(decals). Always use the original equipment size and
type when replacing tires.
W-2829-0510
Tire Tread Depth
Figure 10-120-1

3,0 mm
(0.125 in)
P113797
Always replace tires when tread depth is worn to 3 mm

(0.125 in) [Figure 10-120-1] or less.

TIRE MAINTENANCE (CONT’D) Installation
Wheel Removal And Installation 1. Apply the brakes.
Check the tires regularly for wear, damage and pressure. 2. Put gear selector in Park and stop the engine.
3. Place the wheel in the correct position on the wheel

hub. Be sure the valve stem is towards the outside
WARNING and the rotation arrows on the tire point towards the
forward rotation.
AVOID INJURY OR DEATH 4. Install the wheel nuts and tighten slightly.
Improperly installed wheels can adversely affect tire
wear and vehicle handling, which can result in 5. Lower the utility vehicle to the ground. (See
serious injury or death. Always ensure all nuts are Procedure on Page 10-10-1.)
torqued to specification. Do not service axle nuts
that have a cotter pin installed. See your Bobcat 6. Tighten the wheel nuts to the correct torque.
dealer.
W-2830-0510
Removal
IMPORTANT
1. Apply the brakes.

Do not mix tire sizes. The front and rear tires used on
2. Put gear selector in Park and stop the engine. this model are different sizes. Do not intermix front
and rear tires.
3. Loosen the wheel nuts slightly. I-2332-0510
4. Raise the utility vehicle and install jackstands or

blocks. (See Procedure on Page 10-10-1.)
5. Remove the wheel nuts. Remove the wheel.
Recommended tire pressure must be maintained to avoid

excessive tire wear and loss of stability and handling
capability. Check for correct pressure before operating.
NOTE: Install the wheel with the valve stem facing to

the outside and the rotation arrow on the tire
pointing to the front of the vehicle.

TIRE MAINTENANCE (CONT’D) Tire Pressure
Mounting Remove flammable material before filling. For tire

pressures, (See Tires on Page SPEC-10-8.)
Tires are to be repaired only by an authorized person
using the proper procedures and safe equipment.
Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust.
The tire bead and rim flange must be lubricated with a

rubber lubricant before mounting the tire.
Avoid excessive pressure which can rupture the tire and

cause serious injury or death.
During inflation of the tire, check the tire pressure

frequently to avoid over inflation.
WARNING

Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007


SPARK ARRESTER MUFFLER 1. Remove the plug (Item 1) [Figure 10-130-1] from the
cleanout hole in the spark arrester muffler.
Cleaning Procedure
2. Start the engine.
Clean the spark arrester muffler at the correct service
3. Purge accumulated carbon from the system by
Do not operate the utility vehicle with a defective exhaust
momentarily revving the engine several times.
system.
4. If carbon is expelled, have a second person cover or
plug the exhaust outlet (Item 2) [Figure 10-130-1]
WARNING and rap on the pipe around the cleanout plug while an
operator rev’s the engine several times.
Stop engine and allow the muffler to cool before 5. If particles are still suspected to be in the muffler,
cleaning the spark chamber. Wear safety goggles. elevate the rear of the vehicle one foot higher than the
Failure to obey can cause serious injury. front. Place blocks in front of and behind both front
W-2011-1285 wheels.
6. Repeat steps 3 and 4 until no more particles are

expelled when the engine is revved.
WARNING 7. Stop the engine and allow the spark arrester to cool.
8. Reinstall the plug (Item 1) and remove the outlet cover

AVOID INJURY OR DEATH or plug (Item 2) [Figure 10-130-1].
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning. IMPORTANT
W-2050-0807
This vehicle is factory equipped with a U.S.D.A.
Park the machine in a well ventilated area where there is Forestry Service approved spark arrester exhaust
no flammable materials or fluids. system.
Put the gear selector in Park, stop the engine and exit the The spark arrester muffler, if equipped, must be
vehicle. (See STOPPING THE ENGINE AND LEAVING cleaned to keep it in working condition. The spark
THE UTILITY VEHICLE on Page 10-150-1.) arrester muffler must be serviced by dumping the
spark chamber every 300 hours of operation.
Allow components to cool.
If this machine is operated on flammable forest,
Figure 10-130-1 brush, or grass covered land, it must be equipped
with a spark arrester attached to the exhaust system
and maintained in working order. Failure to do so will
be in violation of California State Law, Section 4442.
PRC. Refer to local laws and regulations for spark
arrester requirements.
I-2331-0211
1 2
P113603


UTILITY VEHICLE STORAGE AND RETURN TO Return To Service
SERVICE
Storage After the utility vehicle has been in storage, it is
necessary to follow a list of items to return the utility
Sometimes it may be necessary to store your utility vehicle to service.
vehicle for an extend period of time. Below is a list of
items to perform before storage. • Check the engine and transmission oil levels; check
coolant level.
• Thoroughly clean the utility vehicle including the
engine compartment. • Install a fully charged battery.
• Lubricate the utility vehicle as shown in the Operation • Check all belt tension.
& Maintenance Manual.
• Check and clean the CVT.
• Replace worn or damaged parts.
• Lubricate the utility vehicle as shown in the Operation
• Check for damaged or missing decals, Replace if & Maintenance Manual.
necessary.
• Check tire inflation and remove blocks from under
• Park the utility vehicle in a dry protected shelter. frame.
• Fill the fuel tank and put fuel stabilizer in the fuel tank • Remove cover from exhaust pipe opening.
and run the engine a few minutes to circulate the
stabilizer to the pump and fuel injectors. (Follow the • Perform the items listed on daily Inspection.

instructions on the fuel stabilizer container.)
• Start the engine and let run for a few minutes while
• Drain and flush the cooling system. Refill with observing the instrument panels and systems for
premixed coolant. correct operation.
• Replace all fluids and filters (engine, transmission, • Operate utility vehicle, check for correct function.
front gearcase, etc.).
• Stop the engine and check for leaks. Repair as
• Inspect and clean or replace air filters. Clean the air needed.
baffles.
• Put blocks under the frame to remove weight from the

tires.
• Put all controls in neutral position.
• Remove the battery. Be sure the electrolyte level is

correct (if applicable) then charge the battery. Store it
in a cool, dry place above freezing temperatures and
charge it periodically during storage.
• Cover the exhaust pipe opening.
• Tag the utility vehicle to indicate that it is in storage

condition.
• Store in a dry, well ventilated area. Do not use plastic

or a coated cover over the vehicle. They do not allow
enough ventilation to prevent condensation, and may
promote corrosion and oxidation.


STOPPING THE ENGINE AND LEAVING THE UTILITY Figure 10-150-2
VEHICLE
Procedure
WARNING 3

Before you leave the operator’s seat: 1
• Park on flat level ground.
• Press the brake pedal and move the gear selector
lever to PARK.
• Stop the engine and remove the key.
W-2974-1212
2 P-97834
Figure 10-150-1
Release the throttle pedal (Item 1) completely and apply

the brake pedal (Item 2) [Figure 10-150-2] and come to a
complete stop.
Move the gear selector lever (Item 3) [Figure 10-150-2]

to PARK.
NOTE: When parking inside an enclosed area, be sure

that the structure is a well ventilated area.
Turn the engine OFF and remove the key to prevent

unauthorized use.
P113779
Park the utility vehicle on a flat and level surface [Figure

10-150-1]. WARNING
ROLLAWAY CAN CAUSE SERIOUS
INJURY OR DEATH
Always put the gear selector lever in PARK before
stopping the engine.
W-2962-1212

STOPPING THE ENGINE AND LEAVING THE UTILITY Figure 10-150-4
VEHICLE (CONT’D)
Procedure (Cont’d)
Figure 10-150-3
P113778
P-97270
Exit the utility vehicle [Figure 10-150-4].

Press the red release button (Item 1) [Figure 10-150-3]
to disconnect the seat belt.
WARNING

Always park machine on flat, level ground.
W-2441-1102

SEAT BELT Figure 10-160-1
Inspection And Maintenance 1
WARNING 3
Failure to properly inspect and maintain the seat belt

can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703
Check the seat belt daily for correct function. 2 4
Inspect the seat belt system thoroughly yearly or more

often if the utility vehicle is exposed to severe
environmental conditions or applications.
The seat belt system should be repaired or replaced if it

shows cuts, fraying, extreme or unusual wear, significant
discolorations due to ultraviolet (UV) rays from the sun,
dusty / dirty conditions, abrasion to the seat belt webbing,

or damage to the buckle, latch plate, retractor (if
equipped), and hardware.
B-22283A
The items below are referenced in [Figure 10-160-1].
1. Check the webbing. If the system is equipped with a

retractor, pull the webbing completely out and inspect
the full length of the webbing. Look for cuts, wear,
fraying, dirt and stiffness.
2. Check the buckle and latch for proper function. Make

sure latch plate is not excessively worn or deformed
and buckle is not damaged.
3. Check the retractor web storage device (if equipped)

by extending the seat belt webbing to determine if it
extends and retracts the webbing correctly.
4. Check webbing in areas exposed to ultraviolet (UV)

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength may have weakened.
See your dealer for approved seat belt system

replacement parts for your utility vehicle.


LUBRICATING THE UTILITY VEHICLE Figure 10-170-3
Lubrication Locations
Lubricate as specified for the best performance of the

utility vehicle. (See SERVICE SCHEDULE on Page 10- 1
50-1.)
Always use a good quality lithium based multi-purpose

grease.
Park the vehicle on flat level ground. Move the gear

selector lever to PARK and stop the engine.
Lubricate the following:
Figure 10-170-1 P-97826
2
4. Trailing Arm - Front Pivot (1) [Figure 10-170-3] (both
sides).
1
Figure 10-170-4
1

1
P-97824
1. Lower A-Arms (2) [Figure 10-170-1] (both sides).
2. Upper A-Arms (1) [Figure 10-170-1] (both sides).

P-97827
Figure 10-170-2
5. Upper Suspension Arm - Front Pivot (1) [Figure 10-

170-4] (both sides).
P113804
3. Trailing Arm - Rear Pivot (1) [Figure 10-170-2] (both

sides).

LUBRICATING THE UTILITY VEHICLE (CONT’D)
Lubrication Locations (Cont’d)
Figure 10-170-5
P-97868
6. Drive Shaft (1) [Figure 10-170-5] (at front

differential).
Figure 10-170-6
P113602
7. Drive Shaft (1) [Figure 10-170-6] (in front of

transmission).

DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
System Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-2
Noise Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-3
System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Hydraulic Brake System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
System Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Master Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-7
Foot Brake Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-8
Bleeding / Fluid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-9
Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-11
Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-12
Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-12
BRAKE (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-1

Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-1
Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-2
Pad Assembly / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-3

Caliper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-4
Caliper Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-5
Caliper Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-6
Caliper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-7
Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-8
Caliper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-8
Disc Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-9
Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-9
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-10
BRAKE (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-1

Caliper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-1
Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-1
Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-2
Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-2
Caliper Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-3
Caliper Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-4
Caliper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-5
Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-6
Caliper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-6
Disc Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-7
Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-7
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-8

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Shift Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
Shift Cable Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Shift Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Shift Cable Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-12
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-16
Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-19
Gear Cluster Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-22
Snorkel Shaft Removal / Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-23
Planetary Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-25
Planetary Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-28
Snorkel Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-29
Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-31
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3

Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Belt Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
CONTINUOUS VARIABLE TRANSMISSION (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

CVT System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Drive Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
CVT Break-In (Drive Belt / Clutches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Maintenance And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-2
Overheating Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
CVT Sealing, Guard And Ducting Components Parts Identification . . . . . . . . . . . . 20-40-6
CVT (Outer) Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
CVT (Inner) Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH) . . . . . . . . . . . . 20-41-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Spring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH) . . . . . . . . . . . 20-42-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-4

FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Bearing Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Bearing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Bearing Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Front Drive Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
Rear Drive Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-8
Drive Shaft / CV Joint Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
Outer CV Joint And Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-50-11
Inner Plunging Joint And Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-50-14
Propshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-17
Propshaft U-Joint Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-18
Propshaft U-Joint Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-20
Front Gearcase Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-23
Front Gearcase Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-26
Front Gearcase Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-28
Front Gearcase Disassembly / Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-29
Front Gearcase Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-33


BRAKE
General Specifications
FRONT BRAKE SYSTEM

Item Standard Service Limit
Front Brake Pad Thickness 7,54 ± 0,178 mm (0.297 ± 0.007 in) 3,8 mm (0.150 in)
Front Brake Disc Thickness 4,78 mm (0.188 in) 4,32mm (0.170 in)
Front Brake Disc Thickness Variance 0,051 mm (0.002 in)
Front Brake Disc Runout 0,254 mm (0.010 in)
Front Caliper Piston Bore I.D. 34,87 mm (1.373 in) 34,93 mm (1.375 in)
Front Caliper Piston O.D. 34,80 mm (1.370 in) 34,75 mm (1.368 in)
REAR BRAKE SYSTEM

Item Standard Service Limit
Rear Brake Pad Thickness 7,56 ± 0,178 mm (0.298 ± 0.007 in) 3,8 mm (0.150 in)
Rear Brake Disc Thickness 4,78 mm (0.188 in) 4,32 mm (0.170 in)
Rear Brake Disc Thickness Variance 0,051 mm (0.002 in)
Rear Brake Disc Runout 0,254 mm (0.010 in)
Rear Caliper Piston Bore I.D. 38,23 mm (1.505 in) 38,28 mm (1.507 in)
Rear Caliper Piston O.D. 38,10 mm (1.500 in) 38,05 mm (1.498 in)

Torque Specifications
Item Torque Torque

N•m ft-lb
Front Brake Disc to Hub Bolts 24 18
Rear Brake Disc to Hub Bolts 38 28
Brake Line Banjo Bolts (All) 20 15
Brake Switch 20 15
Caliper Bleed Screws 6 4
Front Caliper Mounting Bolts 41 30
Rear Caliper Mounting Bolts 65 48
Master Cylinder Mounting Bolts 31 23
Rear Wheel Hub Castle Nut 149 110
Brake Pedal Mount Bracket Nuts 24 18
Wheel Nuts (Steel Wheels) 81 60
Front Wheel Hub Castle Nut 102 75

BRAKE (CONT’D) When the foot activated brake lever is applied it applies
pressure on the piston within the master cylinder. As the
System Service Notes master cylinder piston moves inward it closes a small
opening (compensating port) within the cylinder and
Disc brake systems are light weight, low maintenance, starts to build pressure within the brake system. As the
and perform well in the conditions this vehicle will pressure within the system is increased, the pistons
routinely encounter. There are a few things to remember located in the brake calipers move outward and apply
when replacing disc brake pads or performing brake pressure to the moveable brake pads. These pads
system service to ensure proper system function and contact the brake discs and move the calipers in their
maximum pad service life. floating bracket, pulling the stationary side pads into the
brake discs. The resulting friction reduces brake disc and
• Do not over-fill the master cylinder fluid reservoir. vehicle speed.
• Make sure the brake pedal returns freely and The friction applied to the brake pads will cause the pads
completely. to wear. As these pads wear, the piston within the caliper
moves further outward and becomes self adjusting. Fluid
• Check and adjust master cylinder reservoir fluid level from the reservoir fills the additional area created when
after pad service. the caliper piston moves outward.
• Test for brake drag after any brake system service and Brake fluid level is critical to proper system operation. Too
investigate cause if brake drag is evident little fluid will allow air to enter the system and cause the
brakes to feel spongy. Too much fluid could cause brakes
• Make sure caliper moves freely on guide pins (where to drag due to fluid expansion.
applicable).

Located within the master cylinder is the compensating
• Inspect caliper piston seals for foreign material that port which is opened and closed by the master cylinder
could prevent caliper pistons from returning freely. piston assembly. As the temperature within the hydraulic
system changes, this port compensates for fluid
• Perform a brake burnishing procedure after installing expansion or contraction. Due to the high temperatures
new pads to maximize service life. created within the system during heavy braking, it is very
important that the master cylinder reservoir have
• DO NOT lubricate or clean the brake components with adequate space to allow for fluid expansion. Never
aerosol or petroleum products. Use only approved overfill the reservoir! Do not fill the reservoir beyond the
brake cleaning products. MAX LEVEL line!
The brake system consists of the following components
or assemblies: brake pedal, master cylinder, hydraulic
brake lines, brake calipers brake pads and brake discs,
which are secured to the drive line.

BRAKE (CONT’D)
Noise Troubleshooting
WARNING
Dirt or dust buildup on the brake pads and disc is the
most common cause of brake noise (squeal caused by
vibration). If cleaning does not reduce the occurrence of
brake noise, Permatex™ Disc Brake Quiet can be applied
Operation & Maintenance Manual and signs (decals)
to the back of the pads. Follow directions on the package.
on machine. Follow warnings and instructions in the
This will keep pads in contact with caliper piston(s) to
manuals when making repairs, adjustments or
reduce the chance of squeaks caused by dirt or dust.
servicing. Check for correct function after
adjustments, repairs or service. Untrained operators
The following troubleshooting chart is provided for
and failure to follow instructions can cause injury or
assistance in locating and correcting problems. Many of
death.
the recommended procedures must be done by W-2408-0801
authorized Bobcat Service Personnel only.
BRAKE NOISE TROUBLESHOOTING

POSSIBLE CAUSE SOLUTION
Dirt, dust or imbedded material on pads or disc Spray disc and pads with CRC Brakeleen™ or an equivalent non-
flammable aerosol brake cleaner. Remove pads and / or disc hub
to clean imbedded material from disc or pads.

Pad(s) dragging on disc (noise or premature pad Adjust pad stop (front calipers)
wear) because of improper adjustment 
Master cylinder reservoir overfilled Set to proper level
Master cylinder compensating port restricted Clean compensating port
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal
Operating error (riding the brake) Educate operator
Loose wheel hub or bearings Check wheel and hub for abnormal movement
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
Noise is from other source (axle, hub, disc or wheel) If noise does not change when brake is applied check other
sources. Inspect and repair as necessary
Wrong pad for conditions Change to a softer or harder pad

BRAKE (CONT’D)
System Troubleshooting
WARNING
assistance in locating and correcting problems. Many of
the recommended procedures must be done by
authorized Bobcat Service Personnel only.
death.
W-2408-0801
BRAKES
PROBLEM CAUSE
Brakes squeal / poor brake performance Air in system
Water in system (brake fluid contaminated)
Caliper / disc misaligned

Caliper dirty or damaged
Brake line damaged or lining ruptured
Worn disc and / or friction pads
Incorrectly adjusted stationary pad
Worn or damaged master cylinder or components
Damaged break pad noise insulator
Pedal vibration Disc damaged
Disc worn (runout or thickness variance exceeds service limit)
Caliper overheats (brakes drag) Compensating port plugged
Pad clearance set incorrectly
Parking brake lever incorrectly adjusted
Brake pedal binding or unable to return fully
Parking brake left on
Residue build up under caliper seals
Operator riding brakes
Brakes lock Alignment of caliper to disc
Caliper pistons sticking
Improper assembly of brake system components

BRAKE (CONT’D) Located within the master cylinder is the compensating
port which is opened and closed by the master cylinder
Hydraulic Brake System Operation piston assembly. As the temperature within the hydraulic
system changes, this port compensates for fluid
The brake system consists of the following components expansion or contraction. Due to the high temperatures
or assemblies: brake pedal, master cylinder, hydraulic created within the system during heavy braking, it is very
brake lines, brake calipers, brake pads, and brake discs, important that the master cylinder reservoir have
which are secured to the drive line. adequate space to allow for fluid expansion. Never
overfill the reservoir! Do not fill the reservoir beyond
When the foot activated brake lever is applied it applies the MAX LEVEL line!
pressure on the piston within the master cylinder. As the
master cylinder piston moves inward it closes a small When servicing the brake system use only Bobcat DOT
opening (compensating port) within the cylinder and 4 Brake Fluid.
starts to build pressure within the brake system. As the
pressure within the system is increased, the pistons
located in the brake calipers move outward and apply
pressure to the moveable brake pads. These pads
contact the brake discs and move the calipers in their WARNING
floating bracket, pulling the stationary side pads into the
brake discs. The resulting friction reduces brake disc and
vehicle speed.
After opening a bottle of brake fluid, always discard
any unused portion. Never store or use a partial
The friction applied to the brake pads will cause the pads
bottle. Brake fluid is hygroscopic, meaning it rapidly
to wear. As these pads wear, the piston within the caliper
absorbs moisture from the air. The moisture causes

moves further outward and becomes self adjusting. Fluid
the boiling temperature of the brake fluid to drop,
from the reservoir fills the additional area created when
which can lead to early brake fade and the possibility
the caliper piston moves outward.
of accident or severe injury.
W-2872-0510
Brake fluid level is critical to proper system operation. Too
little fluid will allow air to enter the system and cause the
brakes to feel spongy. Too much fluid could cause brakes
to drag due to fluid expansion.

BRAKE (CONT’D)
System Parts Identification
Master Cylinder Top View LH Front Caliper

LH Front
Brake Line 2
Master Cylinder
1
LH Rear Line
2 RH Front Caliper
LH Rear Caliper 3 Cross
2 Fitting
1
Master Cylinder
1
RH Front 1
3 MC Rear Brake Line
Brake Line
2 1

MC Front
Brake Line
RH Rear Caliper
RH Rear Line
P100150
Item Description Torque N•M Torque ft-

lb
1 Banjo Fitting 20 15
2 Bleed Screw 6 4
3 Flare Fitting 16 - 20 12 - 15

BRAKE (CONT’D) Figure 20-10-2
Master Cylinder Removal And Installation
Figure 20-10-1
2 2
1 4
1
P111633
3
Place a container to catch brake fluid under the master
P111632 cylinder brake lines.
Disconnect the electrical connector from the pressure

Remove the retaining clip (Item 1) and clevis pin (Item 2) sender (Item 1) [Figure 20-10-2].
[Figure 20-10-1] that attaches the master cylinder to the

brake pedal lever. Loosen the banjo bolt (Item 2) and pressure sender (Item
1) [Figure 20-10-2] for the brake lines and allow the fluid
NOTE: Dispose of brake fluid properly and do not re- to drain.
use.
After the fluid is drained, remove the banjo bolt (Item 2)
and pressure sender (Item 1) [Figure 20-10-2].
Installation: Tighten the banjo bolt (Item 2) and pressure

IMPORTANT sender (Item 1) [Figure 20-10-2] to 20 N•m (15 ft-lb)
torque.
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished Remove the two mounting bolts (Item 3) and nuts (Item
surfaces. 4) [Figure 20-10-1] from the master cylinder.
I-2312-0510
Installation: Tighten the cylinder bolts and nuts (Item 4)
[Figure 20-10-1] to 31 N•m (23 ft-lb) torque.
NOTE: Make note of front and rear brake line

locations to master cylinder.
Installation: After Installing the foot brake check pedal

freeplay. Pedal freeplay should not exceed 2,29 mm
(0.090 in).

Foot Brake Pedal Removal And Installation
Figure 20-10-3 2
1 2
1
1
P-99505
Check the bushings (Item 1) and foot brake pedal (Item

P111643 2) [Figure 20-10-5] for wear or damage and replace as
needed.
Remove the retaining clip (Item 1) and clevis pin (Item 2) Installation: After installing the foot brake pedal check
[Figure 20-10-3] to separate cable from brake pedal. pedal freeplay. Pedal freeplay should not exceed 2,29

mm (0.090 in). (See Brake Inspection on Page 20-10-11.)
Figure 20-10-4
Brake Pedal Freeplay 2,29 mm (0.090 in)
1
2
3
P111644
Remove the retaining clip (Item 1) [Figure 20-10-4].
Remove the foot brake pedal (Item 2) and both bushings

(Item 3) [Figure 20-10-4] from the mounting bracket.

Bleeding / Fluid Removal And Installation
NOTE: When bleeding the brakes or replacing the

fluid always start with the furthest caliper 1
from the master cylinder.
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• Pressurized fluids and springs or other stored P111616
energy components.
• Flying debris or loose material is present.
• Engine is running. The master cylinder is located in the left hand front wheel
• Tools are being used. well.
W-2505-0604
Clean the master cylinder reservoir cover (Item 1)
[Figure 20-10-6] thoroughly

Remove the cover from the reservoir.
IMPORTANT If changing fluid, remove the old fluid from the reservoir
with a hand vaccume pump or similar tool.
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished Figure 20-10-7
surfaces. This procedure should be used to change
fluid or bleed brakes during regular maintenance.
I-2313-0510
1
P111616
Add brake fluid to the indicated MAX level (Item 1)

[Figure 20-10-7] of the reservoir. Use Bobcat DOT 4
brake fluid only.

BRAKE (CONT’D)
Bleeding / Fluid Removal And Installation (Cont’d)

IMPORTANT
Figure 20-10-8
Maintain at least 12,7 mm (0.5 in) of brake fluid in the
reservoir to prevent air from entering the master
cylinder.
I-2314-0910
Tighten bleeder screw to 5,3 N•m (47 in-lb) torque.

Remove the bleeder hose.
1
Repeat the procedure for the remaining calipers.
Figure 20-10-9
P-99247
1
Begin the bleeding procedure with the caliper that is

farthest from the master cylinder. Install a box end

wrench on caliper bleeder screw (Item 1) [Figure 20-10-
8]. Attach a clean, clear hose to fitting and place the
other end in a clean container. Be sure the hose fits
tightly on fitting.
Have an assistant slowly pump foot pedal until pressure

builds and holds.
P111616
Hold brake pedal on to maintain pedal pressure, and

open bleeder screw. When pedal reaches the end of Add brake fluid to the MAXIMUM level inside reservoir
travel, close bleeder screw and release foot pedal. (Item 1) [Figure 20-10-9].
NOTE: Do not release foot pedal before bleeder Install master cylinder reservoir cover.
screw is tight or air may be drawn into master
cylinder. Field test machine at low speed before putting into
service. Check for proper braking action and pedal
Repeat procedure until clean fluid appears in bleeder reserve. With pedal firmly applied, pedal reservoir should
hose and all air has been purged. Add fluid as necessary be no less than 1,3 cm (0.50 in) of the reservoir. Use
to maintain level in reservoir. Bobcat DOT 4 brake fluid only.

BRAKE (CONT’D)
Brake Inspection
Figure 20-10-10
P-97770
Position the utility vehicle on a flat level surface. Engage

the park brake and stop the engine. Exit the utility

vehicle.
Check the brake pedal (Item 1) [Figure 20-10-10] for

excessive travel or a spongy feel.
The correct amount of free travel on the brake pedal is

2,29 mm (0.090 in) [Figure 20-10-10].

BRAKE (CONT’D) Burnishing
Brake Pad Inspection It is required that a burnishing procedure be performed

after installation of new brake pads to extend service life
Figure 20-10-11 and reduce noise.
Start machine and slowly increase speed to 48,3 km/h

(30 mph). Gradually apply brakes to stop machine. Allow
pads and disc to cool sufficiently during the procedure.
Do not allow pads or disc to become hot or warping may
result. Do not make more than 3 stops per 1,6 km (1.0
mile). Repeat this procedure 10 times.
3,8 mm (0.15 in)

P-97291
The minimum pad thickness is 3,8 mm (0.15 in) [Figure

20-10-11].

NOTE: The tires must be removed to inspect brake
pads. (See Tires on Page 10-120-1.)

BRAKE (FRONT) Figure 20-11-2
Pad Removal
Lift and block the machine. (See Procedure on Page 10-

10-1.)
2
WARNING 1
Use care when supporting vehicle so that it does not

tip or fall. Severe injury may occur if machine tips or
falls.
W-2848-0510
P111614
Remove the tire assembly. (See TIRE MAINTENANCE

on Page 10-120-1.) Remove the upper and lower caliper mounting bolts, lock
washers and washers (Item 1) and remove the caliper
Figure 20-11-1 (Item 2) [Figure 20-11-2] from the front hub.
NOTE: When removing caliper, use care not to

damage brake line. Support caliper to avoid
1

kinking or bending brake line.
Figure 20-11-3
P111602
Loosen the pad adjuster screw (Item 1) [Figure 20-11-1]

2 - 3 turns.
P111648
Push caliper piston into caliper bore slowly using a

C-clamp or locking pliers with pads installed [Figure 20-
11-3].

BRAKE (FRONT) (CONT’D) Pad Inspection
Pad Removal (Cont’d) Figure 20-11-5
Figure 20-11-4
P111621
P111608
Figure 20-11-6
Remove inner pad (Item 1) [Figure 20-11-4] from the

bracket and caliper.

1
P111613
Measure the thickness of the pad material. Replace pads

if worn beyond the service limit [Figure 20-11-5] and
[Figure 20-11-6].
New pad thickness (Item 1) [Figure 20-11-6] is 7,54 +

0,178 mm (0.297 + 0.007 in).
Service thickness limit is 3,8 mm (0.15 in).

BRAKE (FRONT) (CONT’D) Figure 20-11-8
Pad Assembly / Installation
Figure 20-11-7
1
1
P111614
Install caliper onto front hub and install the mounting

P111617 bolts, lock washers and washers (Item 1) [Figure 20-11-
8]. Tighten the mounting bolts to 41 N•m (30 ft-lb) torque.
Lubricate mounting bracket pins (Item 1) with a light film Slowly pump the brake pedal until pressure has been
of good quality lithium Grease, and install rubber dust built up. Maintain at least 12,7 mm (0.50 in) of brake fluid

boots [Figure 20-11-7]. in the reservoir to prevent air from entering the brake
system.
Compress mounting bracket and make sure dust boots
are fully seated. Install pads with friction material facing Figure 20-11-9
each other.
IMPORTANT
1
If brake pads are contaminated with grease, oil, or
liquid soaked do not use the pads. Use only new,
clean pads.
I-2315-0510
P111602
Install the pad adjuster set screw (Item 1) [Figure 20-11-

9] and turn clockwise until stationary pad contacts disc,
then back off 180° (counterclockwise).
Verify fluid level is reservoir is up to MAX line inside

reservoir and install reservoir cap.
Install the tire assembly. (See Wheel Removal And

Installation on Page 10-120-2.)

BRAKE (FRONT) (CONT’D)
Caliper Removal

10-1.)
WARNING
falls.
W-2848-0510
Remove the tire assembly. (See Wheel Removal And

Figure 20-11-10

3
1
2
4
P111615
Clean caliper area before removal.
Place a container below the caliper to catch brake fluid

when removing the line. Remove brake line from caliper
(Item 1) [Figure 20-11-10].
Loosen the pad adjuster screw (Item 2) [Figure 20-11-

10] 2 - 3 turns to allow brake pad removal after the
caliper is removed.
Remove the two caliper mounting bolts (Item 3), lock

washers and washers and remove the caliper assembly
(Item 4) [Figure 20-11-10].

BRAKE (FRONT) (CONT’D)
Caliper Parts Identification
1. Caliper Assy
2. Set Screw
3. Bleed Screw
4. Brake Pad
5. Caliper Mount
6. Boot
7. Square Ring 1
8. Piston
8
3
6
7* 2

*
8
7*
4
6
**
* Apply Bobcat DOT 4 Brake Fluid

** Apply Bobcat All Purpose Grease NA9456S

Caliper Disassembly
Figure 20-11-11
P-99031
Remove the mounting bracket, pin assembly and dust

P-99034 boot [Figure 20-11-13].
Thoroughly clean the brake caliper before disassembly

Push brake pad retainer pin (Item 1) [Figure 20-11-11] and prepare a clean work area to disassemble the
inward and slip brake pads past the edge. caliper.

Figure 20-11-12
WARNING
1 Use caution and always wear safety glasses when
working with compressed air.
W-2849-0510
Use low pressure compressed air to remove the pistons

from the caliper.
While holding the caliper and covering the pistons with a

shop towel, carefully apply compressed air to the brake
line inlet to force the pistons out from the caliper.
1 P-99033
NOTE: Do Not remove the caliper pistons with a
standard pliers. The piston sealing surfaces
Remove both brake pads (Item 1) [Figure 20-11-12] from will become damaged if a standard pliers is
the caliper. used.

BRAKE (FRONT) (CONT’D) Caliper Inspection
Caliper Disassembly (Cont’d) Figure 20-11-16
Figure 20-11-14
P-99030
P-99028
Inspect caliper body for nicks, scratches, pitting or wear.
Measure bore size and compare to specifications.
Once the pistons are removed, use a pick to carefully Replace if damaged or worn beyond service limit [Figure
remove the square O-rings (Item 1) [Figure 20-11-14] 20-11-16].

from the caliper. O-rings should be replaced during
caliper service. Caliper Piston Bore I.D.
Figure 20-11-15 Std 34,87 mm (1.373 in)

Service Limit 34,93 mm (1.375 in)
1
Figure 20-11-17
P111635
Clean the caliper body (Item 1), pistons (Item 2) and

retaining bracket (Item 3) [Figure 20-11-15] with brake P-99035
cleaner or alcohol.
Inspect piston for nicks, scratches, pitting or wear.
NOTE: Be sure to clean seal grooves in caliper body.
Measure piston diameter and replace if damaged or worn
beyond service limit [Figure 20-11-17].
Caliper Piston O.D.
Std 34,80 mm (1.370 in)


BRAKE (FRONT) (CONT’D) Caliper Installation
Caliper Assembly Figure 20-11-20
Figure 20-11-18
2
3
P111615
P-99029
Install caliper onto front hub and install the mounting
bolts (Item 1) [Figure 20-11-20], lock washers and
Install new O-rings in the caliper body seal grooves (Item washers. Tighten the caliper mounting bolts to 41 N•m
1) [Figure 20-11-18]. Be sure the grooves are clean and (30 ft-lb) torque.

free of residue or brakes may drag upon assembly.
Install the brake line (Item 2) and tighten the banjo bolt
Coat pistons with clean Bobcat DOT 4 Brake Fluid. Install (Item 3) [Figure 20-11-20] to 20 N•m (15 ft-lb) torque.
pistons with a twisting motion while pushing inward.
Piston should slide in and out of bore smoothly, with light Figure 20-11-21
resistance.
Figure 20-11-19
P111603
1
P-99001 Turn the pad adjuster set screw (Item 1) [Figure 20-11-
21] clockwise until stationary pad contacts disc, then
back off 180° (counterclockwise).
Lubricate the mounting bracket pins with a good quality
lithium Grease and install the rubber dust seal boots Perform brake bleeding procedure. (See Bleeding / Fluid
(Item 1) [Figure 20-11-19]. Removal And Installation on Page 20-10-9.)
Compress the mounting bracket and make sure the dust Install the wheel. (See Wheel Removal And Installation
seal boots are fully seated. Install the brake pads. Clean on Page 10-120-2.)
the disc and pads with brake parts cleaner or denatured
alcohol to remove any dirt, oil or grease. NOTE: If new front brake pads are installed, brake
burnishing is recommended. (See Burnishing
on Page 20-10-12.)

BRAKE (FRONT) (CONT’D) Disc Inspection
Disc Runout Lift and block the machine. (See LIFTING AND
BLOCKING THE UTILITY VEHICLE on Page 10-10-1.)
Figure 20-11-22
Figure 20-11-23
P111611
Mount dial indicator as shown to measure disc runout.

Slowly rotate the disc and read total runout on the dial

indicator. Replace the disc if runout exceeds specification P111605
[Figure 20-11-22].
Visually inspect disc for scoring, scratches, or gouges.
Brake Disc Runout Replace the disc if any deep scratches are evident.
Service Limit 0,254 mm (0.10 in) Use a 0-1” micrometer and measure the disc thickness at
eight different points around the pad contact surface.
Replace disc if worn beyond service limit [Figure 20-11-
23].
Brake Disc Thickness
New 4,78 mm (0.188 in)

Brake Disc Thickness Variance Difference Between

Measurements

Disc Removal And Installation
Lift and block the machine. (See LIFTING AND

1
Remove the front brake caliper. (See Caliper Removal on
Page 20-11-4.) 2
Figure 20-11-24
5 P-99249
6
4
3 Clean the wheel hub mating surface and install new disc
1 on wheel hub. Tighten new bolts (Item 1) [Figure 20-11-
25] to 24 N•m (18 ft-lb) torque.
Install wheel hub assembly, washers, and castle nut (Item

2) [Figure 20-11-25]. Tighten the castle nut to 102 N•m

2 (75 ft-lb) and install a new cotter pin before installing the
P-99249 dust cap.
Install front brake caliper. (See Caliper Installation on

Remove dust cap (Item 1), cotter pin (Item 2), castle nut Page 20-11-8.) Follow bleeding procedure. (See
(Item 3) and washers (Item 4) [Figure 20-11-24]. Bleeding / Fluid Removal And Installation on Page 20-10-
9.)
Remove the wheel hub assembly (Item 5) from the
vehicle and remove the four bolts (Item 6) [Figure 20-11- Field test unit for proper braking action before putting into
24] retaining the disc to the hub. service. Inspect for fluid leaks and firm brakes. Make sure
the brake is not dragging when pedal is released. If the
brake drags, re-check assembly and installation.
IMPORTANT
Always use new brake disc mounting bolts. The bolts
have a pre-applied locking agent which is destroyed
upon removal.
I-2316-0510

BRAKE (REAR) Pad Removal
Caliper Removal Figure 20-12-2

WARNING
falls.
W-2848-0510
Remove the tire assembly. (See Wheel Removal And P-99041

Clean the caliper area before removal. Push caliper piston into caliper bore slowly using a C-
clamp or locking pliers with pads installed [Figure 20-12-
Figure 20-12-1 2].

NOTE: Brake fluid will be forced through the
compensating port into master cylinder fluid
3 1 reservoir when piston is pushed back into
caliper. Remove excess fluid from reservoir
as required.
Figure 20-12-3
P110628
Loosen the pad adjuster screw (Item 1) [Figure 20-12-1]

2 - 3 turns.
1
Remove the caliper mounting bolts (Item 2) and remove
the caliper (Item 3) [Figure 20-12-1] off the disc.
P111628
NOTE: When removing caliper, use care not to
damage brake line. Support caliper to avoid
kinking or bending brake line. Remove the brake pads (Item 1) [Figure 20-12-3] from
the caliper.

BRAKE (REAR) (CONT’D) Pad Installation
Pad Inspection Figure 20-12-5
Figure 20-12-4
P111627
P111612
Install new brake pads (Item 1) into the caliper body (Item
2) [Figure 20-12-5].
Clean the caliper with brake cleaner or alcohol.
Figure 20-12-6

Measure the thickness of the pad material [Figure 20-12-
4]. Replace the pads if worn beyond the service limit.
Rear brake pad thickness 2
New 7,56 + 0,178 mm (2.98 + 0.007 in)

3
1
P126793
Install the caliper (Item 1) [Figure 20-12-6].
Tighten the bolts (Item 2) [Figure 20-12-6] to 65 N•m (48

ft-lb) torque.
Install the pad adjustment screw (Item 3) [Figure 20-12-

6] and turn until the stationary pad contacts the disc, then
back off 1/2 turn.
NOTE: If new rear brake pads are installed, brake

burnishing is recommended. (See Burnishing
on Page 20-10-12.)

BRAKE (REAR) (CONT’D)
Caliper Parts Identification
**
1. Socket Set Screw 2
2. Bleeder Screw
3. Caliper Assy.
4. Boot
5. Square O-rings 7 1
6. Piston 9* * *
7. Caliper Mount
8. Brake Pads
**
10 *

8*
6 *
5 4
* Apply Bobcat DOT 4 Brake Fluid

** Apply Bobcat All Purpose Grease
NA9457S

BRAKE (REAR) (CONT’D) Figure 20-12-8
Caliper Disassembly
Figure 20-12-7
7
3
2
1
4
6 P-99021
5
Remove the piston from the caliper using a piece of rod
P111637 and a hammer [Figure 20-12-8]. Tap lightly to avoid
damage.
Remove the brake pad adjuster screw (Item 1) [Figure Figure 20-12-9
20-12-7].

Push the upper pad retainer pin inward and slip the brake
pads (Item 2) [Figure 20-12-7] past edge, if pads are still
installed.
Remove the mounting bracket (Item 3) and dust boot

(Item 4) [Figure 20-12-7].
1
Remove the piston (Item 5) and square O-rings (Item 6)
from the caliper body (Item 7) [Figure 20-12-7]. 2
3
Clean the caliper body, piston and retaining bracket with
brake cleaner or alcohol.
P111649
NOTE: Be sure to clean seal grooves in caliper body.
Clean the caliper body (Item 1), piston (Item 2), and
retaining bracket (Item 3) [Figure 20-12-9] with brake
cleaner or alcohol.

Caliper Inspection
Figure 20-12-10
P111622
Inspect piston for nicks, scratches, pitting or wear.

P111623 Measure piston diameter and replace if damaged or worn
beyond service limit [Figure 20-12-11].
Inspect caliper body for nicks, scratches, pitting or wear. Caliper Piston O.D.
Measure bore size and compare to specifications.

Replace if damaged or worn beyond service limit [Figure Std 38,10 mm (1.500 in)
20-12-10]. Service Limit 38,05 mm (1.498 in)
Caliper Piston Bore I.D.
Std 38,23 mm (1.505 in)


BRAKE (REAR) (CONT’D) Caliper Installation
Caliper Assembly Figure 20-12-14
Figure 20-12-12
1
1
2
3
2
1
P126793
P100152
Install the rear caliper and mounting bolts (Item 1)
[Figure 20-12-14]. Tighten the caliper mounting bolts to
Install new O-rings in the caliper body (Item 1) [Figure 65 N•m (48 ft-lb) torque.
20-12-12]. Be sure the grooves are clean and free of

residue or brakes may drag upon assembly. Install the brake line (Item 2) and tighten the banjo bolt
(Item 3) [Figure 20-12-14] to 20 N•m (15 ft-lb) torque.
Coat piston (Item 2) [Figure 20-12-12] with clean Bobcat
DOT 4 Brake Fluid. Install piston with a twisting motion Install the pad adjustment screw (Item 4) [Figure 20-12-
while pushing inward. Piston should slide in and out of 14] and turn until stationary pad contacts disc, then back
bore smoothly, with light resistance. off 1/2 turn.
Figure 20-12-13 Install the rear wheel. (See Wheel Removal And
Carefully lower the vehicle.
Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
P111631
Lubricate the mounting bracket pins with a good quality

lithium grease and install the rubber dust seal boots (Item
1) [Figure 20-12-13].
Compress the mounting bracket and make sure the dust

seal boots are fully seated. Install the brake pads. Clean
the disc and pads with brake parts cleaner or denatured
alcohol to remove any dirt, oil or grease.

BRAKE (REAR) (CONT’D) Disc Inspection
Disc Runout Figure 20-12-16
Figure 20-12-15
P111606
P111630
Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
Mount a dial indicator and measure disc runout [Figure
20-12-15]. Slowly rotate the disc and read total runout on Use a 0 - 1” micrometer and measure the disc thickness

the dial indicator. Replace the disc if runout exceeds at eight different points around the pad contact surface.
specification. Replace disc if worn beyond service limit [Figure 20-12-
16].
Brake Disc Runout
Brake Disc Thickness
New 4,78 mm (0.188 in)
Brake Disc Thickness Variance Difference Between

Measurements

Disc Removal And Installation

Remove the Rear brake caliper.

2
Figure 20-12-17
1
5
P111607
3
2
1 Clean the wheel hub mating surface and install new disc
on wheel hub. Tighten new bolts (Item 1) [Figure 20-12-
5 18] to 38 N•m (28 ft-lb) torque.
Install wheel hub assembly, washers, and castle nut (Item

2) [Figure 20-12-18]. Tighten the castle nut to 149 N•m

P111607 (110 ft-lb) torque and install a new cotter pin before
installing the dust cap.
Remove dust cap, cotter pin (Item 1), castle nut (Item 2) Install Rear brake caliper. (See Caliper Installation on
and washers (Item 3) [Figure 20-12-17]. Page 20-12-6.) Follow bleeding procedure. (See
Bleeding / Fluid Removal And Installation on Page 20-10-
Remove the wheel hub assembly (Item 4) from the 9.)
vehicle and remove the four bolts (Item 5) [Figure 20-12-
17] retaining the disc to the hub. Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
IMPORTANT
Always use new brake disc mounting bolts. The bolts
have a pre-applied locking agent which is destroyed
upon removal.
I-2316-0510

TRANSMISSION Figure 20-20-3
Bottom Engagement
General Operation
View Dog
“Unlocked”
The vehicle’s transmission has three traction operational
modes: 4WD (4x4), 2WD (Differential Locked) and Turf
(Differential Unlocked). Locking the rear differential is
beneficial in low traction and rough terrain conditions.
Shift
Unlocking the rear differential makes maneuvering easier Planetary
Fork
and minimizes damage to turf and sensitive terrains. Differential
Solenoid
Figure 20-20-1
4x4 (4WD)
P100243
2WD (Differential Locked)
2 Wheel
Turf (Differential Drive
Unlocked) When “Differential-Locked” is selected on the switch,
1
power is removed from the electrical solenoid allowing
the solenoid plunger to retract. Spring tension moves the
shift fork back into place and engages the engagement
dog to the side gear that is part of the planetary

differential assembly. This locks the rear differential as a
P-97687 solid rear axle, increasing traction.
Figure 20-20-4
When “Differential-Unlocked” is selected on the switch,
the rear differential becomes unlocked for tighter turns.
When switch position is set
An electrical solenoid mounted in the rear portion of the
to “Lock”, power is removed
transmission actuates the shift fork. The solenoid plunger
from the solenoid and 
extends out to move the shift fork and slides the
the plunger retracts
engagement dog away from the side gear that is part of
to engage the
the planetary differential assembly. This unlocks the rear
clutch gear
differential. The rear drive shafts are now dependent on
and lock the
the differential allowing for tighter turns
differential.
Figure 20-20-2
P100244
When switch position is set Figure 20-20-5

to “Unlock”, the solenoid is
powered and the  Bottom Engagement
plunger extends View Dog
to disengage the “Locked”
clutch gear and
unlock the
differential.
Shift
Planetary
P100242 Fork
Differential
Solenoid
P100245

TRANSMISSION (CONT’D)
Check the following items when shifting difficulty is

encountered.
• Shift cable adjustment / condition
• CVT clutch alignment
• Transmission Lubricant type / quality
• Drive belt deflection (where applicable)
• Loose fasteners on sector gear cover
• Worn rod ends, clevis pins or pivot arm bushings
• Shift selector rail travel
• Worn, broken or damaged internal transmission

components

NOTE: To determine if shifting difficulty or problem
is caused by an internal transmission
problem, isolate the transmission by
disconnecting the shift cable end from the
transmission bellcrank. Manually select each
gear range at the transmission bellcrank, and
test ride vehicle. If it functions properly, the
problem is outside the transmission.

If transmission problem remains,
disassemble transmission and inspect all
gear dogs for wear (rounding) or damage.
Inspect all bearings, circlips, thrust washers
and shafts for wear.

TRANSMISSION (CONT’D) Figure 20-20-8
Shift Lever Removal And Installation
Remove the upper dash panel.

1
Figure 20-20-6
3
1
P110808
Remove the clip (Item 1), washer (Item 2), and cable
(Item 3) [Figure 20-20-8] from the lever.
P111163 Figure 20-20-9

Remove the shift knob cover (Item 1) [Figure 20-20-6].
Figure 20-20-7 2
1
1
P110809
2 Remove the clip (Item 1) [Figure 20-20-9].
P111164 Remove both bushings (Item 2) and shift lever (Item 3)

[Figure 20-20-9] from the vehicle.
Remove the screw (Item 1) and shift knob (Item 2)

[Figure 20-20-7] from the shift lever.
Remove the rubber grommet (Item 3) [Figure 20-20-7]

from the dash.

Shift Lever Removal And Installation
Figure 20-20-10
1 P-99377
Check the bushings (Item 1), and shift lever (Item 2)

[Figure 20-20-10] for wear and damage. Replace as

needed.

Shift Cable Inspecting
Shift cable adjustment is necessary when any of the

following is noticed:
• No gear position or AWD display on instrument

cluster.
1
• Ratcheting noise on deceleration.
2
• Inability to engage a gear
• Excessive gear clash (noise).
• Gear selector is moving out of desired range. P-97771
Inspect the shift cable, clevis pins, and pivot bushings

and replace if worn or damaged. Check the cable Figure 20-20-12
adjustment per the following procedure:

2
1
P-97772
Stop the vehicle on a flat and level surface.
Chock the wheels.
With the gear selector lever (Item 1) in the PARK position,

make sure the lever (Item 1) is not contacting the bottom
of the shift slot (Item 2) [Figure 20-20-11].
Move the gear selector lever (Item 1) to the HIGH

position, make sure the lever (Item 1) is not contacting
the top of the shift slot (Item 2) [Figure 20-20-12].
If there is contact at either the bottom (Item 2) [Figure

20-20-11] or the top (Item 2) [Figure 20-20-12] of the
gear selector shift slot, the shift cable will need to be
adjusted. Do the following:

TRANSMISSION (CONT’D) Shift Cable Removal And Installation
Shift Cable Adjustment Remove the upper dash. (See Upper Dash Panel
Figure 20-20-13
Figure 20-20-14
2 3 5
1
1
P110626 4
2
Position the utility vehicle on a flat level surface. Place the

P111673
gear select lever in Park and stop the engine. Exit the

utility vehicle. Place blocks in front of and behind the rear
wheels so the utility vehicle can not roll. Remove the clip and washer (Item 1) retaining the shift
cable (Item 2) to the shift lever (Item 3) [Figure 20-20-
Raise the cargo box. 14].
Loosen the lower jam nut (Item 1) and pull the cable out Loosen the lower jam nut (Item 4) and pull the cable out
of the mount bracket to loosen the upper jam nut (Item 2) of the shift bracket (Item 5) [Figure 20-20-14].
[Figure 20-20-13].
Figure 20-20-15
Adjust the shift cable so there is the same amount of
cable travel when shifting slightly past HIGH gear and
PARK.
Thread the upper or lower jam nut as required to obtain

proper cable adjustment. 2
NOTE: This procedure may require a few attempts to

obtain the proper adjustment.
1
Once the proper adjustment is obtained, place the shift
cable and upper jam nut into the mount. Tighten the
lower jam nut (Item 1) [Figure 20-20-13] against the
3
mount.
P110625
Start engine and shift through all gears to ensure the shift
cable is properly adjusted. If transmission still ratchets
after cable adjustment, the transmission will require Locate the shift cable (Item 3) [Figure 20-20-15] in the
service. right rear wheel well.
Remove the clip (Item 1) and washer (Item 2) [Figure 20-

20-15] from the shift cable.
Remove cable (Item 3) [Figure 20-20-15] from the shift

lever.

Shift Cable Removal And Installation (Cont’d)
Figure 20-20-16
2 2
1
1 P111667
Remove the plastic rivets retaining the cover and remove

P110626 the cover to access the shift cable (Item 1) [Figure 20-
20-18]
Loosen the lower jam nut (Item 1) and remove the cable Remove the cable from the vehicle.
(Item 2) [Figure 20-20-16] from the bracket.

Route the new shift cable same as previously removed.
Figure 20-20-17 Be sure to route the shift cable (Item 1) together with the
brake line (Item 2) [Figure 20-20-18] in the area under
the drive shaft cover as previously shown.
2
1 1
1
P-97854
Remove the fasteners (Item 1) retaining the skid plate

(Item 2). Remove the skid plate to access the shift cable
[Figure 20-20-17]

Removal 3
4
2
WARNING 1

falls.
W-2848-0510
Disconnect the (-) negative battery cable from the battery.

P126789

10-1.) Remove the clip (Item 1) and pin (Item 2) and safety
cable (Item 4) (if equipped) [Figure 20-20-19].
Remove the cargo box. (See Removal And Installation on
Page 30-130-1.) Remove the cargo box shock (Item 3) [Figure 20-20-19]
from the vehicle
Remove the front gearbox. (See Front Gearcase

Figure 20-20-20
Remove the rear drive shafts. (See Rear Drive Shaft
Remove the Inner CVT Cover. (See CVT (Inner) Cover

If internal transmission repair is required, drain the 3

transmission lubricant.
P120324
Loosen the clamp (Item 1) and remove the hose (Item 2)

[Figure 20-20-20].
Remove the tie strap (Item 3) [Figure 20-20-20].

Removal (Cont’d)
Figure 20-20-21
2
1
1 P118445
Disconnect the harness from the Vehicle Speed Sensor

P120325 (VSS) (Item 1) [Figure 20-20-23].
Remove the tie strap (Item 2) [Figure 20-20-23].

Remove the bolt (Item 1) [Figure 20-20-21].
Figure 20-20-24

Figure 20-20-22
1 4
1
3
P120341
P120326
Remove the tie strap (Item 1) and disconnect the harness

Rotate the air duct (Item 1) [Figure 20-20-22] forward from the gear position switch (Item 2) [Figure 20-20-24].
and let it rest against the rear of the cab.
Loosen the clamp (Item 3) and remove the transmission
vent line (Item 4) [Figure 20-20-24].

Removal (Cont’d)
Figure 20-20-25
1
1 2
3
P118442
Remove the bolt and nut (Item 1) [Figure 20-20-27]

P120342 securing the intake plenum to the rear transmission
mount.
Remove the clip (Item 1), washer (Item 2) and shift cable Figure 20-20-28
end (Item 3) [Figure 20-20-25] from the bellcrank.

Figure 20-20-26
1
2
1
2
P120181
P120343 Loosen the clamp (Item 1) and remove the hose (Item 2)
from the engine [Figure 20-20-28].
Mark the location of the upper shift cable jam nut (Item 1) Remove the intake plenum.
[Figure 20-20-26].
Loosen the lower jam nut (Item 2) [Figure 20-20-26] and

remove the shift cable assembly.

Removal (Cont’d)
Figure 20-20-29
1
1
P120339
Remove the two transmission to engine bolts (Item 1)

P120340 [Figure 20-20-31].
Figure 20-20-32
Use an overhead or portable hoist to support the
transmission by securing a strap (Item 1) [Figure 20-20-

29] through the rear mount.
NOTE: Place a spacer or support between the vehicle

frame and engine to hold the engine up in
position while removing the transmission to
engine mounting bolts.
Figure 20-20-30
1
P120340
1 Remove the rear transmission mount bolt (Item 1)

[Figure 20-20-32].
Remove the transmission.
NOTE: Have an assistant help guide the transmission

in and out of the vehicle while using a hoist to
P120337 prevent personal injury or damage to the
vehicle.
Remove the two transmission to engine bolts (Item 1)

[Figure 20-20-30].

Installation
Figure 20-20-33
1
P120335
Install new bolts (Item 1) [Figure 20-20-35] securing the

P120340 transmission coupler bracket to the engine.
Do not torque bolts at this time.

Use a overhead or portable hoist and suitable strap to
lower the transmission into the vehicle frame. Figure 20-20-36

NOTE: Place a spacer or support between the vehicle
frame and engine to hold the engine up in
position while removing the transmission to
engine mounting bolts.
Align both front and rear transmission mounting

locations. Install the rear transmission mount bolt (Item 1)
[Figure 20-20-33]. Do not torque the bolt at this time.
1
Align the front transmission mounting holes with the
transmission joint bracket holes.
Figure 20-20-34
P120336
Install new bolts (Item 1) [Figure 20-20-36] hand tight.

1
P120334
Install the Clutch Center Distance Tool (Item 1) [Figure

20-20-34] onto the crankshaft and transmission input
shafts to properly position the clutch center distance.

TRANSMISSION (CONT’D) Remove the lifting straps and overhead or portable hoist.
Installation (Cont’d) Figure 20-20-39
Figure 20-20-37
3
1
P120182
P120337
Position the intake plenum (Item 1). Slide the hose (Item
2) onto the intake and tighten the hose clamp (Item 3)
Install the bolts (Item 1) [Figure 20-20-37] and tighten to [Figure 20-20-39] to 4 N•m (3 ft-lb) torque.
64 N•m (47 ft-lb) torque.

Figure 20-20-40
Figure 20-20-38
10
6 5
3 1
7 8
4
2
9
P118445
P120338
Connect the vehicle speed sensor harness (Item 1) and

Torque the right side mounting bolts in two steps [Figure install the tie strap (Item 2) [Figure 20-20-40].
20-20-38].
• Step 1: Tighten 3, 4 and 5 to 7 N•m (5 ft-lb) torque.
• Step 2: Tighten 6, 7, 8, 9, and 10 to 64 N•m (47 ft-lb)

torque.
Remove the clutch center tool.
Remove the spacer or support between the vehicle frame

and engine.
Tighten the rear transmission mount bolt to 54 N•m (40 ft-

lb) torque.

Installation (Cont’d)
Figure 20-20-41
1
2
3
P120343
Note the location marks on the shift cable made during

P118442 transmission removal and install the shift cable (Item 1)
on the bracket (Item 2) [Figure 20-20-43].
Install the bolt and nut (Item 1) [Figure 20-20-41]. While holding the upper shift cable jam nut (Item 3),
Tighten the nut to 30 N•m (22 ft-lb) torque. tighten the lower jam nut (Item 4) [Figure 20-20-43].

Figure 20-20-42
3 2
P120342
Install the shift cable end (Item 1), washer (Item 2), and
clip (Item 3) [Figure 20-20-42].

Figure 20-20-44
1 2
P120341
Connect the harness to the gear position switch (Item 1)

and install the tie strap (Item 2) [Figure 20-20-44].

Loosen the clamp (Item 3) and install the transmission
vent line (Item 4) [Figure 20-20-44].
Install the CVT inner clutch cover. (See CVT (Inner)

Cover Removal And Installation on Page 20-40-8.)
Install the drive clutch. (See Removal And Installation on

Page 20-41-1.)
Install the driven clutch. (See Removal And Installation

on Page 20-42-1.)
Install the drive belt. (See Installation on Page 20-30-3.)
Install the outer clutch cover. (See CVT (Outer) Cover

Install the rear drive shafts. (See Rear Drive Shaft

Install the front prop shaft. (See Propshaft Removal And


Parts Identification
1 1
1
2
3
4
7 25
1
76
11
8
9
10 2
6
11
13 5 7 7 50
14 48 47
18 16
46
1314
17 38
12 12 40
46 53 51
15 43 52
49
19 41 47
23 21

25 45
11 39 39
37 56
32 44
20 30 31
22 59 57
42 61
24 60
26 40
54
38 55 90
62 91
29 36
28 34 66
27 35
10
33 63 89 93
76
7170 64
94
72 65 92
73 96
98
72 67
69
75 64
55 86
68 95
73 83 97
82
81
74 80
79
78 64
77
76 86 88
38 50
39
85 87
84 83
76
* Apply Loctite® 242

** Apply Loctite® 262
***Apply White Lithium Based Grease NA9460S

TRANSMISSION (CONT’D) REF. Description
Parts Identification (Cont’d) 47. Washer, Thrust
48. Gear 49T
REF. Description 49. Bearing, Needle Cage
1. Screw, M8 x 1.25 x 25 50. Bearing, Ball
2. Bearing 51. Solenoid
3. Differential Cover 52. Spring, Compression
4. Slide Gear, Female 53. Weldment, Rear Mount Bracket
5. Plug, Expansion 54. Seal, Dual Lip
6. Bearing 55. Seal, Triple Lip
7. Planet Gear 56. Case, LH
8. Slide Gear, Male 57. Fill Plug
9. Ring Gear 58. Nylock, M8 x 1.25
10. Bearing 59. Fork, Pivot Shaft
11. Retaining Ring 60. Retainer, Fork
12. Cup Washer 61. Spring, Torsion
13. Spring, compression 62. Screw, M6 x 1 x 16
14. Shift Fork 63. Dog, Engagement
15. Spring, compression 64. Screw, M6 x 1 x 18
16. Collar, Shift 65. Plate, Park, 12-Face

17. Rail, Shift Shaft 66. Pin, Dowel
18. Drum, Shift 67. Case, RH
19. Gear, Sector 16T 68. Drain Plug, Magnetic
20. Spacer 69. Tube, Vent 1/4 in.
21. Star, Detent 70. O-ring
22. O-ring
23. Switch, Rotary, 2-pin
24. Washer, Thrust
25. Spring Washer
26. Retaining Ring
27. Retaining Ring
28. Bellcrank
29. O-ring
30. Pawl, Detent
31. Shaft, Shift
32. Gear, Sector 31T
33. Screw, M8 x 50
34. Spring, Compression
35. Bracket, Rear Mount
36. Bearing, Ball
37. Shift Dog, Park
38. Retaining Ring, External
39. Washer
40. Bearing, Needle Cage
41. Gear4, Low 67T
42. Shaft, Reverse 27T
43. Sprocket, 48T, 6-Face
44. Chain, Silent
45. Engagement, 6-Face

Parts Identification (Cont’d)
REF. Description
71. Sensor, Speed
72. Screw, M6 x 1 x 20
73. Bracket, Wire Harness
74. Screw, M8 x 1.25 x 30
75. Cover, Sector Gears
76. Bearing, Ball
78. Washer
79. Gear, 46T
80. Screw, M6 x 1 x 40
81. Cover, Bearing, Center Drive
83. Bearing, Ball
84. Shaft, Idler 29T
85. Gear, 46T
86. Bearing, Ball

87. Shaft, Input Helical
90. Washer
91. Gear, Snorkel, 13T
92. Shaft, Front Output
93. Tube, Snorkel
94. Shim
96. Shim
98. O-ring

Transmission Disassembly 4
Place the transmission in HIGH gear before disassembly. 5

6
Figure 20-20-45
1
3
7 2
6 7
5
8 2
1 P126761
3
4 Remove the compression spring (Item 1) [Figure 20-20-
46].
P111659
Remove the detent star (Item 2). [Figure 20-20-46] Note
how the detent star fits onto the splined shaft with the
skip tooth aligned and tall center hub facing outward for

Remove the bellcrank nut (Item 1) and bellcrank (Item 2) reassembly.
[Figure 20-20-45].
Remove the spacer (Item 3) [Figure 20-20-46].
Remove the E-clip (Item 3) that retains the spring washer
(Item 4), flat washer and gear switch (Item 5) [Figure 20- Remove the shift shaft (Item 4), detent pawl (Item 5) and
20-45]. Remove the switch. the shift sector gears (Item 6) and (Item 7) [Figure 20-
20-46].
Remove the sector cover bolts (Item 6) and remove the
sector cover (Item 7) [Figure 20-20-45]. NOTE: Note the timing marks on the shift gears (Item
5) and (Item 6) [Figure 20-20-46] for
NOTE: Removal can be aided by using your thumbs to reassembly.
press in on the shafts while pulling out the
cover with your fingers. Remove the O-rings (Item 8) [Figure 20-20-46] from
each shaft and discard. Use new O-rings upon assembly.
Figure 20-20-47
P111687
Remove all the transmission case bolts. Using suitable

pry bars, remove the cover using the designated pry
points (Item 1) [Figure 20-20-47].

Transmission Disassembly (Cont’d)

1
Figure 20-20-48
P118242
Remove the rear output shaft assembly (Item 1) [Figure

P118475 20-20-50] by lifting underneath the gear or by tapping the
shaft from the opposite side. If use of a pry bar is
necessary, take care not to pry on sealing surfaces of
Lift up on the shift shaft rail (Item 1) and move the rail case.
assembly rearward to allow the shift fork pins to be

removed from the shift drum (Item 2) [Figure 20-20-48] Figure 20-20-51
and remove the shift drum from the housing.
Figure 20-20-49
2
1 1
2 P118244
P118240 Remove the idler gear shaft assembly (Item 1) and

cluster assembly (Item 2) [Figure 20-20-51] from the
transmission housing by pulling both assemblies straight
Lift up to remove the shift shaft rail (Item 1) and shift forks up.
(Item 2) [Figure 20-20-49] from the transmission housing
as an assembly.

Transmission Disassembly (Cont’d)
Figure 20-20-52
3 1
1
1
3
P118246
2
Remove the screws (Item 1) and (Item 2) securing the
P118238 pinion shaft assembly (Item 3) [Figure 20-20-53].
Screw (Item 2) [Figure 20-20-53] is longer than the other

Slide the engagement dog (Item 1) [Figure 20-20-52] off three and must go back into the same hole to lock the
of the shift fork guides. snorkel tube.

Remove the two screws (Item 2) [Figure 20-20-52] and Lift the pinion shaft assembly straight up to remove it
retaining plates. Lift the shift fork (Item 3) [Figure 20-20- from the housing.
52] and torsion spring out of the housing

Gear Cluster Disassembly
Reference [Figure 20-20-54] for the following steps.
Figure 20-20-54
P111690
Remove the bearing, engagement dog, retaining ring,

washer, gear and needle bearing from the reverse shaft
[Figure 20-20-55].
Figure 20-20-56

1 1
P118477
P111670
Remove the bearing from the reverse shaft using a Remove the snap ring (Item 1) [Figure 20-20-56] on
bearing puller. Remove the retaining ring and slide the either end of the shift rail to disassemble.
washers, 49T gear and needle bearing of the reverse
shaft (Item 1). NOTE: The compressed springs on the shift rail may
pop off when the snap rings are removed.
Remove the retaining ring and engagement dog from the
reverse shaft.
Remove the retaining ring, washer, needle bearing and

sprocket from the reverse shaft.
Tilt the two shafts towards each other and remove the
silent chain from the two shafts.

Snorkel Shaft Removal / Disassembly
Figure 20-20-57
P111679
1
Remove the snorkel tube and shaft assembly (Item 1)

P111677 [Figure 20-20-59] from the transmission case.
Figure 20-20-60
Extract the seal (Item 1) [Figure 20-20-57] from the
snorkel shaft to access the snorkel tube.

Figure 20-20-58
1
2
P111684
Remove the snap ring (Item 1) and shim (Item 2) [Figure

P111678 20-20-60] from the snorkel shaft.
Use an arbor press to remove the snorkel tube from the

Using the Snorkel Tool (PA-50231) (Item 1) [Figure 20- snorkel shaft.
20-58], fully loosen the snorkel tube.

Snorkel Shaft Removal / Disassembly (Cont’d)

3
Figure 20-20-61
1 4
2
1 P111683
Remove the retaining ring (Item 1), to remove the

2 P111681 remaining washer (Item 2), bearing (Item 3) and gear
(Item 4) [Figure 20-20-63] from the snorkel shaft.
Remove the snap ring (Item 1) and shim (Item 2) [Figure Remove all seals from the halves and clean the cases in
20-20-61] retaining the bearing in the snorkel tube. preparation for assembly.

Figure 20-20-62
P111682
Lightly tap on the bearing from the opposite side to

remove it from the snorkel tube [Figure 20-20-62].
Remove the retaining ring (Item 1) to remove the

remaining washer (Item 2) [Figure 20-20-62], bearing
and gear from the snorkel shaft.

Planetary Differential Disassembly
NOTE: If the gearcase is completely assembled,

perform the “Gearcase Disassembly and
Inspection” procedure.
Figure 20-20-64 1
P111693
Remove the six planet gears (Item 1) and each side gear
assembly (Item 2) [Figure 20-20-66] from the ring gear.
Figure 20-20-67
P111691

1 2
Use a scribe to mark the differential cover and ring gear

prior to disassembly [Figure 20-20-64].
3
3
Figure 20-20-65
3 3 P111694
1
Inspect the female side gear (Item 1), male side gear
(Item 2), planet gears (Item 3) and ring gear (Item 4)
[Figure 20-20-67]. Replace components or bushings as
needed. Bushing replacement can be performed on all
necessary differential components.
P111692
Remove the six bolts (Item 1) [Figure 20-20-65] retaining

the differential cover and remove the cover.

TRANSMISSION (CONT’D) Planet Gear Bushing Removal And Installation
Planetary Differential Disassembly (Cont’d) Figure 20-20-70
Ring Gear Bushing Removal And Installation
Figure 20-20-68
P111653
1
Press the old bushing (Item 1) [Figure 20-20-70] out of

P111665 the planet gear.
Thoroughly clean the bore of the planet gear and check

Press the old bushing (Item 1) [Figure 20-20-68] out of for any unwanted burs.
the ring gear.
Press the new bushing (Item 1) [Figure 20-20-70] into
Thoroughly clean the bore of the ring gear and check for the planet gear until it is flush on each end. Repeat this
any unwanted burs. procedure for the remaining planet gears.
Figure 20-20-69
1 mm
(0.04 in)
P111664

the ring gear housing. Install the bushing so it is flush to 1
mm (0.04 in) recessed from end face of hub.

TRANSMISSION (CONT’D) Female Side Gear Bushing Removal And Installation
Planetary Differential Disassembly (Cont’d) Figure 20-20-73
Differential Cover Bushing Removal And Installation
Figure 20-20-71
P111688
Locate the bushing split. Using a small chisel or flat blade

P111652 screwdriver, peel back and remove the old bushing from
the side gear, being careful not to damage the side gear
[Figure 20-20-73].

Press the old bushing (Item 1) [Figure 20-20-71] out of
the differential cover. Figure 20-20-74
Thoroughly clean the bore of the differential cover and

check for any unwanted burs. 1

the differential cover.
Figure 20-20-72
8,7 - 10,7 mm
(0.343 - 0.421 in)
P111654
NEW
Thoroughly clean the bore of the side gear and check for
BUSHING
any unwanted burs.

the side gear until it bottoms out.
P111651
Install the bushing to the depth illustrated in [Figure 20-

20-72].

TRANSMISSION (CONT’D) Snorkel Shaft Assembly
Planetary Differential Assembly Figure 20-20-77
Thoroughly clean the differential components.

2
Figure 20-20-75
1
4
3
P111683
1
Install the gear (Item 1), bearing (Item 2), washer (Item 3)
P111693 and retaining ring (Item 4) [Figure 20-20-77].
Figure 20-20-78

Assemble the side gears (Item 1) and place them onto
the ring gear along with the six planet gears (Item 2)
[Figure 20-20-75].
3
Figure 20-20-76
1
2 1
P111682
Install the bearing (Item 1), washer (Item 2) and snap ring
(Item 3) [Figure 20-20-78].
P111692
Align and install the differential cover (Item 1) [Figure 20-

20-76] using the previously made scribe marks.
Apply Loctite® 2760 to cover bolts.
Install the bolts (Item 2) [Figure 20-20-76] hand tight.

Place assembly in soft jaw vise and tighten the bolts to
24 - 30 N•m (18 - 22 ft-lb) torque.

TRANSMISSION (CONT’D) Snorkel Gear Backlash
Planetary Differential Assembly (Cont’d) Figure 20-20-81
Snorkel Shaft Assembly (Cont’d)
Figure 20-20-79
1
1
P111679
2
3 After the 13T gear and bearing are pressed onto the
P111681 snorkel shaft (flush to the shoulder), install the washer
and new retaining ring.

Install the bearing (Item 1), shim (Item 2) and snap ring Press the gear back towards the retaining ring. Avoid
(Item 3) [Figure 20-20-79]. excessive force so the retaining ring is not damaged or
pre-stressed significantly.
Figure 20-20-80
Failure to press the gear back against the washer and
retaining ring will lead to a gear backlash change after
vehicle is placed into service.
Apply a small amount of white lithium grease or Anti-

1 Seize on the threads (Item 1) [Figure 20-20-81] of the
snorkel tube.
P111684
Install the shaft (Item 1), shim (Item 2) and snap ring
(Item 3) [Figure 20-20-80].

TRANSMISSION (CONT’D) Install only the three screws (Item 1) [Figure 20-20-83]
that secure the pinion shaft assembly as shown. Leave
Snorkel Gear Backlash (Cont’d) the longer locking screw (Item 2) [Figure 20-20-83] out
at this point.
Figure 20-20-82
Tighten the screws to 11 - 14 N•m (8 - 10 ft-lb) torque.
Rotate the snorkel tube counterclockwise using the

1 snorkel tool (PA-50231) until the snorkel gear and pinion
gear have ‘zero’ backlash.
NOTE: DO NOT over tighten the snorkel tube when

backing it out. At the “zero” backlash
position, you should still be able to turn the
snorkel shaft using your fingers, but it will feel
rough and may have some tight spots.
Look down into the transmission housing to see the

snorkel locking screw hole opening to reference your
P111678 starting point.
NOTE: If you have a hard time seeing into the hole,

Install the snorkel shaft into the gearcase. Using the insert a small Allen wrench, punch or
Snorkel Tool (PA-50231), (Item 1) [Figure 20-20-82] screwdriver into the hole to feel when the

tighten the snorkel tube until it is lightly seated in the notch is aligned with the hole.
transmission housing.
Figure 20-20-84
Inspect the pinion shaft assembly. Replace bearings if
needed. Inspect each gear for damage, chips or
abnormally worn teeth.
NOTE: If pinion shaft was disassembled, the bearing

cover must be installed on the shaft before
installing the 46T gear.
Install the pinion shaft assembly. Be sure to properly 1

mesh the snorkel shaft bevel gear with the pinion shaft
bevel gear.
Figure 20-20-83
P111685
Slowly rotate the snorkel tube clockwise while counting

2 the number of notches passing through the hole opening
(Item 1) [Figure 20-20-84] as you rotate the tube. Rotate
the snorkel tube to the 3rd notch from the ‘zero’ backlash
position earlier obtained.
Check the pinion shaft gear backlash again by feel. If the

1 pinion shaft gear lash appears to be too tight, rotate the
snorkel shaft clockwise to the next notch (4th notch).
P111690
Apply Loctite® 242 to the threads of the bearing cover

retaining screws.

TRANSMISSION (CONT’D) Transmission Assembly
Snorkel Gear Backlash (Cont’d) NOTE: The snorkel shaft and pinion shaft must be
installed prior to transmission assembly. The
Figure 20-20-85 snorkel shaft cannot be installed after
assembling the transmission.
Clean both transmission case halves thoroughly. Inspect

case half mating surfaces for damage.
Figure 20-20-87
1 1
P111676
Once the backlash is set, apply Loctite® 242 to the

threads and install the locking screw (Item 1) [Figure 20-

20-85] to secure the snorkel tube.
P111707
Figure 20-20-86
Install the input shaft seal (Item 1) into the transmission

LH case half. The seal (Item 1) [Figure 20-20-87], should
be pressed in until it is flush with the internal bearing
surface as shown.
P111690
Tighten the locking screw (Item 1) [Figure 20-20-86] to

11 - 14 N•m (8 - 10 ft-lb) torque.

Transmission Assembly (Cont’d)
Figure 20-20-88
2
2
P111689
Install shift fork (Item 1) [Figure 20-20-88] and torsion

spring into transmission housing as an assembly. Load

spring as shown.
Apply Loctite® 242 to the screws (Item 2) [Figure 20-20-

88] and install with retaining plates over shift fork. Tighten
the screws to 10 - 14 N•m (7 - 10 ft-lb) torque.
Slide the engagement dog (Item 3) [Figure 20-20-88] P118477

onto retaining pins of shift fork.
Figure 20-20-89
Assemble the reverse shaft assembly and input shaft
assembly if previously disassembled as shown in [Figure
20-20-89] and [Figure 20-20-90]
Figure 20-20-91
P118476
P118244
Install the idler gear shaft assembly (Item 1) and gear

cluster assembly (Item 2) [Figure 20-20-91] into the
transmission housing at the same time.

Figure 20-20-92
1 1
P118240
Install the shift shaft rail (Item 1)[Figure 20-20-94] and

P118242 shift forks into the transmission housing as an assembly.
Be sure the shift forks are engaged into the engagement
dogs.
Install the rear output shaft assembly (Item 1) [Figure 20-
20-92]. Rotate the output shaft assembly to align slots NOTE: Shift fork pins (Item 2) [Figure 20-20-94]

with engagement dog. Ensure bearing is fully seated should be offset towards the input shaft as
upon assembly. shown above.
Figure 20-20-93 Figure 20-20-95
P111670 P111708
Assemble shift shaft rail if previously disassembled. Inspect the shift drum for any damage or wear. Inspect
the splines (Item 1) [Figure 20-20-95] of the shift drum.
NOTE: Both shift forks need to be orientated the same
way, so that the shift fork pins (Item 1) [Figure
20-20-93] are both offset to the same side of
the rail.

Transmission Assembly (Cont’d) 3
Figure 20-20-96
1
3
2
1
2
P111697
Install new seals into the transmission case halves.

P118474
NOTE: The input shaft seal (Item 1) [Figure 20-20-98],
should have been installed in [Figure 20-20-
Install the shift drum (Item 1) [Figure 20-20-96] into the 87]. The seal must be pressed in until it is
transmission housing. Lift up on the shift shaft rail (Item flush with the internal bearing surface, which

2) and move the rail assembly towards the shift drum to can not be seen with the transmission
allow the shift fork pins to be installed into the shift drum assembled.
(Item 1) [Figure 20-20-96].
The snorkel shaft seal (Item 2) [Figure 20-20-98], should
Figure 20-20-97 be pressed in until it seats against the housing counter-
bore.
The rear output shaft seals (Item 3) [Figure 20-20-98],

can be installed using a standard bushing installation
tool. Seals should be installed just past the case lead-in
1
3 chamfer (1,8 mm or [0.070] inch from outer face of bore).
3 Figure 20-20-99
P111686
NOTE: Six of the case bolts (Item 3) [Figure 20-20-97]

are longer than the rest. These bolts are used
to retain the motor flange at the input shaft
location and to retain the rear mount brackets
to the transmission.
P111709
Apply a gasket eliminator such as Loctite® 518 in a
continuous bead to the left hand transmission mating
surface. Thoroughly clean the shift shaft housing (Item 1) [Figure
20-20-99]. Shift the transmission into High gear to ease
Install the transmission case cover (Item 1) and retaining assembly.
bolts (Item 2) [Figure 20-20-97]. Tighten the bolts to 20 -
27 N•m (15 - 20 ft-lb) torque.

Figure 20-20-100
1
1
3
3 3
2
P111699
3
2
Install the detent star (Item 1) [Figure 20-20-102] onto
P111698 the shift drum shaft. Be sure to install the detent star
(Item 1) [Figure 20-20-102] with the raised edge facing
outward and skip-tooth aligned.
Install the sector gear (16T) (Item 1) [Figure 20-20-100]
onto the shift drum shaft. Install the shift shaft assembly Install the detent pawl (Item 2) onto the shift shaft and

and sector gear (11T) (Item 2) [Figure 20-20-100] into carefully install the compression spring (Item 3) [Figure
the bushing pocket on the left side. Align the timing 20-20-102].
marks (Item 3) [Figure 20-20-100] on the gears as
shown (high gear). Figure 20-20-103
Figure 20-20-101
P111700
P118522
Install a new O-ring (Item 1) [Figure 20-20-103] on each
shift shaft. Apply a small amount of white lithium grease
Install the spacer (Item 1) [Figure 20-20-101] onto the on the O-rings, shift shafts and component contact
shift drum shaft. surfaces prior to installing the sector cover.

Figure 20-20-104
4
1
3 2
P111659
Clean the transmission and gear sector cover mating

surfaces thoroughly.

Apply a gasket eliminator such as Loctite® 518 in a
continuous bead to the cover and transmission case
mating surface.
Install the sector cover (Item 1) [Figure 20-20-104] and

align the transmission case dowel (Item 2) [Figure 20-
20-104] and [Figure 20-20-104] with the alignment hole.
Install the bolts (Item 3) [Figure 20-20-104] and tighten
to 12 - 16 N•m (9 - 12 ft-lb) torque.
Install the drain plug.
Install the bellcrank (Item 4) [Figure 20-20-104] onto the

shift shaft. Note the key splined on the bellcrank and shift
shaft. Tighten the nut to 16 - 24 N•m (12 - 18 ft-lb) torque.

DRIVE BELT Figure 20-30-3
Removal
Stop the machine on a flat level surface. Engage the

parking brake, put the gear selector in gear (L) and stop
the engine.
Allow the belt and clutches to cool.

1
Disconnect the negative battery cable.
Figure 20-30-1
P126796
Reposition the air intake assembly (Item 1) [Figure 20-

30-3] for access to the CVT outer cover.
Figure 20-30-4

1
P126794
1
Loosen the clamp (Item 1) [Figure 20-30-1] and remove

the hose from the air box.
Figure 20-30-2 2
P118589
Remove the eight bolts (Item 1) from the CVT outer cover
(Item 2) [Figure 20-30-4].
1
NOTE: Do not allow the belt to be twisted or turned
inside out. This damages the internal belt
cords and may cause the belt to flip (invert)
during usage. If this happens, the belt must be
replaced.
P126795

DRIVE BELT (CONT’D)
Removal (Cont’d)
IMPORTANT
Figure 20-30-5
Do not use any type of tool to remove the drive belt
from the clutches or drive belt and / or clutch damage
may occur.
I-2333-0510
1
Pull upward and rearward on the belt to open the driven

clutch sleeves.
Pull out and down on the belt (Item 1) [Figure 20-30-6] to

slip the belt over the driven clutch outer sleeve.
Figure 20-30-7
P113518
Remove the CVT outer cover (Item 1) [Figure 20-30-5].

Figure 20-30-6
P113520
Remove the belt from the drive clutch (Item 1) [Figure

1 20-30-7].
P113519
NOTE: Mark the drive belt rotation. If reusing the

existing belt, it must be reinstalled so that it
rotates in the same direction.

inside out. This damages the internal belt
cords and may cause the belt to flip (invert)
during usage. If this happens, the belt must be
replaced.

DRIVE BELT (CONT’D) Belt Inspection
Installation Inspect the belt for hourglass (extreme circular wear in at

least one spot and on one side of the belt). Hour glassing
Place the machine on a flat and level surface with the occurs when the drive train does not move and the drive
engine off. clutch engages on the belt.
Disconnect the (-) negative battery cable before installing Inspect belt for loose cords, missing cogs, cracks,
or removing the belt. abrasion, thin spots, or excessive wear. Compare belt
measurements with a new belt. Replace as needed.
Block the wheels so the machine will not roll. Put the gear
selector in neutral (N). Belts with thin spots, burn marks, etc. should be replaced
to eliminate noise, vibration, or erratic CVT operation.
Figure 20-30-8
Figure 20-30-9

2
P113519
P-97377

inside out. This damages the internal belt Make sure the belt can be rotated by hand and that the
cords and may cause the belt to flip (invert) drive clutch is fully open and the driven clutch is in the
during usage. If this happens, the belt must be closed position.
replaced.
To check belt deflection (stretch), place a straight edge
If installing the existing belt, make sure it is being (Item 1) over the top of the belt. Press down in the center
installed in the correct rotation direction. of the belt until lightly tensioned and measure (Item 2)
[Figure 20-30-9] the belt deflection.
If installing a new belt, install the belt so the numbers on
the belt are readable when installed. The correct deflection is 29 - 32 mm (1.12 - 1.25 in).
Loop the belt over the drive clutch and over the top of the If the belt deflection is out of range, either install a new
driven sheave [Figure 20-30-8]. belt or the driven clutch will need to be adjusted.
While pushing down on the top of belt, turn the back or

movable driven sheave clockwise [Figure 20-30-8] until
the belt is installed.
Reinstall the CVT cover.
Installation: Tighten the bolts to 5 - 5,6 N•m (45 - 50 in-

lb) torque.
Reconnect the negative battery cable.

DRIVE BELT (CONT’D) Glazing
Belt Damage Figure 20-30-11
The following section discusses and illustrates several

types of damage that can occur to the vehicle’s drive belt
due to abuse or misuse which are not covered under the
vehicle warranty.
Hour Glassing / Spin Burning

1
Figure 20-30-10
P-97555
1
The belt (Item 1) [Figure 20-30-11] has been
overheated, causing it to melt and be shiny in
appearance.
Glazing is usually caused by belt slippage due to an oil

contaminated belt, inadequate belt break-in or improper
gear selection for the application.
1
P-97554
Ensure that the drive system is setup properly. Consider

using low gear when pulling a load or driving up a slope.
When the belt is worn narrow or uneven (Item 1) [Figure Make certain that the clutch sheaves and belt are clean
20-30-10] in one section is commonly referred to as “hour and free of contamination. Review proper belt break-in
glassed or spin burned”. procedure.
This is caused as a result of heat that is generated when

the drive clutch is spinning and the belt remains
stationary. This type of failure can be caused when the
belt to sheave clearance is incorrect, belt deflection is
inadequate, an improper gear is selected or the drive
system is locked and / or jammed. Typical reasons for this
type of damage are from overloading the belt by
operating in high gear when trying to pull a heavy load
(such as a trailer), push a heavy load (such as a snow
blade), or climb a grade (such as loading a vehicle on a
trailer).
Verify that the correct belt is on the machine and the

correct gear for the application is selected. Adjust
deflection and ensure belt to sheave clearance is correct.
See that the drive system moves freely before installing a
new belt, repair if needed.

DRIVE BELT (CONT’D) Broken Cord
Belt Damage (Cont’d) Figure 20-30-13
Broken Belt
Figure 20-30-12
2
1
P-97557
P-97556
A frayed cord (Item 1) is shown in the first stage of failure.

Shock loading the drive belt (Item 1) [Figure 20-30-12] The cord (Item 2) [Figure 20-30-13] has been severed
will often cause breakage. and has begun unraveling.

Shock loading can be caused by excessive engagement This failure is caused by extreme heat and friction on the
rpm, incorrect belt (causes binding on the bottom of the side of the belt from clutch misalignment, excessive
secondary), improper gear selected for application, speeds or by an improper belt break-in procedure. As the
clutch center to center distance being too long, or heat melts away the edge of the belt, the cords become
jammed / locked drive train. Driving at top speed or in exposed and are slowly pulled out by the constant
high gear for extended periods can also cause belt scrubbing of the clutch sheaves
breakage.
Align clutches to the proper offset, reduce idle speed and
Verify that the correct belt is being used and the drive review proper belt break-in procedure. Do not continue
train moves freely without resistance. Ensure that using this belt as further use will cause the belt to
engagement rpm is appropriate, clutch center to center disintegrate.
distance is correct, and correct gear is being used for the
application. Avoid traveling at top speed for extended
periods of time.

DRIVE BELT (CONT’D) Disintegration
Belt Damage (Cont’d) Figure 20-30-15
Flex Cracks Between Cogs

1
Figure 20-30-14
1 P-97558
P-97559
The drive belt is cracked on the inner cogs (Item 1) The drive belt (Item 1) [Figure 20-30-15] has been
[Figure 20-30-14]. abused and / or used beyond it’s capabilities.
This type of failure can occur if the belt is out of service This type of failure can be caused by different belt

limit, flexed in extremely cold weather or turned inside out conditions, such as: hour glassing, glazing, broken cords,
at any time. flex cracks or misalignment.
Do not use belts that are out of spec and never turn a belt Verify the correct belt is used. Check deflection and belt
inside out. In extremely cold weather, warm the belt to sheave clearance. Ensure that the proper gear was
before use by engaging the park brake and putting the selected for the application and that the belt and sheaves
gear selector in NEUTRAL, slightly increase engine RPM are clean. Review proper belt break-in procedure. Never
and allow the belt to rotate on the clutches for a few turn the belt inside out.
minutes to warm the belt.

CONTINUOUS VARIABLE TRANSMISSION (CVT) Driven Clutch Operation
CVT System Overview Driven clutches primarily sense torque, opening and
closing according to the forces applied to it from the drive
belt and the transmission input shaft. If the torque
resistance at the transmission input shaft is greater than
WARNING the load from the drive belt, the drive belt is kept at the
outer diameter of the driven clutch sheaves.
All CVT maintenance or repairs should be performed As engine rpm and horsepower increase, the load from
by a certified Bobcat technician who has received the drive belt increases, resulting in the belt rotating up
the proper training and understands the procedures toward the outer diameter of the drive clutch sheaves and
outlined in this manual. Because of the critical nature downward into the sheaves of the driven clutch. This
and precision balance incorporated into the CVT action, which increases the driven clutch speed, is called
components, it is absolutely essential that no upshifting.
disassembly or repair be made without factory
authorized special tools and service procedures. Should the throttle setting remain the same, and the
W-2860-0510 vehicle is subjected to a heavier load, the drive belt
rotates back up toward the outer diameter of the driven
clutch and downward into the sheaves of the drive clutch.
The Continuous Variable Transmission (CVT) consists of This action, which decreases the driven clutch speed, is
three major assemblies: called backshifting.
1) The Drive Clutch In situations where loads vary (such as uphill and

downhill), and throttle settings are constant, the drive and
2) The Driven Clutch driven clutches are continually shifting to maintain
optimum engine rpm. At full throttle a perfectly matched
3) The Drive Belt CVT system should hold engine rpm at the peak of the
power curve. This rpm should be maintained during
The internal components of the drive clutch and driven clutch upshift and backshift. In this respect, the CVT
clutch control engagement (initial vehicle movement), system is similar to a power governor. Rather than vary
clutch upshift and backshift. During vehicle development, throttle position, as a conventional governor does, the
the CVT system is matched first to the engine power CVT system changes engine load requirements by either
curve; then to average riding conditions and the vehicle’s upshifting or backshifting.
intended usage. Therefore, modifications or variations of
components at random are never recommended. Proper CVT Break-In (Drive Belt / Clutches)
clutch setup and careful inspection of existing
components must be the primary objective when A proper break-in of the clutches and drive belt will
troubleshooting and tuning. ensure a longer life and better performance. Break in the
clutches and drive belt by operating at slower speeds
Drive Clutch Operation during the 10 hour break-in period as recommended. Pull
only light loads. Avoid aggressive acceleration and high
Drive clutches primarily sense engine rpm. The two speed operation during the break-in period.
major components which control its shifting function are
the shift weights and the coil spring. Whenever engine
rpm is increased, centrifugal force is created, causing the
shift weights to push against rollers on the moveable
sheave, which is held open by coil spring preload. When
this force becomes higher than the preload in the spring,
the outer sheave moves inward and contacts the drive
belt. This motion pinches the drive belt between the
spinning sheaves and causes it to rotate, which in turn
rotates the driven clutch.
At lower rpm, the drive belt rotates low in the drive clutch
sheaves. As engine rpm increases, centrifugal force
causes the drive belt to be forced upward on drive clutch
sheaves.

(CONT’D)
Maintenance And Inspection
Under normal use the CVT system will provide years of

trouble free operation. Periodic inspection and
maintenance is required to keep the system operating at
peak performance. The following list of items should be
inspected and maintained to ensure maximum
performance and service life of CVT components. For
more information (See System Troubleshooting on Page
20-20-2.)
Belt Tension, Drive to Driven Clutch Alignment / Offset,

and Belt Inspection.
Drive and Driven Clutch Buttons and Bushings, Drive

Clutch Shift Weights and Pins, Drive Clutch Spider
Rollers and Roller Pins, Drive and Driven Clutch Springs.
Sheave Faces. Clean and inspect for wear.
CVT System Sealing. Refer to appropriate illustrations on

the following pages. The CVT system is air cooled by fins
on the drive clutch stationary sheave. The fins create a
low pressure area in the crankcase casting, drawing air
into the system through an intake duct. The opening for
this intake duct is located at a high point on the vehicle
(location varies by model). The intake duct draws fresh
air through a vented cover. All connecting air ducts (as
well as the inner and outer covers) must be properly
sealed to ensure clean air is being used for cooling the
CVT system and also to prevent water and other
contaminants from entering the CVT area. This is
especially critical on units subjected to frequent water
forging.

CONTINUOUS VARIABLE TRANSMISSION (CVT) (CONT’D)
Overheating Troubleshooting During routine maintenance, or when ever CVT system

overheating is evident, it’s important to check the inlet
and outlet ducting for obstructions. Obstructions to air
flow through the ducts will significantly increase CVT
WARNING system operating temperatures. The vehicle should be

operated in Low when plowing or pulling heavy loads, or
if extended low speed operation is anticipated.
death.
W-2408-0801
CLUTCH DRIVE BELT AND COVER RELATED ISSUES: DIAGNOSIS

POSSIBLE CAUSES SOLUTIONS
Loading the vehicle into a truck or tall Shift transmission to Low during loading of the vehicle to prevent belt

trailer when in high range. burning.
Starting out going up a steep incline from a
When starting out on an incline, shift the transmission to Low.
stopped position.
Driving at a low rpm or low ground speed Drive at higher speed or use Low. The use of Low is highly recommended
(at approximately 5 - 11 km/h (3 - 7 mph). for cooler CVT operating temperatures and longer component life.
Warm engine at least 5 minutes, then with transmission in neutral, advance
Insufficient engine warm-up when exposed
throttle to approx. 1/8 throttle in short bursts, 5 - 7 times. The belt will
to low ambient temperatures.
become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Towing / Pushing at low rpm / low ground
Use Low only.
speed.
Plowing snow, dirt, etc. / utility use. Use Low only.
Shift the transmission to Low, carefully use fast, aggressive throttle
Stuck in mud or snow. application to engage clutch. WARNING: Excessive throttle may cause loss
of control and vehicle overturn.
Shift the transmission to Low, carefully use fast, aggressive, brief throttle
Climbing over large objects from a stopped
application to engage clutch. WARNING: Excessive throttle may cause loss
position.
of control and vehicle overturn.
Remove the CVT drain plug. Shift the transmission to Neutral. Using the
throttle, vary the engine rpm from idle to full throttle. Repeat several times
Belt slippage from water or snow ingestion
as required. During this procedure, the throttle should not be held at the full
into the CVT system.
position for more than 10 seconds. Clutch seals should be inspected for
damage if repeated leaking occurs.
For inspection of clutch components, please contact your dealer. Shift
Clutch malfunction.
transmission to Low during loading of the vehicle to prevent belt burning.
Fouled spark plug, foreign material in fuel tank, restricted fuel lines, or faulty
Poor engine performance.
fuel injector.
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding
GENERAL RANGE OPERATION
through rough terrain (swamps, mountains, etc.), low ground speeds.
GUIDELINES:
High: High ground speeds, speeds above 7 MPH.

ENGINE
PROBLEM CAUSE SOLUTION
Wrong or broken drive clutch spring. Replace with recommended spring.
Engine rpm below specified Drive clutch shift weight too heavy. Install correct shift weight kit to match engine
operating range, although application.
engine is properly tuned Driven clutch spring broken or installed in Replace spring; refer to proper installation
wrong helix location. location.
Drive clutch Binding. A. Disassemble drive clutch; inspect shift
weights for wear and free operation.
B. Clean and polish stationary shaft hub;
reassemble clutch without spring to
Erratic engine operating rpm
determine problem area.
during acceleration or load
Belt worn unevenly - thin / burnt spots. Replace belt.
variations
Driven clutch malfunction. A. Replace ramp buttons.
B. Inspect moveable sheave for excessive
bushing clearance.
Sheave face grooved. Replace the clutch
Incorrect drive clutch spring (too high spring Install correct recommended spring.
rate).

Drive clutch shift weights incorrect for Install correct recommended shift weights.
application (too light).
Drive clutch binding. Disassemble and clean clutch, inspecting
shift weights and rollers. Reassemble
Engine rpm above specified without the spring and move sheaves
operating range through entire range to further determine
probable cause.
Driven clutch binding. Disassemble, clean, and inspect driven
clutch, noting worn sheave bushing and
ramp buttons and helix spring location.
Converter sheaves greasy; belt slippage. Clean sheaves with denatured alcohol or
brake cleaner, install new belt.
Drive belt worn too narrow. Replace belt.
Harsh drive clutch
Excessive belt / sheave clearance with new Perform belt / sheave clearance adjustment
engagement
belt. with shim washers beneath spider.
Wrong belt for application. Replace with correct belt.
Drive belt turns over Clutch alignment out of spec. Adjust alignment offset.
Engine mount broken or loose. Inspect / adjust or replace.
Abuse (continued throttle application when Caution operator to operate machine within
vehicle is stationary, excess load) guidelines.
Dragging brake. Vehicle operated with park brake on. Inspect
Belt burnt, thin spots
brake system.
Slow, easy clutch engagement. Fast, effective use of throttle for efficient
management.
Plugged air intake or outlet. Clear obstruction.
Belt slippage due to water, oil, grease, etc., Inspect system. Clean, repair or replace as
rubbing on cover. necessary. Seal CVT system ducts.
Clutches or weight being applied to cover Remove weight. Inform operator.
CVT cover overheating
while in operation.
(melting)
High vs. low range. Instruct operator on guidelines for operation
in proper driving range for different terrain as
outlined in the Operation & Maintenance
Manual.

System Troubleshooting (Cont’d)
ENGINE
PROBLEM CAUSE SOLUTION
Cover seals or ducts leaking. Find leak and repair as necessary.
Operator error. Instruct operator on guidelines for operation
Water ingestion
in wet terrain as outlined in the Operation &
Maintenance Manual.
Belt worn out. Replace belt.
Belt slippage Water ingestion. Inspect and seal CVT system.
Belt contaminated with oil or grease. Inspect and clean.
Belt worn or separated, thin spots, loose Replace belt.
belt.
CVT noise
Broken or worn clutch components, cover Inspect and repair as necessary.
hitting clutches.
Thin spots on belt, worn belt. Replace belt. Refer to belt burnout
Engagement erratic or
troubleshooting and instruct operator.
stabby
Drive clutch bushings stick. Inspect and repair clutches.

CVT Sealing, Guard And Ducting Components Parts Identification

1. Air Intake Hose
2. Clamp
3. Screw (2)
4. Air Duct
5. Intake Hose
6. Screw (4)
7. Air Duct
8. Seal
9. Inner Cover
10. Bracket
11. Air Outlet Duct
12. Cover Seal 14
16
13. Outer Cover
14. O-Ring
11
15. Screw (8) 2
16. Drain Plug
15

13
9 12
8 10
1
7 2
4 3
2
6 5
P126754

CONTINUOUS VARIABLE TRANSMISSION (CVT) Figure 20-40-3
(CONT’D)
CVT (Outer) Cover Removal And Installation
Figure 20-40-1
P126796
Reposition the air intake assembly (Item 1) [Figure 20-

1 40-3] for access to the CVT outer cover.
Figure 20-40-4
P126794

Loosen the clamp (Item 1) [Figure 20-40-1]and remove
the hose from the air box. 1
Figure 20-40-2
1
2
P118589
Remove the bolts (Item 1) [Figure 20-40-4].
Remove the outer cover (Item 2) [Figure 20-40-4].
P126795

(CONT’D)
CVT (Inner) Cover Removal And Installation
Remove the seat.
Raise the rear cargo box.
Remove the outer CVT cover. (See CVT (Outer) Cover

Remove the drive belt. (See Removal on Page 20-30-1.)
Remove the drive clutch. (See Removal And Installation

on Page 20-41-1.)
Remove the driven clutch. (See Removal And Installation

on Page 20-42-1.)
Figure 20-40-5

1
1
P118595
Remove the bolts (Item 1) [Figure 20-40-5] retaining the

inner cover.
Inspect the inner cover. Replace if cracked or broken.
Inspect inner clutch cover seal (engine side). Replace if

cracked, torn or damaged.
Place a new seal on transmission input shaft.

(DRIVE CLUTCH)
Removal And Installation
Raise the rear cargo box.

Order drive clutch puller (PN PA-48595).
Figure 20-41-1
P-99313
Remove the plastic bushing (Item 1) [Figure 20-41-2]

from the drive clutch.
Installation: Inspect the plastic bushing for wear or

damage and replace if needed.

Figure 20-41-3
1
P-99290
Remove the drive clutch retaining bolt (Item 1) [Figure

20-41-1].
Installation: Tighten the retaining bolt to 64 N•m (47 ft-

lb) torque.
1
P-99313A
Remove the drive clutch using the drive clutch puller

(Item 1) [Figure 20-41-3].
Installation: Clean the crankshaft taper and taper bore

inside the drive clutch.

(DRIVE CLUTCH) (CONT’D)
Spring Specifications
The drive clutch spring has two primary functions:
To control clutch engagement rpm. The springs, which

have a higher rate when the clutch is in neutral, will
increase clutch engagement rpm.
To control the rate at which the drive belt moves upward

in the drive clutch sheaves. This is referred to as drive
clutch upshift.
There are other components which control upshift, but

the spring is one of the primary components in ensuring
optimum performance. It is very important that the spring
is of the correct design and is in good condition.

CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH) (CONT’D)
1. Fixed Sheave
2. Thrust Washer
3. Brass Bushing (Teflon™ Coated)
4. Movable Sheave
5. Spider
6. Spring
7. Cover (Bearing)
8. Plastic Bushing
9. Washer
10. Star Washer
11. Bolt
12. Button
13. Pin
14. Roller
15. Nut
16. Shift Weight
17. Bearing
11
18. Spacer
10
9

7 8
3
5
6
4
11
12
3
13
18 9
2 14
17 9
2 12
1
15
16
11
NA5663S

Disassembly
IMPORTANT
The clutch assembly is a precisely balanced unit.
Never replace parts with used parts from another 1
clutch assembly.
I-2323-0510
P-99778
Figure 20-41-4
Inspect cover bushing (Item 1) [Figure 20-41-5]. The

outer cover bushing is manufactured with a Teflon™
coating. Bushing wear is determined by the amount of
1 Teflon™ remaining on the bushing.
Cover Bushing Inspection: Replace the cover bushing if

more brass than Teflon™ is visible on the bushing.
Figure 20-41-6
P-99471
2
Using a permanent marker, mark the cover, spider,
movable and stationary sheaves, and steel post to the
stationary sheave for reference [Figure 20-41-4].
Mark the stationary sheave and clutch shaft to verify the

shaft has not turned in the sheave after tightening the
spider during clutch assembly.
P-99473
Remove cover bolts (Item 1) [Figure 20-41-4] evenly in a
cross pattern, and remove cover plate.
Remove the clutch spring (Item 1) [Figure 20-41-6].
Inspect the area on shaft (Item 2) [Figure 20-41-6] where

bushing rides for wear, galling, nicks or scratches.
Replace clutch assembly if worn or damaged.

CONTINUOUS VARIABLE TRANSMISSION (CVT) Drive Clutch Spring Inspection
Disassembly (Cont’d)
Bearing Inspection
IMPORTANT
Figure 20-41-7
Never shim a drive clutch spring to increase its
compression rate. This may result in complete
stacking of the coils and subsequent clutch cover
failure.
I-2322-0510
The drive clutch spring is one of the most critical

components of the CVT system. It is also one of the
easiest to service. Due to the severe relaxation the spring
is subject to during operation, it should always be
inspected for tolerance limits during any clutch operation
diagnosis or repair.
1
Figure 20-41-8
P118599

Rotate the clutch bearing (Item 1) [Figure 20-41-7] in
both clockwise and counterclockwise directions. The
non-braking bearing should rotate both directions on the
shaft with only a slight amount of drag.
Verify there is no binding or rough spots.
P-99469
With the spring resting on a flat surface, measure its free

length from the outer coil surfaces as shown. The spring
free length is 91,8 mm (3.614 in). Also check to see that
spring coils are parallel to one another. Distortion of the
spring indicates stress fatigue, requiring replacement
[Figure 20-41-8].

CONTINUOUS VARIABLE TRANSMISSION (CVT) Button To Tower Clearance Inspection
Figure 20-41-11
Shift Weight Inspection
Figure 20-41-9
2 P118597
1
Inspect for any clearance between spider button to tower.

If clearance exceeds specification, replace all buttons
P-99908 and inspect surface of towers [Figure 20-41-11].

Button To Tower Clearance:
Remove the nut (Item 1), bolt (Item 2) and shift weight
(Item 3) [Figure 20-41-9] from the movable sheave.
Service Limit 0 - 0,127 mm (000 - 0.005 in)
Figure 20-41-10
Inspect sheave surfaces. Replace the entire clutch if
worn, damaged or cracked.
2
1
P-99909
Inspect the shift weight (Item 1) and bolt (Item 2) [Figure

20-41-10] for damage or wear and replace as needed.
NOTE: A damaged shift weight is usually caused by a

damaged or stuck roller in the spider
assembly.
Installation: Tighten the nut to 5,6 N•m (50.0 in-lb)

torque.

Disassembly (Cont’d) 1
Spider Removal
Order clutch holding fixture (PN 2871358-B).
Order spider removal tool (PN 2870341).
Figure 20-41-12
P-99904
Remove the spider (Item 1) [Figure 20-41-14] from the

clutch assembly.
1
NOTE: To maintain proper clutch balance and belt-to-
sheave clearance, be sure to install the
original quantity and thickness of washers /

spacers beneath the spider during assembly.
P-99902 Figure 20-41-15
1
Install the holding fixture (PN 2871358-B) (Item 1)
[Figure 20-41-12] in a vise.
Figure 20-41-13
P118598
Inspect the Teflon™ coating on the movable sheave

bushing (Item 1) [Figure 20-41-15] from the clutch
assembly.
P-99903
Replace the bushing if more brass than Teflon™ is visible
on the bushing.
Install clutch in holding fixture and loosen the spider
(counterclockwise) using spider removal tool (PN
2870341) (Item 1) [Figure 20-41-13].

Roller, Pin And Thrust Washer Inspection
Figure 20-41-16
1 4 2 3 2 1
P-99907
1 Remove the buttons (Item 1), thrust washers (Item 2),

roller (Item 3) and roller pin (Item 4) [Figure 20-41-17]
from the spider. Check for wear or damage and replace
as needed.
P-99905
NOTE: The roller pin must be clean and free of any

residue. Do not lubricate these components.
Inspect all rollers, bushings and roller pins by pulling a
flat metal rod across the roller (Item 1) [Figure 20-41-16].
Turn roller over with your finger. If you notice resistance,
galling, or flat spots, replace rollers, pins and thrust
washers in sets of three. Also inspect to see if roller and
bushing are separating. Bushing must fit tightly in roller.
Use the Roller Pin Tool (PN 2870910) to replace rollers
and pins. Take care not to damage roller bushing or
bearing surface of the new pin during installation.

Clutch Inspection 2
Figure 20-41-18
2
1
1
P118639
Lift the bearing (Item 1) and DuPont™ Vespel® washers

(Item 2) [Figure 20-41-20] of the shaft. If any parts are
worn or damaged replace as an assembly.
P118640 Measure the thickness of the Vespel® washers. Replace

if they exceed the minimum service limit of 0.64 mm

(0.025 in).
Remove the movable clutch sheave spacer (Item 1)
[Figure 20-41-18]. Inspect for damage and wear. Figure 20-41-21
Figure 20-41-19
P118642
P118641
Inspect the shaft surface (Item 1) [Figure 20-41-21] for
pitting, grooves or damage.
Remove the movable sheave (Item 1) [Figure 20-41-19].
Inspect for damage and wear. Measure the outside diameter. Replace the drive clutch
assembly if shaft is worn beyond the service limit of
34,86 mm (1.372 in).

CONTINUOUS VARIABLE TRANSMISSION (CVT) Bushing Service
Figure 20-41-23
2 3 5
Movable Sheave Bushing Inspection
Figure 20-41-22
9
10
8
1 P118647
Clutch Bushing Replacement Tool Kit (2871226) [Figure

20-41-23].
P118648
ITEM QTY PART DESCRIPTION PART #

2 1 P-90 Drive/Driven Clutch 5020628
Inspect the Teflon™ coating on the movable sheave
Bushing Install Tool
bushing (Item 1) [Figure 20-41-22]. Inspect both
sheaves for signs of wear, grooving or cracking. De-glaze 3 1 Drive Clutch Cover Bushing 5020629
sheave surfaces with a 3M Scotch-Brite™ Pad if needed. Removal/Installation Tool
5 1 P-90 Driven Clutch Cover 5020631
Bushing Removal Tool
8 1 Main Puller Adapter 5020632
9 1 Adapter Reducer 5010279
10 1 Number two puller Adapter 5020633
NOTE: Bushings are installed at the factory using

Loctite®. In order to remove bushing it will be
necessary to apply heat evenly to the area
around each bushing. Clean all residual
Loctite® from bushing bore prior to installing
new bushings.

Movable Sheave Bushing Removal And Installation
Order piston pin puller (PN 2870386).
A bushing replacement tool kit is available, order

(2871226). 2
Figure 20-41-24
P-99481
Insert the Number Two Adapter (#10) (Item 1) into the

bushing from belt side as shown. With towers pointing
toward vise, slide sheave (Item 2) [Figure 20-41-25] and
bushing onto puller rod.
2 Figure 20-41-26

1
P-99478
1
Install handle end of the piston pin puller (Item 1) [Figure
20-41-24] securely into bench vise and lightly grease
puller threads.
Remove nut from puller rod and set aside.
Install the main puller adapter (#8) (Item 2) [Figure 20-

41-24] onto the piston pin puller.
P-99482
Install the nut (Item 1) [Figure 20-41-26] removed earlier

onto end of puller rod and hand tighten. Turn puller barrel
to increase tension on sheave if needed. Nut is left hand
thread.
Turn sheave and puller barrel together counterclockwise

on puller rod until bushing is removed.
Pull bushing removal tool and adapter from puller rod.

Remove bushing from tool and discard.

Movable Sheave Bushing Removal And Installation

(Cont’d)
Figure 20-41-27
P-99483

Installation: Place the Main Puller Adapter (#8) (PN
5020632) onto the puller.
Installation: Apply Loctite® 680 to the back side of new

bushing. Push bushing into center of sheave on tower
side by hand.
Installation: Insert the Clutch Bushing Installation Tool

(#2) into center of sheave and with towers pointing away
from vise, slide sheave onto puller rod. Install nut (Item 1)
[Figure 20-41-27] on puller rod and hand tighten. Turn
barrel to apply additional pressure if needed.
Installation: Turn clutch cover and barrel together

counterclockwise on puller rod until bushing is seated.
Remove nut from puller rod and take installation tool and
clutch cover off the rod.

Clutch Cover Bushing Removal And Installation
Order piston pin puller (PN 2870386).
A bushing replacement tool kit is available, order (PN

2871226).
Figure 20-41-28
P-99484
From outside of clutch cover, insert the drive cover

bushing remover (#3) (Item 1) [Figure 20-41-29] into the
cover bushing. With inside of cover toward vise, slide
cover onto puller.
2 Figure 20-41-30

1
P-99478
1
Install the main puller adapter (#8) (Item 2) [Figure 20-
41-28] onto the piston pin puller.
Install handle end of the piston pin puller (Item 1) [Figure

20-41-28] securely into bench vise and lightly grease
puller threads.
P-99485
Insert nut (Item 1) [Figure 20-41-30] onto puller rod and

hand tighten. Turn puller barrel to increase tension as
needed.
Turn clutch cover counterclockwise on puller rod until

bushing is removed.
Remove bushing and bushing removal tool from puller

rod. Discard the bushing.

Clutch Cover Bushing Removal And Installation (Cont’d)
Figure 20-41-31
1
P-99487
Installation: Install nut (Item 1) [Figure 20-41-32] on

puller rod and hand tighten. Turn puller barrel to apply
P-99486 more pressure if needed.
Installation: Turn clutch cover and barrel together

Installation: Apply Loctite® 680 to the back side of new counterclockwise on puller rod until bushing is seated.
bushing. Working from inside of cover, insert bushing and

Remove nut from puller rod and take installation tool and
bushing installation tool into center of clutch cover. clutch cover off the rod.
Installation: Place the Main Puller Adapter (#8) (PN

5020632) (Item 1) [Figure 20-41-31] onto the puller,
insert cover onto puller rod, placing outside of cover
toward vise.

Assembly
Order clutch holding fixture (PN 2871358-B).
Order spider removal tool (PN 2870341).
Reassemble the drive clutch in the following sequence.

Be sure the marks that were made earlier are aligned
during each phase of assembly.
1
Figure 20-41-33
P-99908
2
Install shift weights using new locknuts on the bolts. The

nuts (Item 1) [Figure 20-41-35] must be installed on the
machined surface side.
1
Figure 20-41-36

P-99793
1
2
Place the fixed sheave (Item 1) onto the holding fixture
and install the nut (Item 2) [Figure 20-41-33].
Figure 20-41-34
1 P104385
2 Place the movable sheave (Item 1) [Figure 20-41-36]

1 onto the fixed sheave.
Place the spacer (Item 2) [Figure 20-41-36] onto the

fixed sheave.
NOTE: The Teflon™ bushing on the movable sheave

is self-lubricating. Do not apply oil or grease
to the bushing.
P104382
Place the thrust washers (Item 1) and bearing (Item 2)

[Figure 20-41-34] onto the fixed sheave.

Assembly (Cont’d)
IMPORTANT
Figure 20-41-37
Be sure the spider spacer washers are fully seated in
the recessed area in the spider. Any misalignment
will alter clutch balance. Inverting the clutch while
initially tightening the spider will help position the
washers.
I-2324-0510
Figure 20-41-39
1 4 2 3 2 1
P-99907
Assemble the buttons (Item 1), thrust washers (Item 2),

roller (Item 3) and roller pin (Item 4) [Figure 20-41-37]

onto the spider. Take care not to damage roller pin or 2
roller or bearing surface of the new pin during installation.
NOTE: The roller pin must be clean and free of any 3

P-99903
residue. Do not lubricate these components.
NOTE: The rubber side of the button is positioned Using the spider tool (PN 2870341) (Item 1) tighten the
toward the rubber roller pin. spider to 393 N•m (290 ft-lb) torque. Torque with smooth
motion to avoid damage to the stationary sheave. Make
Figure 20-41-38 sure that the marks (Item 2) made earlier on spider and
movable sheave align with the mark that was made
earlier in the stationary sheave (Item 3) [Figure 20-41-
39].
1
P-99904
Place the spider (Item 1) [Figure 20-41-38] onto the fixed

sheave shaft. Compress spider buttons for each tower
and install spider, making sure that the marks that were
made earlier on spider align with the marks that were
made earlier in the movable sheave.

Assembly (Cont’d)
Figure 20-41-40
P-99473
Reinstall the clutch spring (Item 1) [Figure 20-41-40].

Figure 20-41-41
2 1
P-99471
Reinstall cover (Item 1) [Figure 20-41-41] aligning the

mark with the other marks.
Install the bolts (Item 2) and tighten evenly in a cross

pattern to 12 N•m (9 ft-lb) torque.
NOTE: An assistant may be needed to hold down on

the cover while the bolts are installed.


(DRIVEN CLUTCH)

Figure 20-42-1
1
P118432
2 Installation: Clean the splines inside the driven clutch

1 and on the transmission input shaft (Item 1) [Figure 20-
42-2]. Apply a light film of grease to the splines on the
shaft.
Figure 20-42-3

3
P118425
1
Remove the bolt (Item 1), lock washer (Item 2), washer
and driven clutch (Item 3) [Figure 20-42-1].
Installation: Tighten the bolt to 52 N•m (38 ft-lb) torque.
P118651
Mark the position of the clutch sleeves before

disassembly or use the X’s (Item 1) [Figure 20-42-3] on
the sheaves for reference. This aids in reassembly and
maintains clutch balance after assembly.

CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH) (CONT’D)
1. Screw
2. Retainer Plate
3. Spring Cup
4. Compression Spring
5. Movable Sheave
6
7
8
9
10 7 8
6

6. Clutch Roller
7. Thrust Washer
8. Retaining Clip
4
9. Thrust Washer
10. Stationary Clutch 5
3
1
P126755

(DRIVEN CLUTCH) (CONT’D)
Disassembly
WARNING 2

• Pressurized fluids and springs or other stored
energy components. 1
• Engine is running. P118652
• Tools are being used.
W-2505-0604
Remove the cover plate (Item 1), spring cup (Item 2)
[Figure 20-42-5] and spring.
Figure 20-42-4
Figure 20-42-6

1
2 1
3
P118649
P120043
Place the driven clutch into the Universal Clutch
Compressor (Item 1) [Figure 20-42-4].
Remove stationary sheave and note the number of
spacer washers (Item 1) [Figure 20-42-6].
Spin the handle down to apply downward pressure on the
spring cup (Item 2) [Figure 20-42-4].
Remove the five retaining ring fasteners (Item 3) [Figure

20-42-4].
Use care when removing the compressor tool. The spring

cup is under spring pressure. Remove the compressor
tool.

CONTINUOUS VARIABLE TRANSMISSION (CVT) Assembly
(DRIVEN CLUTCH) (CONT’D)
Align the reference or “X” marks on each of the sheaves
Disassembly (Cont’d) during reassembly.
Figure 20-42-7 Assemble the clutch sheaves.
Position the spring, spring cup and retaining plate into the
moveable sheave. Do not apply oil or grease to the
bearings.
Place the clutch into the universal clutch compressor.

1 Apply downward pressure on the spring cup.
Install the bolts and tighten to 12 - 16 N•m (9 - 12 ft-lb)

torque.
P118427
Inspect the rollers (Item 1) [Figure 20-42-7] in the

stationary sheave. If rollers are worn replace the driven
clutch assembly.
Inspect driven clutch sheave faces for wear or damage.
Clean and inspect splines on helix and transmission input

shaft.
Lube splines with a light film of grease. Do not lubricate

the bearings.

FINAL DRIVE Bearing Carrier Removal
Description Lift and block the machine. (See LIFTING AND

Care should be exercised during drive shaft removal or
when servicing CV joints. Drive shaft components are
precision parts.
Cleanliness and following these instructions is very WARNING

important to ensure proper shaft function and a normal
service life.
Serious injury may result if machine tips or falls. Be
sure machine is secure before beginning this service
• The complete drive shaft and joint should be handled
procedure. Wear eye protection when removing
by getting hold of the interconnecting shaft to avoid
bearings and seals.
disassembly or potential damage to the drive shaft W-2863-0510
joints.
• Over-angling of joints beyond their capacity could Figure 20-50-1

result in boot or joint damage.
• Make sure surface-ground areas and splines of shaft

are protected during handling to avoid damage.
• Do not allow boots to come in contact with sharp

edges or hot engine and exhaust components.
• Drive shaft is not to be used as a lever arm to position

other suspension components.
• Never use a hammer or sharp tools to remove or to

install boot clamps.
• Be sure joints are thoroughly clean and that the P113787

proper amount and type of grease is used to refill
when joint boots are replaced and when joints are
Check bearings for side play by grasping the tire / wheel
cleaned.
firmly and checking for movement. Grasp the top and
bottom of the tire. The tire should rotate smoothly without
binding or rough spots [Figure 20-50-1].
NOTE: Side to side play could also indicate tie rod

end wear and top to bottom play could also
indicate upper or lower ball joint wear. Be
sure to closely inspect these components if
play is found.

FINAL DRIVE (CONT’D) Figure 20-50-4
Bearing Carrier Removal (Cont’d)
Figure 20-50-2
3
2
2
P112380
1
Remove the cotter pin (Item 1), castle nut (Item 2) and
P111532 washers (Item 3) [Figure 20-50-4].
Figure 20-50-5
Remove the center cap and / or rubber dust cap. Remove
the cotter pin (Item 1) and loosen the front wheel hub

castle nut (Item 2) [Figure 20-50-2].
NOTE: Lower the vehicle so the front wheels are on

the ground to prevent the wheel from
spinning while attempting to loosen the castle
nut.
Remove the tire assembly. (See Wheel Removal And 1

Figure 20-50-3
P112377
2 Remove the hub assembly (Item 1) [Figure 20-50-5].
P111514
Remove the two brake caliper mounting bolts (Item 1)

and brake caliper (Item 2) [Figure 20-50-3].
NOTE: Do not hang the caliper by the brake line. Use

wire to hang the caliper to prevent possible
damage to the brake line.

FINAL DRIVE (CONT’D) Bearing Removal And Installation
Bearing Carrier Removal (Cont’d) Removal
Figure 20-50-6 Figure 20-50-8
1
2
P111512
P111515
Remove cotter pin (Item 1) [Figure 20-50-6].

Remove the outer snap ring (Item 1) [Figure 20-50-8].
Remove the nut (Item 2) and bolt (Item 3) [Figure 20-50-

6] retaining the tie rod end to the bearing carrier. Figure 20-50-9
Figure 20-50-7
P111511
P111943
From back side of the bearing carrier, tap on the outer
bearing race with a drift punch in the reliefs as shown
Remove the upper and lower ball joint pinch bolts (Item [Figure 20-50-9].
1) [Figure 20-50-7].
Drive bearing out evenly by tapping on outer race only.
Using a soft faced hammer, lightly tap the bearing carrier Once bearing is at bottom of casting, support casting on
while removing the upper and lower ball joints ends from outer edges so bearing can be removed.
the bearing carrier.
Inspect bearing carrier housing for scratches, wear or
Pull the bearing carrier out to remove it from the drive damage. Replace front bearing carrier if damaged.
shaft.
Rotate bearing by hand and check for rough spots. The

bearing should rotate quietly and smoothly with no
detectable up and down movement and minimal
movement sideways between the inner and outer races.
Visually inspect for moisture, dirt or corrosion.

FINAL DRIVE (CONT’D) Bearing Carrier Installation
Bearing Removal And Installation (Cont’d) Figure 20-50-11
Installation
5
Thoroughly clean the front bearing carrier housing and 1
the outer race on the new bearing. Be sure that all oil
4
residue has been removed from each surface.
3
Support the bottom of the bearing carrier housing. 6
2
Figure 20-50-10
P111512
1
Install the end of the drive shaft through the backside of

2
the bearing carrier.
Install the upper (Item 1) and lower (Item 2) [Figure 20-

50-11] ball joint ends into the front bearing carrier.
Install the pinch bolts (Item 3) [Figure 20-50-11] and

P111516 tighten to 57 N•m (42 ft-lb) torque.
Position the steering rod end (Item 4) and install the bolt
Apply Loctite® 603 retaining compound to the outer (Item 5) and nut (Item 6) [Figure 20-50-11].
circumference of the new bearing race (Item 1) [Figure
20-50-10] and carefully press the new bearing into the Tighten the nut to 54 N•m (40 ft-lb) torque.
bearing carrier housing.
Apply a good quality lithium grease to the splines (Item 7)
NOTE: Use care to not allow any of the Loctite® [Figure 20-50-11] of the drive shaft.
compound to get in the bearing.
Wipe the housing clean of any excess compound and

install the snap ring.
Install the snap ring (Item 2) [Figure 20-50-10].

Bearing Carrier Installation (Cont’d)
Figure 20-50-12
2
1
1
P111514
Install the brake caliper using new bolts (Item 1) [Figure

P112378 20-50-14]. Tighten the bolts to 41 N•m (30 ft-lb) torque.
Figure 20-50-15
Install front wheel hub assembly (Item 1) and cone
washers (Item 2) [Figure 20-50-12] domed side out.

Figure 20-50-13
P-99432
Washers and wheel nuts (Item 1) [Figure 20-50-15].

P112379 Tighten the nuts evenly in a criss-cross pattern to 81 N•m
(60 ft-lb) torque.
Install the castle nut (Item 1) [Figure 20-50-13] hand

tight.
IMPORTANT
New bolts have a pre-applied locking agent which is
destroyed upon removal. Always use new brake
caliper mounting bolts upon assembly.
I-2326-0510

FINAL DRIVE (CONT’D)
Bearing Carrier Installation (Cont’d)
Figure 20-50-16
1
2
P-99433
Lower the vehicle and tighten the front spindle nut (Item
1) [Figure 20-50-16] to 102 N•m (75 ft-lb) torque.

Install a new cotter pin (Item 2) [Figure 20-50-16]
Figure 20-50-17
P-99435
Rotate wheel and check for smooth operation. There

should not be any binding, rough spots or side play.
Install the hub dust cap (Item 1) [Figure 20-50-17].

Front Drive Shaft Removal And Installation
WARNING
procedure. Wear eye protection when removing 1
bearings and seals.
W-2863-0510
Lift and block the machine. (See LIFTING AND P-99568

NOTE: Before removing the bearing carrier, check Installation: Install a new spring ring (Item 1) [Figure
the bearings for side play by grasping the tire 20-50-19] on the end of the drive shaft. Apply an anti-
/ wheel firmly and checking for movement. It seize compound to the splines.
should rotate smoothly without binding or
rough spots. Figure 20-50-20

Remove the bearing carrier. (See Bearing Carrier
Removal on Page 20-50-1.)
NOTE: Perform all removal steps with the exception

of removing the steering tie rod end. It will not
be necessary to remove the tie rod end from
the front bearing carrier when removing the
front drive shaft.
Figure 20-50-18
1
P111517
Installation: Align the splines of drive shaft (Item 1)

[Figure 20-50-20] with front gearcase and install the
drive shaft. Use a rubber mallet to tap on the outboard
end of the drive shaft if necessary. Lightly tug on the shaft
to make sure the retaining ring is locked into the front
gearcase.
1
Installation: Install drive shaft into the front bearing
P111517 carrier.
Installation: Install the bearing carrier. (See Bearing

With a short, sharp jerk, remove the drive shaft (Item 1) Carrier Installation on Page 20-50-4.)
[Figure 20-50-18] from the front gearcase.

Rear Drive Shaft Removal And Installation

Remove the rear wheels. (See Wheel Removal And 3

2
1
Figure 20-50-21
2
P110634
washers (Item 3) [Figure 20-50-23] (both sides).
Installation: Tighten the nut to 149 N•m (110 ft-lb)

1 torque.

Remove the hub / disc assembly (both sides).
P110628
Figure 20-50-24
Remove the bolts (Item 1) and caliper (Item 2) [Figure

20-50-21] (both sides).
Installation: Tighten the bolts to 65 N•m (48 ft-lb) torque.
Figure 20-50-22 1 2
P126787
Remove the bolt (Item 1) and the brake junction box (Item
1 2) [Figure 20-50-24] from the rear axle brace.
P110632
Remove the dust cap (Item 1) [Figure 20-50-22] (both

sides).

FINAL DRIVE (CONT’D) Later Models
Rear Drive Shaft Removal And Installation (Cont’d) Figure 20-50-27
Figure 20-50-25
1
P126791
P110631
Remove the bolt (Item 1) [Figure 20-50-27] and nut
retaining the upper suspension link to the rear axle brace.
Remove the brake line (Item 1) [Figure 20-50-25] from
the retaining clips. Installation: Tighten the nut to 54 N•m (40 ft-lb) torque.

Earlier Models All Models
Figure 20-50-26 Figure 20-50-28
P110636 P110633
Remove the bolt (Item 1) [Figure 20-50-26] and nut Remove the nuts (Item 1) [Figure 20-50-28] and bolts
retaining the upper suspension link to the rear axle brace. attaching the lower suspension link to the axle brace
(both sides).
Installation: Tighten the nut to 54 N•m (40 ft-lb) torque.
Installation: Tighten the nuts to 54 N•m (40 ft-lb) torque.
Guide the half shafts out of the bearings while removing

the axle brace.

FINAL DRIVE (CONT’D) Drive Shaft / CV Joint Handling
Rear Drive Shaft Removal And Installation (Cont’d) Care should be exercised during drive shaft removal or
when servicing CV joints. Drive shaft components are
Figure 20-50-29 precision parts.
Cleanliness and following these instructions is very

important to ensure proper shaft function and a normal
service life.
• The complete drive shaft and joint should be handled

by getting hold of the interconnecting shaft to avoid
disassembly or potential damage to the drive shaft
joints.
• Over-angling of joints beyond their capacity could

result in boot or joint damage.
• Make sure surface-ground areas and splines of shaft

P110637 are protected during handling to avoid damage.
• Do not allow boots to come into contact with sharp

With a short, sharp jerky move, remove the drive shaft edges or hot engine and exhaust components.
from the transmission [Figure 20-50-29].

• The drive shaft is not to be used as a lever arm to
Figure 20-50-30 position other suspension components.
• Never use a hammer or sharp tools to remove or to

install boot clamps.
• Be sure joints are thoroughly clean and that the

proper amount and type of grease is used to refill
when joint boots are replaced and when joints are
cleaned. Refer to text for grease capacity of CV joints
and CV joint boots.
1
P-99568
Installation: Install a new spring ring (Item 1) [Figure

20-50-30] on the end of the drive shaft. Apply an anti-
seize compound to the splines.
Align the splines of the drive shaft with the transmission

and reinstall the drive shaft,. Use a rubber mallet to tap
on the outboard end of the drive shaft in necessary.
Install the rear axle brace. (See Axle Brace Removal And

Outer CV Joint And Boot Removal And Installation
Remove the front drive shaft from the vehicle. (See Front
Drive Shaft Removal And Installation on Page 20-50-7.)
1
Order Boot Clamp Pliers Earless Type (P/N 8700226).
Figure 20-50-31
P111550
1
Use a soft-faced hammer, or brass drift (Item 1) [Figure
20-50-33] to separate the CV joint from the drive shaft.
NOTE: If using a brass drift, be sure to tap on the

inner race of the joint only.

P111546 Figure 20-50-34
Remove and discard the boot clamps (Item 1) [Figure

20-50-31].
Figure 20-50-32
1
P111551
Make sure the circlip (Item 1) [Figure 20-50-34] remains

on the shaft and not left in the joint. Discard the circlip.
P111547 Remove the boot from the shaft.
Remove the large end of the boot (Item 1) [Figure 20-50-

32] from the CV joint and slide the boot down the shaft.
Clean the grease from the face of the joint.

FINAL DRIVE (CONT’D) Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in it’s groove
Outer CV Joint And Boot Removal And Installation machined in the shaft.
(Cont’d)
Install a NEW circlip on the end of the shaft.
Grease the joint with the special CV joint grease provided

IMPORTANT in the boot replacement kit. Fill the cavity behind the balls
and the splined hole in the joint’s inner race. Pack the ball
tracks and outer face flush with grease. Place any
Complete disassembly of the CV joint is NOT remaining grease into the boot.
recommended. The internal components are a
precision fit and develop their own characteristic
wear patterns. Intermixing the internal components
could result in looseness, binding, and / or
premature failure of the joint. IMPORTANT
I-2329-0510
The grease provided in the replacement kit is
NOTE: If the grease in the joint is obviously specially formulated for wear resistance and
contaminated with water and / or dirt, the joint durability. DO NOT use substitues or mix with other
should be replaced. lubricants.
I-2328-0510
Figure 20-50-35
NOTE: The amount of grease that’s provided is pre-

measured, so use all the grease.
Boot Replacement Grease Requirements:
Outer CV Joint Capacity 150 g
Figure 20-50-36
P111552
Thoroughly clean the joint with an appropriate solvent

and dry the joint to prevent any residual solvent from
being left in the joint upon reassembly [Figure 20-50-35].
Visually inspect the joint by tilting the inner race to one

side to expose each ball. Severe pitting, galling, play P111554
between the ball and its cage window, any cracking or
damage to the cage, pitting or galling or chips in
raceways call for joint replacement. Slide the joint onto the drive shaft splines and align the
circlip with the lead-in chamfer on the inner race of the
NOTE: Shiny areas in ball tracks and on the cage joint [Figure 20-50-36].
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Use a soft-faced hammer to tap the joint onto the drive
Replace CV joint only if components are shaft until it locks into place.
cracked, broken, worn or otherwise
unserviceable. Pull on the joint to make sure it is securely locked in
place.
Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.

Outer CV Joint And Boot Removal And Installation

(Cont’d)
Remove excess grease from the CV joint's external

surfaces and place the excess grease in the boot.
Figure 20-50-37
P111543
Install and secure the CV boot with the large clamp (Item
1) [Figure 20-50-38] using the “earless” clamp pliers (P/
N 8700226).
1
Figure 20-50-39
P-99572

Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
boot is not dimpled or collapsed.
While pulling out on the CV shaft, fully extend the CV

joint and slide a straight O-ring pick or a small slotted
screw driver (Item 1) [Figure 20-50-37] between the
small end of the boot and the shaft. This will allow the air
pressure to equalize in the CV boot in the position that
the joint will spend most of its life. Before you remove 1
your instrument, be sure the small end of the boot is in its
correct location on the shaft. P111544
Install and tighten the small clamp (Item 1) [Figure 20-

50-39] using the “earless” clamp pliers (P/N 8700226).

Inner Plunging Joint And Boot Removal And

Installation
Figure 20-50-40
P111549
Use a soft-faced hammer, or brass drift (Item 1) [Figure

20-50-42] to separate the joint from the drive shaft.
P111546
NOTE: If using a brass drift, be sure to tap on the
inner race of the joint only.
Remove and discard the boot clamps (Item 1) [Figure

20-50-40]. Figure 20-50-43
Figure 20-50-41
1
P111551
P111548
Make sure the circlip (Item 1) [Figure 20-50-43] is on the
shaft and not left in the joint.
Remove the large end of the boot from the plunging joint
and slide the boot down the shaft [Figure 20-50-41]. Remove the boot from the shaft.
Clean the grease from the face of the joint.
Place the drive shaft in a soft-jawed vise.

FINAL DRIVE (CONT’D) Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
Inner Plunging Joint And Boot Removal And and the splined hole in the joint’s inner race. Pack the ball
Installation (Cont’d) tracks and outer face flush with grease. Place any
remaining grease into the boot.
IMPORTANT IMPORTANT
Complete disassembly of the CV joint is NOT The grease provided in the replacement kit is
recommended. The internal components are a specially formulated for wear resistance and
precision fit and develop their own characteristic durability. DO NOT use substitues or mix with other
wear patterns. Intermixing the internal components lubricants.
could result in looseness, binding, and / or I-2328-0510
premature failure of the joint.
I-2329-0510
NOTE: The amount of grease that’s provided is pre-
measured, so use all the grease.
NOTE: If the grease in the joint is obviously
contaminated with water and / or dirt, the joint Boot Replacement Grease Requirements:
should be replaced.
Outer CV Joint Capacity 150 g
Figure 20-50-44

Figure 20-50-45
P111553
P111555
Thoroughly clean the joint with an appropriate solvent
and dry the joint to prevent any residual solvent from Fully compress the joint and push the drive shaft firmly
being left in the joint upon reassembly [Figure 20-50-44]. into the inner race.
Visually inspect the joint for damage. Replace if needed. Align the circlip with the lead-in chamfer.
Clean the splines on the end of the shaft and apply a light Use a soft-faced hammer to tap the joint onto the drive
coat of grease prior to reassembly. shaft until you reach the end of the splines and the joint
locks in place [Figure 20-50-45].
Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in it’s groove Slide the joint onto the drive shaft splines and align the
machined in the shaft. circlip with the lead-in chamfer on the inner race of the
joint.
Install a NEW circlip on the end of the shaft.
Use a soft-faced hammer to tap the joint onto the drive
shaft until it locks into place.
Pull on the joint to test that the circlip is seated and that
the joint is securely fastened to the shaft.

Inner Plunging Joint And Boot Removal And

Remove excess grease from the plunging joint's external

surfaces and place the excess grease in the boot.
Figure 20-50-46
P111544

Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
boot is not dimpled or collapsed.
Install and tighten the small clamp (Item 1) [Figure 20-

50-46].
Pull out on drive shaft to center joint in the housing. Slide

a straight O-ring pick or a small slotted screw driver
between the large end of the boot and the joint housing
and lift up to equalize air pressure in the boot.
Figure 20-50-47
1
P111542
Position the boot lip in its groove. Install and tighten the
large clamp (Item 1) [Figure 20-50-47] using the
appropriate clamp tool.

FINAL DRIVE (CONT’D) Model 3400XL
Propshaft Removal And Installation Figure 20-50-49
WARNING
bearings and seals.
W-2863-0510
Remove the front gearcase. (See Front Gearcase 2

1
Removal And Installation on Page 20-50-26.).
P126758
Model 3400
Figure 20-50-48 Separate the front section of the propshaft (Item 1) from
the splines in front of the flex bearing (Item 2) [Figure 20-
50-49].

Figure 20-50-50
1
P120050
Pull the propshaft towards the front of the vehicle until the
splines on the rear yoke disengage from the transmission P120050
snorkel shaft.
Remove the propshaft (Item 1) [Figure 20-50-48] out the Pull the propshaft towards the front of the vehicle.
front of the vehicle.
Remove the propshaft (Item 1) [Figure 20-50-50] out the
front of the vehicle.

FINAL DRIVE (CONT’D) Propshaft U-Joint Disassembly
Propshaft Removal And Installation (Cont’d)
Figure 20-50-51 WARNING

• Pressurized fluids and springs or other stored
energy components.
1
• Engine is running.
• Tools are being used.
W-2505-0604
2 Figure 20-50-52
P126759
Remove the two bolts (Item 1) [Figure 20-50-51]

securing the flex bearing to the frame.

Pull the propshaft (Item 2) [Figure 20-50-51] towards the
front of the vehicle until the splines on the rear yoke
disengage from the transmission snorkel shaft.
1
Remove the propshaft through the rear floor opening.
P126762
Remove the snap ring (Item 1) [Figure 20-50-52] from all

bearing caps.
NOTE: If yoke or bearing is removed, cross bearing

must be replaced. Note orientation of grease
fitting and mark inner and outer yoke for
correct repositioning during installation.

Propshaft U-Joint Disassembly (Cont’d)
Figure 20-50-53
P126765
1
Position the clamp (Item 1) [Figure 20-50-55] over
P126763 receiving adapter and remover adapter.
Figure 20-50-56
Using a commercially available U-Joint Press Set, place
receiving cup adapter (Item 1) [Figure 20-50-53] with a

larger ID than the U-joint cap OD on one end.
Figure 20-50-54
P126766
1
Tighten the clamp (Item 1) [Figure 20-50-56] to force U-
joint cups out of the yoke.
P126764
Replace all U-joint parts that were removed from the
yoke.
Place a remover adapter (Item 1) [Figure 20-50-54] on
the other end of the u-joint with a smaller OD than the U-
joint cap.

Propshaft U-Joint Assembly
Figure 20-50-57
1 1
P126769
Place caps (Item 1) [Figure 20-50-59] into yoke bores

P126767 and align with U-joint ends.
Figure 20-50-60
Remove two opposing caps (Item 1) [Figure 20-50-57]
from the new U-joint going into the yoke.

Secure the remaining caps so they do not fall off during
installation
Clean yoke bores and ring grooves before installing new

U-joint.
Figure 20-50-58
1 1
1 P126770
Place clamp and installer adapters (Item 1) [Figure 20-

50-60] with smaller OD than the caps over each cap.
P126768
Place U-joint ends (Item 1) [Figure 20-50-58] without

caps into the yoke bores.

Propshaft U-Joint Assembly (Cont’d)
Figure 20-50-61
P126773
Install the retaining ring (Item 1) [Figure 20-50-63] with

1
P126771 sharp, square edge facing away from U-joint into
exposed groove.
Tighten the clamp (Item 1) [Figure 20-50-61] Figure 20-50-64

simultaneously into yoke bores.

Push U-joint side to side during clamping to seat into
caps properly
Figure 20-50-62
P126774
Place larger adapter (Item 1) [Figure 20-50-64] with ID

1 larger than yoke bore on the side with retaining ring
installed.
P126772
Tighten the clamp until other cap is below retaining ring
groove.
Tighten clamp until both caps are flush with yoke and one
cap is past retaining ring groove (Item 1) [Figure 20-50-
62].

Propshaft U-Joint Assembly (Cont’d)
Figure 20-50-65
P126775
Install the second retaining ring (Item 1) [Figure 20-50-

65] with sharp, square edge facing away from U-joint into

exposed groove.
Verify the U-joint moves freely and does not bind

Front Gearcase Operation Rollers

Rollers
1
The AWD switch may be turned on or off while the vehicle Ring Gear
is moving, however, AWD will not enable until the vehicle
speed drops below 24 kph (15 mph). Once the AWD is
enabled, it remains enabled until the switch is turned off.
Engage the AWD switch before getting into conditions

where the front wheel drive may be needed. If the rear
wheels are spinning, release the throttle before switching
to AWD.
Roll Cage
Roll Cage
P-99705
IMPORTANT
AWD Engagement: When the AWD switch is activated,
Switching to AWD while the rear wheels are spinning the AWD coil (Item 1) [Figure 20-50-66] is powered by a
may cause severe drive shaft and gearcase damage. 12 Vdc input which creates a magnetic field. This
Always switch to AWD while the rear wheels have magnetic field attracts an armature plate (Item 2) [Figure
traction or are at rest. 20-50-66] that is keyed to the roll cage. When the ring
I-2321-0710 gear (Item 3) and roll cage (Item 4) [Figure 20-50-66] are

spinning (vehicle is moving), the energized coil and
With the AWD switch off, the vehicle drives through the armature plate will apply drag to the roll cage that
rear wheels only (2 wheel drive). When the AWD is indexes the rollers inside the ring gear to an engagement
enabled, the front drive acts as an on-demand AWD position. While in the engagement position, the front
system. This means, the front drive will engage once the drive will be in an “over-running” condition (not engaged),
rear wheels have lost traction, and will remain engaged until the rear wheels lose traction. Once the rear wheels
until the torque requirement goes away (i.e. rear wheels begin to lose traction, the front drive will engage by
regain traction). coupling the output hubs to the ring gear via the rollers.
The front drive will remain engaged until the torque
Figure 20-50-66 requirement goes away (i.e. rear wheels regain traction).
NOTE: Rollers (Item 1) [Figure 20-50-67] are non -

directional.
1 2
4
3
IMPORTANT
If the rear wheels are spinning, release the throttle
before turning the AWD switch on.
If AWD is engaged while the wheels are spinning,
severe drive shaft and clutch damage could result.
I-2330-0710
P-99696
AWD Disengagement: Once the rear wheels regain

traction, the front wheels will return to the “over-running”
condition. The vehicle is now back to rear wheel drive
until the next loss of rear wheel traction occurs.

Front Gearcase Operation (Cont’d)
Symptom: AWD Will Not Engage
Figure 20-50-68
P-99584
Inspect the armature plate for a consistent wear pattern.

There should be two distinct wear bands (one band
inside the other). If only one band of wear is present (or if
P111501 there is wear between the two bands). A wear band with
an interrupted wear mark may indicate a warped plate,
which may cause intermittent operation [Figure 20-50-

Check the gearcase coil resistance. To test the coil 69].
resistance, measure between the Grey and Brown /
White wires. The measurement should be within Figure 20-50-70
specification [Figure 20-50-68].
Gearcase Cover Plate Asm.
Front Gearcase Coil Resistance:
Coil Resistance 21,6 - 26,4 ohm

CoilCoil
Turn the ignition switch and AWD switch on and place
gear selector in High or Low gear. Check for minimum
battery voltage at the Gray and Brown / White chassis
wires that power the coil. A minimum of 11 Vdc should be
present.
U-shaped insert
If electrical tests are within specification, remove
gearcase. (See Front Gearcase Removal And Installation Side cutaway view of
on Page 20-50-26.) and inspect components. gearcase cover Insert P111510
Check to make sure the coil is seated in the U-shaped

insert that is pressed into the gearcase cover. The top of
the coil should be seated below the U-shaped insert. The
U-shaped insert controls the pole gap. If the top of the
coil is above the surface of the U-shaped insert it raises
the armature plate, thereby increasing pole gap. If the
pole gap increases, the coil will not be strong enough to
engage the AWD system. If this is found, replace the
cover plate assembly [Figure 20-50-70].

Front Gearcase Operation (Cont’d)
Symptom: AWD Will Not Engage (Cont’d)
Figure 20-50-71
P111563

Inspect the rollers (Item 1) [Figure 20-50-71] for nicks
and scratches. The rollers must slide up, down, in and out
freely within the roll cage sliding surfaces and H-springs.
Inspect the roll cage assembly (Item 2) [Figure 20-50-71]

for cracks or excessive wear. If damaged, replace the roll
cage assembly.

Front Gearcase Removal And Installation
WARNING 2
1
bearings and seals.
W-2863-0510
Lift and block the machine. (See LIFTING AND P111640

Remove both front drive shafts from the front gearcase. Loosen the clamp (Item 1) and remove the vent line (Item
(See Front Drive Shaft Removal And Installation on Page 2) [Figure 20-50-73] from the gearcase.
20-50-7.)
Figure 20-50-74
Figure 20-50-72

1
1 1
P110960
P110649
Remove the four bolts (Item 1) [Figure 20-50-74]

Access the front propshaft roll pin (Item 1) [Figure 20-50- securing the bottom of the gearcase to the skid plate
72] through passenger side front wheel well. Drive the frame.
roll pin from the propshaft.
Installation: Install new mounting bolts and tighten to 54
Installation: Install a new roll pin. N•m (40 ft-lb) torque.
Slide the propshaft off the front gearcase input shaft

splines.
Disconnect the AWD wire harness from the main

harness.

Front Gearcase Removal And Installation (Cont’d)
Figure 20-50-75
P111527
Remove the front gearcase (Item 1) [Figure 20-50-75]

from the vehicle.

Installation: Add proper lubricant to the front gearcase.
(See Fluid And Capacities on Page SPEC-10-7.)

Front Gearcase Parts Identification
1. Bushing
2. Output Hub
3. Nylon Spacer
4. Bearing
6 5. Coil Pocket Insert
8
6. AWD Coil
7. O-ring
1
8. Output Cover
2 9. Seal
3 10. Grommet
4 11. Screw
9 12. Connector End
5 13. Armature Plate
7 14 Retainer Ring
12 15. Roll Cage
10
21 16. H - Clip Springs
17. Rollers
11 17 18. Spring Retainer
19. Torsion Spring
20. Ring Gear

16
21. Spacer (Gear)
22 22. O-ring
23. Vent Tube Fitting
19 20 24. Plug
18 25. Bushing
26. Gearcase
14 27. Pinion Gear
15
14 28. Bearing
29. Retaining Ring
30. Seal
13
23
24
9
26
27
28
29 29
25
4
3 30
2
24
NA5342S

Front Gearcase Disassembly / Inspection
Figure 20-50-76
1
1
1
1 P111565
Remove the LH output hub assembly (Item 1) [Figure

1 P111503 20-50-78] from the clutch housing or (Item 1) [Figure 20-
50-79] outer cover plate assembly.
Drain and properly dispose of used lubricant. Remove Inspect the bearing and contact surfaces of the output
any metal particles from the drain plug magnet. hub for signs of wear or damage. Replace component if

found to be worn or damaged.
Remove the seven screws (Item 1) [Figure 20-50-76]
retaining the outer cover assembly. Figure 20-50-79
Figure 20-50-77
2
1
P111533
1
P-99696
Inspect the nylon spacer (Item 2) [Figure 20-50-79] in
the outer cover plate assembly.
Remove the output cover assembly (Item 1) [Figure 20-
50-77] from the gearcase. NOTE: The nylon spacer is not serviceable and
should not be removed.

Front Gearcase Disassembly / Inspection (Cont’d)
Figure 20-50-80 1
P111564
Remove the spring retainer (Item 1) [Figure 20-50-82].

P111500
Figure 20-50-83
Remove the armature plate (Item 1) [Figure 20-50-80].

Figure 20-50-81
1 P111567
Remove the torsion spring (Item 1) [Figure 20-50-83].

P111502
Inspect the armature plate (Item 1) [Figure 20-50-81] for

a consistent wear pattern. Uneven wear of the armature
plate indicates a warped plate, which may cause
intermittent operation.
NOTE: For more details about uneven wear of the

armature plate. (See Front Gearcase
Operation (Cont’d) on Page 20-50-24.)

Front Gearcase Disassembly / Inspection (Cont’d)

3
Figure 20-50-84
P111536
Remove pinion seal (Item 1), internal retaining ring (Item

P111562 2) and pinion gear assembly (Item 3) [Figure 20-50-86]
from the gearcase housing. Inspect and clean the
gearcase housing and replace all oil seals and O-rings.
Remove the clutch housing / ring gear and roll cage
assembly from the gearcase housing (Item 1) [Figure 20- Figure 20-50-87

50-84].
2
Figure 20-50-85 1
P111537
P111566 Inspect the pinion gear (Item 1) [Figure 20-50-87] for

chipped, broken or missing teeth.
Remove the RH output hub assembly (Item 1) [Figure Inspect the pinion bearing (Item 2) for signs of wear and
20-50-85] from the gearcase housing. the pinion shaft seal surface (Item 3) [Figure 20-50-87]
for pitting.

FINAL DRIVE (CONT’D) Thoroughly clean all parts and inspect the rollers (Item 2)
[Figure 20-50-89] for nicks and scratches. The rollers
Front Gearcase Disassembly / Inspection (Cont’d) must slide up and down and in and out freely within the
roll cage sliding surfaces and H-springs.
Figure 20-50-88
Inspect the clutch housing ring gear (Item 4) [Figure 20-
50-89] for a consistent wear pattern and chipped, broken
or missing teeth.
2
1 Figure 20-50-90
3
3 1
P111502
2
Inspect the AWD coil (Item 1) [Figure 20-50-88] located

in the outer cover plate assembly. Refer to “AWD

Diagnosis” for detailed inspection process.
P111528
Replace the cover plate seal (Item 2) and O-ring (Item 3)

[Figure 20-50-88]. Inspect the roll cage assembly (Item 1) sliding surfaces
(Item 2) and H-springs (Item 3) [Figure 20-50-90]. The
Figure 20-50-89 sliding surfaces must be clean and free of nicks, burrs or
scratches. If damaged, replace the roll cage assembly.
4
Figure 20-50-91
3
1
P111521
Remove the roll cage assembly (Item 1) and rollers (Item

P111535
2) from the clutch housing (Item 3) [Figure 20-50-89].
Use a shop towel to cover the housing in order to retain
all the rollers. Inspect both output hub assemblies. Inspect the bearings
and replace if needed [Figure 20-50-91].
NOTE: Rollers are spring loaded. Take care not to
allow them to fall out or lose them upon
removal of the roll cage.

Front Gearcase Assembly
Thoroughly clean the gearcase components before

beginning reassembly. 1
Figure 20-50-92
P111560
1 Install the RH output hub (Item 1) [Figure 20-50-94] into

the gearcase housing.
Figure 20-50-95
P-99712

Install the pinion shaft assembly (Item 1) and install the
snap ring (Item 2) [Figure 20-50-92]. 2
Figure 20-50-93
1
P111520
1 Carefully install the rollers (Item 1) into the roll cage

assembly (Item 2) while installing the assembly into the
clutch housing (Item 3) [Figure 20-50-95].
P111504 NOTE: Install the roll cage so that the ring gear
grooves line up with the roll cage slots (see
below).
Install a new input shaft seal (Item 1) [Figure 20-50-93].
Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.

Front Gearcase Assembly (Cont’d)
Figure 20-50-96
1
1 P111531
Check the action of the torsion spring by rotating in both

P111529 directions to ensure the spring and retainer are installed
properly [Figure 20-50-98].
Install the torsion spring by wrapping reach leg (Item 1) of Figure 20-50-99
the spring around the dowel pin (Item 2) [Figure 20-50-

96] on the ring gear.
1
Figure 20-50-97
P111518
Install the armature plate (Item 1) [Figure 20-50-99]. Be

P111530 sure the armature plate tabs are fully engaged into the
roll cage assembly and are resting on the cut-grooves of
the ring gear.
Align the spring retainer dowel pin (Item 1) [Figure 20-
50-97] with the ring gear dowel pin and install the retainer NOTE: Verify armature plate tabs are in the slots on
on top of the torsion spring. roll cage and are resting in the ring gear
grooves.

Front Gearcase Assembly (Cont’d)

1
Figure 20-50-100
2
1
P111503
Install the output cover assembly (Item 1) [Figure 20-50-

P111561 102] onto the gearcase housing.
Tighten the seven screws to 10 - 15 N•m (7 - 11 ft-lb)

Carefully install the ring gear (Item 2) and roll cage torque.
assembly (Item 1) [Figure 20-50-100] into the gearcase

housing.
Figure 20-50-101
2
P111505
Install a new seal (Item 1) and O-ring (Item 2) [Figure 20-

50-101] onto the output cover.
Carefully install the LH output hub assembly (Item 3)

[Figure 20-50-101] into the cover plate. Take care not to
damage the new cover plate seal while installing the
output hub.


MAINFRAME
ROLL OVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Seat Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Seat Base Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
DASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Front Access Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Upper Dash Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Lower Dash Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Storage Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
BUMPER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

REAR SUSPENSION LINK AND AXLE BRACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Upper Suspension Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Lower Suspension Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Axle Brace Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Rear Axle Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Tilt Steering Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Steering Wheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-3
Steering Wheel / Upper Steering Shaft Removal And Installation . . . . . . . . . . . . . . 30-60-4
Steering Shaft Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-5
Power Steering Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-6
Power Steering Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-7
STEERING BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

SHOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1
Rear Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1
Front Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-2
Shock Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-3

A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1
Lower A-Arm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1
Upper A-Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-2
Upper A-Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-6
Ball Joint Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-7
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110-1
Toe Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110-2
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120-1
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120-2
CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130-1

FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140-1
Removal And Installation (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140-1

Removal And Installation (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140-1
Flare Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140-3

ROLL OVER PROTECTIVE STRUCTURE (ROPS) All Models
Removal And Installation Figure 30-10-3
Earlier Models
NOTE: During installation of the ROPS sections,

install the nuts and bolts finger tight only.
Once all pieces are bolted together, finish
tightening to the specified torque.
Figure 30-10-1
1
P111894
Remove the bottom hip bolster bolt (Item 1) [Figure 30-

10-3].
1 Installation: Tighten the bolt to 19 N•m (14 ft-lb) torque.

Figure 30-10-4
P117933
Remove the two top screws (Item 1) [Figure 30-10-1]

securing the hip bolster to the cab frame (both sides).
Later Models
Figure 30-10-2
P117932
Remove the nut (Item 1) [Figure 30-10-4] from the top of

the center seat belt harness.
1 Installation: Tighten the bolt to 19 N•m (14 ft-lb) torque.
P126721
Remove the two top screws (Item 1) [Figure 30-10-2]


ROLL OVER PROTECTIVE STRUCTURE (ROPS) Figure 30-10-7
(CONT’D)
Removal And Installation (Cont’d)
Figure 30-10-5
P111900
Remove the plastic rivet (Item 1) [Figure 30-10-6] and

[Figure 30-10-7] securing the upper fender to the lower
P117931
fender.
Figure 30-10-8
Remove the bolt (Item 1) [Figure 30-10-5] and nut from

the top of the seat belt harness (both sides).
Figure 30-10-6
1
P111892
1 Figure 30-10-9
P117938
P111898
Remove the screw (Item 1) [Figure 30-10-8] and [Figure

30-10-9] from the bottom of the upper fender.

(CONT’D)
Removal And Installation (Cont'd)
Figure 30-10-10
1
1
P117935
Figure 30-10-13
P117944
Remove the plastic rivet (Item 1) [Figure 30-10-10]

securing the upper fender to the back panel (both sides).
Figure 30-10-11
2
1 1
P117934
Remove the screws (Item 1) [Figure 30-10-12] and

1 [Figure 30-10-13] from the seat back.
P117937
Loosen the clamp (Item 1) and remove the upper fender

(Item 2) [Figure 30-10-11] from the inlet duct (both
sides).
Installation: Tighten the clamp to 4 N•m (35 in-lb) torque.

(CONT’D)
Figure 30-10-14 1
1
1 1
P117936
Remove the two screws (Item 1) [Figure 30-10-16]

2
securing the intake duct to the rear panel.
P111906
Remove the rear panel.
Remove the plastic rivets (Item 1) and screws (Item 2) Figure 30-10-17

[Figure 30-10-14] securing the rear panel to the cab
frame.
Figure 30-10-15
1
1
1
1
P117939
Remove the nut (Item 1) [Figure 30-10-17] securing the

P120791 seat belt base to the cab frame.
Remove the screw (Item 1) [Figure 30-10-15] securing

the seat back to the cab frame.
Remove the seat back.

ROLL OVER PROTECTIVE STRUCTURE (ROPS) Later Models
(CONT’D)
Figure 30-10-19
2
Earlier Models
Figure 30-10-18
2
1
P126720
1
Remove the two nuts (Item 1) [Figure 30-10-19] and
bolts (both sides).
P111886
Remove the upper windshield mount (Item 2) [Figure 30-

10-19].
Remove the two bolts (Item 1) (both sides) and upper
windshield mount (Item 2) [Figure 30-10-18]. NOTE: Do not tighten any structure bolts until all
parts are loosely installed. Starting with the
NOTE: Do not tighten any structure bolts until all top of the cab frame and working down,
parts are loosely installed. Starting with the torque all bolts to 40,7 N•m (30 ft-lb) torque.
top of the cab frame and working down,
torque all bolts to 40,7 N•m (30 ft-lb) torque. Installation: Tighten the bolts to 61 N•m (45 ft-lb) torque.
Installation: Tighten the bolts to 40,7 N•m (30 ft-lb) All Models
torque.
Figure 30-10-20
P111885
Remove the two bolts (Item 1) [Figure 30-10-20] (both

sides).

ROLL OVER PROTECTIVE STRUCTURE (ROPS) Earlier Model 3400XL
(CONT’D)
Figure 30-10-23
Figure 30-10-21
1
2
P117952
P111884 Remove the two top screws (Item 1) [Figure 30-10-23]

Remove the two bolts (Item 1) [Figure 30-10-21] and Later Model 3400XL

nuts (both sides).
Figure 30-10-24
Remove the support bar (Item 2) [Figure 30-10-21].
Figure 30-10-22
1
1 P126721
P117947 Remove the two top screws (Item 1) [Figure 30-10-24]

Remove the two bolts (Item 1) and nuts from each side of
the lower main frame supports and remove the rear cab
frame (Item 2) [Figure 30-10-22].
NOTE: During installation of the ROPS sections,

install the nuts and bolts finger tight only.
Once all pieces are bolted together, finish
tightening to the specified torque.

(CONT'D)
All Model 3400XL
Figure 30-10-25 1
P117941
1
Remove the front seat belt upper mounting bolts (Item 1)
[Figure 30-10-27] (both sides).
Installation: Tighten the nut to 47 - 54 N•m (35 - 45 ft-lb)

P111894 torque.

Remove the bottom hip bolster bolt (Item 1) [Figure 30-
10-25].
Figure 30-10-26
P117940
Remove the bolt and nut (Item 1) [Figure 30-10-26]. from

the upper center seat belt.
Installation: Tighten the bolt to 47 - 54 N•m (35 - 45 ft-lb)

torque.

(CONT'D)
Figure 30-10-28
1
P118255
2 2 2 1
1
securing the upper fender to the lower fender (both
P117945 sides).
Figure 30-10-31
Figure 30-10-29

2
TOOK
2
2
1
1
P117951
P117946
Remove the plastic rivet (Item 1) and screw (Item 2)

Remove the bolts (Item 1) [Figure 30-10-28] and [Figure [Figure 30-10-31] (both sides).
30-10-29] securing the seat belt base to the cab frame.
Installation: Tighten the screws to 2,0 - 2,25 N•m (18 -

20 in-lb) torque.

[Figure 30-10-29] securing the seat back to the cab
frame.

(CONT’D)
Figure 30-10-32
P117938
Figure 30-10-35
P111892
Figure 30-10-33

1
P111900
1
Remove the plastic rivet (Item 1) [Figure 30-10-34] and

[Figure 30-10-35] from the bottom of the upper fender
P111898 (both sides).
Remove the screw (Item 1) [Figure 30-10-32] and

[Figure 30-10-33] from the bottom of the upper fender.

(CONT’D)
Figure 30-10-36
1 1
P117935
Figure 30-10-39
P117944

Figure 30-10-37
1 1
P117934
2 Remove the screws (Item 1) [Figure 30-10-38] and

1 [Figure 30-10-39] from the seat back.
P117937
Loosen the clamp (Item 1) and remove the upper fender

(Item 2) [Figure 30-10-37] from the inlet duct (both
sides).
Installation: Tighten the clamp to 4 N•m (35 in-lb) torque.

(CONT’D)
Figure 30-10-40
1
1 1 1
P117936

2 securing the intake duct to the rear panel.
P111906
Remove the rear panel.
Remove the plastic rivets (Item 1) and screws (Item 2) Figure 30-10-43

[Figure 30-10-40] securing the rear panel to the cab
frame.
Figure 30-10-41
1
1
1
1
P117939

P120791 seat belt base to the cab frame.
Remove the screw (Item 1) [Figure 30-10-41] securing


(CONT'D)
Figure 30-10-44
1 1
P111884
Remove the two bolts (Item 1) [Figure 30-10-46] from

the rear of the mid cab frame (both sides).
P118257
Installation: Tighten the bolts to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Install a plug (Item 1) [Figure 30-10-44] into the inlet duct

(both sides). Remove the mid cab frame (both sides).
Figure 30-10-45 Figure 30-10-47
1
1
P117942
P117947
Remove the two bolts (Item 1) [Figure 30-10-45] from Remove the bolts (Item 1) [Figure 30-10-47] and nuts
the front of the mid cab frame (both sides). securing the rear cab frame to the main frame (both
sides).
lb) torque. Installation: Tighten the bolts to 20 - 24 N•m (16 - 18 ft-
lb) torque.
Remove the rear cab frame.

(CONT’D)
Figure 30-10-48
1
P117950
1
Remove the two bolts (Item 1) [Figure 30-10-50] and
nuts securing the center post to the main frame (both
P117943 sides).

securing the front cab frame to the middle upright (both
sides).
Remove the rear cab frames.
Figure 30-10-49
P111885

securing the front cab frame to the main frame (both
sides).

lb) torque.
Remove the front cab frame.


OPERATOR SEAT Figure 30-20-3
Seat Back Removal And Installation
For Model 3400 And 3400XL Rear Seat
Figure 30-20-1 1
P120791
Remove the screw (Item 1) [Figure 30-20-3] securing the

seat back to the cab frame.
Figure 30-20-4
P117944

Figure 30-20-2
P117935
1 1 Figure 30-20-5
P111906
Remove the plastic rivets (Item 1) [Figure 30-20-2]

securing the rear panel to the cab frame.
1 1
P117934
Remove the screws (Item 1) [Figure 30-20-4] [Figure

30-20-5] from the seat back.
Remove seat back.

OPERATOR SEAT (CONT’D) Seat Base Removal And Installation
Seat Back Removal And Installation (Cont’d) NOTE: The photo’s below are showing seat base
removal on a standard machine front seat.
For Model 3400XL Front Seat Rear seat removal on 3400XL models is
similar to the seat shown.
Figure 30-20-6
Removal
Figure 30-20-8
1
1
P117945
Figure 30-20-7

P126786
Lift up on the rear center (Item 1) [Figure 30-20-8] of the

seat. (There is a retainer post in the rear center of the
seat that fits into a grommet that secures the front seat.)
1 Tilt the seat up and forward to remove.
1
NOTE: Operator’s side shown, passengers side is
removed the same way.
P117946

[Figure 30-20-7] securing the seat back to the cab
frame.
Remove seat back.

OPERATOR SEAT (CONT’D) Seat Belt Removal And Installation
Seat Base Removal And Installation (Cont’d) Remove the seat base. (See Seat Base Removal And
Installation
Figure 30-20-11
Figure 30-20-9
1
1 2
P-101060
P-97881
Remove the nut and bolt (Item 1) [Figure 30-20-11] from

Position the tabs (Item 1) [Figure 30-20-9] on the front of the seat belt stud.

the seat to the grooves in the frame.
Remove the end release latch (Item 2) [Figure 30-20-
Figure 30-20-10 11].
Installation: Tighten the nut and bolt to 84 - 92 N•m (62 -

1
65 ft-lb) torque.
Figure 30-20-12
2
1
P-97797
Position the seat posts (Item 1) into the rubber grommets

(Item 2) [Figure 30-20-10] in the frame.
Press down on the rear edge (Item 1) [Figure 30-20-10] P117931

of the seat until the seat is secured.
Remove the bolt (Item 1) [Figure 30-20-12] and nut from
NOTE: The tabs (Item 1) [Figure 30-20-9] must be fully the top of the seat belt harness.
engaged into the grooves before pressing the
seat tabs (Item 1) [Figure 30-20-10] into the Installation: Tighten the mounting nut to 41 - 68 N•m (30
grommets (Item 2) [Figure 30-20-10] or the - 50 ft-lb) torque.
grommets may be pressed out of there
mounts and lost.

OPERATOR SEAT (CONT’D) Figure 30-20-15
Seat Belt Removal And Installation (Cont’d)
Figure 30-20-13
1 1
1 P117934

[Figure 30-20-15] securing the seat back.
P117944
Figure 30-20-16
securing the upper fender to the rear panel.

Figure 30-20-14
1 1
2
P111906
1
Remove the plastic rivets (Item 1) and screws (Item 2)
P117935 [Figure 30-20-16] securing the rear panel to the cab
frame.

OPERATOR SEAT (CONT’D) Figure 30-20-19
Seat Belt Removal And Installation (Cont’d)
Figure 30-20-17
P117939

seat belt retractors to the cab frame.
P120791
Installation: Tighten the mounting bolt to 41 - 68 N•m

Remove the screw (Item 1) [Figure 30-20-17] securing (30 - 50 ft-lb) torque.

Figure 30-20-18
1 1
P117936

securing the intake duct to the rear panel


DASH Lower Dash Panel Removal And Installation
Front Access Cover Removal And Installation Remove the upper dash. (See Upper Dash Panel
Figure 30-30-1
Figure 30-30-3
1 1
2
1
P110772
P110611
Rotate the two fasteners (Item 1) 90° and slide the cover
(Item 2) [Figure 30-30-1] forward to remove. Remove the two screws (Item 1) [Figure 30-30-3] from

the bottom of the control panel.
Upper Dash Panel Removal And Installation
Figure 30-30-4
Figure 30-30-2
1 1
1
1
2 P-111912
P110608
Disconnect the switch harness (Item 1) [Figure 30-30-4]

Remove the four plastic rivets (Item 1) [Figure 30-30-2]. by depressing the connector locks (Item 2) [Figure 30-
30-4] and pulling on the connector. Do not pull on the
Pull the panel towards the seats to release the front tabs wiring.
and remove the upper dash panel.

DASH (CONT’D) Figure 30-30-7
Lower Dash Panel Removal And Installation (Cont’d)
Figure 30-30-5
1
1
P111914
1 Remove the four screws (Item 1) [Figure 30-30-7] from

P111918 the glove box.
Figure 30-30-8
Remove the wires (Item 1) [Figure 30-30-5] from the 12V
power points.

Figure 30-30-6
1
1
P111911

P111158 attaching the right fender to the lower dash.
Remove the screws (Item 2) [Figure 30-30-8] below the

Remove the screw (Item 1) [Figure 30-30-6] on the glove box.
inside of the glove box.

DASH (CONT’D) Figure 30-30-11
Figure 30-30-9
1
2
1
P111194
Remove the screw (Item 1) and gear shift knob (Item 2)

P111915 [Figure 30-30-11].
Figure 30-30-12
Remove the three plastic rivets (Item 1) [Figure 30-30-9].
from the top of the panel. 1

Figure 30-30-10
P111910
Remove the nut (Item 1) [Figure 30-30-12] from the key

P111163 switch and push the switch inside the panel.
Remove the three screws (Item 2) [Figure 30-30-12]

Remove the cap (Item 1) [Figure 30-30-10] from the from the bottom of the panel.
gear shift lever.
.

DASH (CONT’D)
Figure 30-30-13
P111917

attaching the left fender from the lower dash panel.

Figure 30-30-14
P111909
Disconnect the main harness (Item 1) [Figure 30-30-14]

from the instrument cluster.
Tilt the steering wheel to its lowest position and put the
gear select lever in Low or High gear.
Carefully puff the lower dash panel towards the seat and
up to remove.

DASH (CONT’D)
Storage Panel Removal And Installation
Figure 30-30-15
1
1
P110890
Remove the screws (Item 1) [Figure 30-30-15] (both

sides) and the storage panel.


BUMPER COVER Figure 30-40-3
Remove the front access cover. (See Front Access Cover

Remove the fenders. (See Removal And Installation 1

(Front) on Page 30-140-1.) 1
Figure 30-40-1
P118398
Remove the two screws (Item 1) [Figure 30-40-3].
Figure 30-40-4
1

P118396
1
Disconnect the light wire harness (Item 1) [Figure 30-40-

1] (both sides).
Figure 30-40-2
P118400
Remove the screw (Item 1) [Figure 30-40-4] (both

1 sides).
P118399
Remove the two screws (Item 1) [Figure 30-40-2] (both

sides).

BUMPER COVER (CONT’D)
Figure 30-40-5
P118402
Remove the screw (Item 1) [Figure 30-40-5] (both

sides).

Figure 30-40-6
P118401
Remove the two plastic rivets (Item 1) (both sides) and

bumper cover (Item 2) [Figure 30-40-6].

REAR SUSPENSION LINK AND AXLE BRACE Later Models
Upper Suspension Link Removal And Installation Figure 30-50-2
Lift and block the machine.

Page 30-130-1.)
Remove the rear wheels. (See Wheel Removal And

1
Earlier Models
Figure 30-50-1
P126791
1 Remove the nut and bolt (Item 1) [Figure 30-50-2]

attaching the upper suspension link to the axle brace.

All Models
Figure 30-50-3
P110636
Remove the nut and bolt (Item 1) [Figure 30-50-1]

P111879
Remove the nut (Item 1) [Figure 30-50-3] and bolt

attaching the upper suspension link to the frame (both
sides).
Remove the upper suspension link.

REAR SUSPENSION LINK AND AXLE BRACE Figure 30-50-5
(CONT’D)
Lower Suspension Link Removal And Installation


Page 30-130-1.)
Removed the rear wheel. (See Wheel Removal And

1
Figure 30-50-4
P111878

attaching the lower suspension link to the frame (both
sides).
2
1 Installation: Tighten the nut to 54 N•m (40 ft-lb) torque.

Remove the upper suspicion link.
P110633
Remove the nut (Item 1) [Figure 30-50-4] and bolt from

the lower shock mount.

attaching the lower suspension link to the axle brace.

REAR SUSPENSION LINK AND AXLE BRACE Figure 30-50-8
(CONT’D)
Axle Brace Removal And Installation
Lift and block the machine. (See LIFTING AND 2


Page 30-130-1.)
Removed the rear wheel. (See Wheel Removal And

Installation on Page 10-120-2.) 1
3
Figure 30-50-6
P110634
washers (Item 3) [Figure 30-50-8] (both sides).
Remove the hub assembly (both sides).
Installation: Tighten the nut to 149 N•m (110 ft-lb) torque

after the wheel has been installed and the vehicle
1 lowered to the ground.
Earlier Models
P110628
Figure 30-50-9
Remove the two bolts (Item 1) [Figure 30-50-6] attaching

the caliper to the axle brace (both sides).

1
Figure 30-50-7
P110630

attaching the brake junction box to the axle brace.
1
P110632
Remove the hub dust cap (Item 1) [Figure 30-50-7] (both

sides).

REAR SUSPENSION LINK AND AXLE BRACE Later Models
(CONT’D)
Figure 30-50-12
Axle Brace Removal And Installation (Cont’d)
Later Models
Figure 30-50-10
P126791

P126787

Remove the bolt (Item 1) [Figure 30-50-10] attaching All Models
the brake junction box to the axle brace.
Figure 30-50-13
Installation: Tighten the nut to 4 N•m (35 in-lb) torque.
Remove the brake line from the retaining clips.
Earlier Models
Figure 30-50-11
1 P110633

attaching the lower suspension link to the axle brace
(both sides).

P110636
Guide the half shafts out while removing the axle brace.
attaching the upper suspension link to the axle brace. Remove the axle brace.

Rear Axle Bearing Replacement Wipe the housing clean and install the snap ring.
Remove the rear axle brace. (See Axle Brace Removal

And Installation on Page 30-50-3.)
Figure 30-50-14
P111591
Remove the snap ring (Item 1) [Figure 30-50-14].

Figure 30-50-15
P111593A
From the back side, tap on the outer bearing race with a
drift punch in the casting reliefs (Item 1) [Figure 30-50-
15] to remove the race.
Thoroughly clean the rear bearing carrier housing and

the outer race on the new bearing. Be sure that all oil
residue has been removed from each surface.
Support the bottom of the axle brace bearing housing in

preparation for new bearing installation
Apply Loctite® 603 retaining compound to the outer

circumference of the new bearing race and carefully
press the new bearing into the axle brace bearing
housing.


STEERING COLUMN Tilt Steering Shock Removal And Installation
Description Remove the storage panel. (See Storage Panel Removal

And Installation on Page 30-30-5.)
Figure 30-60-1
Figure 30-60-2
1
1
3
P-97684 2
P111596
The steering column connects the steering wheel (Item

1) [Figure 30-60-1] to the steering box using a steering Remove the upper nut and bolt (Item 1) [Figure 30-60-2]
shaft assembly and pivot tube containing bearings. An

retaining the tilt shock to the pivot tube.
adjustable tilt steering shock allows the steering wheel to
be positioned at different angles. A power steering unit is Installation: Tighten nut and bolt to 10 N•m (7 ft-lb)
attached to the steering shaft to decrease steering effort. torque.
Remove the lower nut and bolt (Item 2) [Figure 30-60-2]

retaining the tilt shock to the pivot tube.
Installation: Tighten nut and bolt to 16 N•m (12 ft-lb)

torque.
Remove the tilt steering shock (Item 3) [Figure 30-60-2]

from the vehicle.

STEERING COLUMN (CONT’D)
1. Cap
2. Nut
3. Steering Wheel
4. Bushing
5. Tilt Steering 1
6. Bolt
2
7. Shock 3
8. Nuts
9. Upper Shaft
10. Electric Power Steering (EPS)
4
11. Bracket 6
12. Lower Shaft
13. Gear Box 5
14. Cotter Pin
8
4
6

6
9
8
10
8
8
6 6 11
6 8
8 12
8
14 13
8 6
14 8
NA-9461S

STEERING COLUMN (CONT’D) Figure 30-60-4
Steering Wheel Removal And Installation
Remove the upper steering shaft and steering wheel as

an assembly before attempting to remove the steering
wheel. (See Steering Wheel / Upper Steering Shaft
IMPORTANT
Striking the steering wheel or steering shaft while P104353
still connected to the steering unit can permanently
damage the power steering unit and cause a power
steering fault. Loosen the nut (Item 1) [Figure 30-60-4] and back it half
way off the steering shaft.
I-2349-0811
Figure 30-60-5
NOTE: The upper steering shaft and steering wheel

must be removed from the vehicle as an
assembly before the steering wheel can be
removed or damage to the power steering unit
can result.
Figure 30-60-3
1
P104354
Place the assembly in a vise.
Using a large bronze drift and hammer, strike the

steering shaft nut (Item 1) [Figure 30-60-5] to pop the
steering wheel off the shaft taper.
P104352
Once the steering wheel pops loose, completely remove
the nut (Item 1) [Figure 30-60-5] and remove the
Remove the steering wheel cap (Item 1) [Figure 30-60- steering wheel from the shaft.
3].
Installation: Be sure wheels are facing straight forward
and align as needed. Apply Loctite® and tighten the nut
to 88 N•m (65 ft-lb) torque.

Steering Wheel / Upper Steering Shaft Removal And

Installation
Remove the upper dash panel. (See Upper Dash Panel

Remove the lower dash panel. (See Lower Dash Panel

1
IMPORTANT
P120106
Striking the steering wheel or steering shaft while

still connected to the steering unit can permanently Remove the steering tilt assembly bolts (Item 1) and nuts
damage the power steering unit and cause a power (Item 2) [Figure 30-60-7].
steering fault.
I-2349-0811
Remove the steering wheel, upper steering shaft and

pivot out as an assembly.
Figure 30-60-6
Figure 30-60-8
P120105
P120100
Mark the upper steering shaft and power steering unit

splines to assist with steering wheel alignment during Remove the steering wheel cap (Item 1) [Figure 30-60-
installation [Figure 30-60-6]. 8].
Remove the pinch bolt (Item 1) [Figure 30-60-6] Loosen the nut and back it half way off the steering shaft.
retaining the upper steering shaft to the power steering
unit. Place the assembly is a vise.
Installation: Tighten the bolts to 47 N•m (35 ft-lb) torque. Using a large bronze drift and hammer, strike steering
shaft nut to pop the steering wheel off the tapered shaft.
Once the steering wheel pops loose, completely remove

the nut and lift the steering wheel off the shaft.

STEERING COLUMN (CONT’D) NOTE: Use care not to allow any of the Loctite® to get
in the bearing.
Steering Shaft Bearing Replacement
Apply Loctite® 271 to the outer circumference of the new
NOTE: The replacement pivot tube assembly comes upper bearing race. Slide the new upper bearing onto the
with new upper and lower bearings installed. steering shaft (Item 1) [Figure 30-60-9] and press it into
Use this procedure if replacing bearings only. the pivot tube by hand.
Remove the steering wheel / upper steering shaft NOTE: Use care not to allow any of the Loctite® to get
assembly. (See Steering Wheel / Upper Steering Shaft in the bearing.
NOTE: Bearings will be seated in the pivot housing
Remove the steering wheel from the upper steering upon tightening the steering wheel nut.
shaft. (See Steering Wheel Removal And Installation on
Page 30-60-3.)
Figure 30-60-9
2
2

1
P120053
Press the steering shaft out (Item 1) [Figure 30-60-9] of

the pivot tube.
Note the location of the bushings (Item 2) [Figure 30-60-

9] on each end of the pivot tube.
Drive the bearings out of the pivot tube using a drift

punch.
Inspect the pivot tube bearing surfaces for signs of

excessive wear or damage.
Apply Loctite® 271 to the outer circumference of the new

lower bearing race. Slide the new lower bearing onto the
steering shaft and install the steering shaft through the
pivot tube.

Power Steering Unit Removal
Remove the Steering Wheel / Upper Shaft. (See Steering

Wheel / Upper Steering Shaft Removal And Installation
on Page 30-60-4.)
Figure 30-60-10
1
P120130
1 Figure 30-60-13
1
P120107

Disconnect the electrical harnesses (Item 1) [Figure 30-
60-10] from the top of the power steering unit.
Figure 30-60-11
P120129
1
Remove the bolts (Item 1) [Figure 30-60-12] and [Figure
30-60-13] retaining the power steering mount to the
frame.
2
P120132
Remove the nut (Item 1) and pinch bolt (Item 2) [Figure

30-60-11] retaining the lower steering shaft to the power
steering unit.

Power Steering Unit Installation
Install the power steering unit onto the mount bracket.

Tighten the bolts to 41 N•m (30 ft-lb) torque.
1
Figure 30-60-14
1 P120132
Install the pinch bolt (Item 1) and nut (Item 2) [Figure 30-
60-16]. Tighten the nut to 20 N•m (15 ft-lb) torque.
Figure 30-60-17
P120130

Figure 30-60-15
P118423
With the front wheels pointing straight ahead and the

P120129 steering wheel straight, align the skip-tooth spline (Item
1) [Figure 30-60-17] with the opening in the upper
steering shaft and install the upper steering shaft onto
Position the power steering and mount assembly and the power steering input shaft.
install the bolts (Item 1) [Figure 30-60-14] and [Figure
30-60-15]. Tighten the bolts to 19 N•m (14 ft-lb) torque.

STEERING COLUMN (CONT’D)
Power Steering Unit Installation (Cont’d)
Figure 30-60-18
2
2
1
P120105
Install the upper steering shaft pinch bolt (Item 1) [Figure

30-60-18]. Tighten the bolt to 20 N•m 15 ft-lb) torque.

Connect the electrical harnesses (Item 2) [Figure 30-60-
18] onto to the top of the power steering unit.
Figure 30-60-19
P120106
Tighten the nuts (Item 1) [Figure 30-60-19] to 54 N•m

(40 ft-lb) torque.
Position the steering wheel, pivot tube and upper steering

shaft assembly.
Be sure the front wheels are pointing straight ahead and

that the steering wheel is straight.

STEERING BOX

Remove the tie rod. (See Removal And Installation on

Page 30-110-1.)
Figure 30-70-1
3
3

P101082
Remove the nut (Item 1) [Figure 30-70-1] and bolt.
Installation: Apply Loctite® 242 or equivalent thread

locker to the threads of the bolt and tighten the nut to 41
N•m (30 ft-lb) torque.
Separate the steering shaft (Item 2) [Figure 30-70-1]

from the steering box.
Remove the bolts and nuts (Item 3) [Figure 30-70-1]

securing the steering box to the frame.
Installation: Tighten the bolts and nuts to 22 N•m (16 ft-

lb) torque.
Remove the steering box.


FUEL TANK
Removal And Installation WARNING

Remove the front seats on standard vehicles or the rear
seats on XL vehicles and storage bins.
Disconnect the negative battery cable.
Remove both rear fenders. (See Removal And sparks or lighted tobacco away from fuel and oil.
Installation (Rear) on Page 30-140-1.) Failure to use care around combustibles can cause
explosion or fire.
Figure 30-80-1
W-2103-0508
1 1
NOTE: Siphon as much fuel from the tank as possible
before attempting to remove it from the
vehicle
Figure 30-80-3

1
1 2
P120134
Remove the plastic rivets (Item 1) and drive shaft cover 3

(Item 2) [Figure 30-80-1]. 4 1 5
Figure 30-80-2
P118753
Pull out on the tabs (Item 1) and slide the fuel line clamp
(Item 2) [Figure 30-80-3] forward.
1 1
Remove the fuel line (Item 3) [Figure 30-80-3].
NOTE: A small amount of fuel may come out of the

fuel line. Properly drain fuel into suitable
container.
Disconnect the fuel pump electrical harness (Item 4) and

remove the fuel tank vent line (Item 5) [Figure 30-80-3]
P120135
Remove the twelve screws (Item 1) [Figure 30-80-2].
Lift up and remove the floor.

FUEL TANK (CONT’D)
Figure 30-80-4
1
P118363
Remove the fuel tank bracket fasteners (Item 1) and

remove the fuel tank vent line (Item 2) [Figure 30-80-4].

Installation: Tighten the bracket bolts to 11 N•m (8 ft-lb)
torque.
Figure 30-80-5
1 1
P118364
Remove the plastic ties (Item 1) [Figure 30-80-5]

retaining the main harness to the fuel tank.
Slide the fuel tank toward the front of the vehicle and
remove.

SHOCKS Figure 30-90-3
Rear Shock Removal And Installation


Figure 30-90-1
1
P111167
Remove the bottom shock mount nut (Item 1) [Figure 30-

90-3] and bolt.
Remove the shock.

1

P113784
Lift up on the handle (Item 1) [Figure 30-90-1] and tilt the

cargo box.
Figure 30-90-2
P111166
Remove the top shock mount nut (Item 1) [Figure 30-90-

2] and bolt.

SHOCKS (CONT’D)
Front Shock Removal And Installation
Figure 30-90-4
P111170
Remove the top shock mount nut (Item 1) [Figure 30-90-

4] and bolt.

Figure 30-90-5
P111171
Remove the bottom shock mount nut (Item 1) [Figure 30-

90-5] and bolt.
Remove the shock.

SHOCKS (CONT’D) Figure 30-90-8
Shock Spring Removal And Installation
Remove the shock. (See Rear Shock Removal And

Installation on Page 30-90-1.) or (See Front Shock
Note the spring preload cam setting for reinstallation.
Figure 30-90-6
2 1
P-101105
2
Remove the spring (Item 1) and adjusting cam (Item 2)

[Figure 30-90-8].

P-101103
Using a spring compression (Item 1), compress the

shock spring far enough to remove the spring retainer
(Item 2) [Figure 30-90-6].
Figure 30-90-7
1
P-101104
Remove the spring retainer (Item 1) [Figure 30-90-7].


A-ARMS Figure 30-100-2
Lower A-Arm Removal And Installation


NOTE: The removal and installation procedure is the

same for left and right A-Arms.
1
Figure 30-100-1 2
P111173
Figure 30-100-3

1
2
P111577
Remove the lower ball joint pinch bolt (Item 1) [Figure

30-100-1] at the bearing carrier.
P111174
Remove the bolts and nuts (Item 1) from the lower A-Arm
(Item 2) [Figure 30-100-2] and [Figure 30-100-3].
Installation: Tighten the nuts to 54 N•m (40 ft-lb) torque.
Remove the lower arm from the machine.

A-ARMS (CONT’D) Figure 30-100-6
Upper A-Arm Removal


NOTE: The removal procedure is the same for left

and right A-Arms.
Figure 30-100-4
P133721
Mark each side off the break line as shown before

removing the brake line from the clamps [Figure 30-100-
2 6].
Figure 30-100-7

2
1 1
P118398
2 1
Remove the two bolts (Item 1) and lower front fascia
(Item 2) [Figure 30-100-5].
Figure 30-100-5
P133722
Remove the brake line (Item 1) from the clamps (Item 2)

[Figure 30-100-7].
1 2
P133720
Remove the bottom shock mount nut (Item 1) and bolt

(Item 2) [Figure 30-100-5] from the upper A-Arm.

Upper A-Arm Removal (Cont’d)
Figure 30-100-8
1
1
P133725
2
Remove the nut (Item 1) [Figure 30-100-10] from the

upper A-Arm bolt.
P133723
Figure 30-100-11
Remove the upper brake caliper bolt (Item 1) and loosen
the lower brake caliper bolt (Item 2) [Figure 30-100-8].
Rotate the caliper to access the ball joint pinch bolt.

Figure 30-100-9 1
P133726
Remove the A-Arm bolt (Item 1) [Figure 30-100-11].
2 Remove the upper A-Arm and discard hardware.

1 P133724
Remove the upper ball joint pinch bolt (Item 1) and nut
(Item 2) [Figure 30-100-9].
Remove the ball joint end from the bearing carrier.

Upper A-Arm Installation
NOTE: The preapplied locking agent on existing

hardware was destroyed during removal. DO
NOT reuse old hardware. Use new hardware
during installation.
Figure 30-100-12
1
2 3
P133724
Install the A-Arm ball joint end (Item 1) [Figure 30-100-

14] into the bearing carrier.
Install the pinch bolt (Item 2) and Nut (Item 3) [Figure 30-
1 100-14].
Tighten the nut to 57 N•m (42 ft-lb) torque.

P133726
Figure 30-100-15
Position the upper A-Arm and install the new bolt (Item 1)
[Figure 30-100-12].
Figure 30-100-13
1
P133727
Rotate the brake caliper (Item 1) [Figure 30-100-15] onto

the steering knuckle.
P133725
Install the top brake caliper bolt (Item 2) [Figure 30-100-

15].
Install the new nut (Item 1) [Figure 30-100-13].
Tighten both caliper bolts to 41 N•m (30 ft-lb) torque.

Upper A-Arm Installation (Cont’d)
Figure 30-100-16
2 1
1
P133720
2
2 Install the shock mount bolt (Item 1) and nut (Item 2)
[Figure 30-100-18].
P133728

Install the brake line into the brake line clamps (Item 1)
[Figure 30-100-16]. Figure 30-100-19

Install the clamps (Item 1) using the rivets (Item 2)
[Figure 30-100-16] onto the upper A-Arm.
Figure 30-100-17
1
2 2
P118398
Position the front fascia (Item 1) and install the two bolts
(Item 2) [Figure 30-100-19].
P133721 Install the tire assembly. (See Wheel Removal And

Verify the alignment marks (Item 1) [Figure 30-100-17]
are visible on both sides of the clamps.

A-ARMS (CONT’D)
Inspection
NOTE: The inspection procedure is the same for all A-

Arms.
Figure 30-100-20
2
1
P111576

Inspect the bushings (Item 1) and pivot tubes (Item 2)
[Figure 30-100-20] for wear or damage and replace as
needed.

Ball Joint Removal And Installation
NOTE: It may be necessary to remove the lower shock

mount bolt to gain enough access for the ball
joint tool.
Removal

1
Remove the appropriate tire assembly. (See Wheel
P111634
Remove the brake caliper. (See Caliper Removal on
Page 20-11-4.)
Remove the retaining ring (Item 1) [Figure 30-100-22]
Figure 30-100-21 from the ball joint.
Figure 30-100-23

3 1
P111583
4
P111581
The A-Arm does not need to be removed to perform this
procedure if ball joint tool PU-50506 is used [Figure 30-
100-21]. Install the spacer (Item 1) [Figure 30-100-23] over the
top of the ball joint face.
If necessary, remove the lower front shock fastener from
the A-Arm to gain enough clearance to install ball joint Place the removal adapter (Item 2) [Figure 30-100-23]
tool PU-50506 on the ball joint. over the ball joint shaft.
Install the press assembly (Item 3) [Figure 30-100-23]

onto the A-Arm to engage the ball joint removal adapter.
IMPORTANT: Be sure the press assembly opening is

only contacting the spacer (Item 1) [Figure 30-100-23]
and not the ball joint face.
Tighten the press assembly screw (Item 4) [Figure 30-

100-23] and fully remove the ball joint from the A-Arm.

A-ARMS (CONT’D)
Ball Joint Removal And Installation (Cont’d)
Installation
Install the new ball joint into the A-Arm by hand.
Figure 30-100-24
3
1
2
P111582

Position the installation adapter (Item 1) [Figure 30-100-
24] over the face of the ball joint.
Position the spacer (Item 2) [Figure 30-100-24] over the

shaft of the ball joint so it is against the A-Arm.
Install the press assembly (Item 3) [Figure 30-100-24]

onto the A-Arm to engage the installation adapter and
spacer
Tighten the press assembly screw (Item 4) [Figure 30-

100-24] and fully install the ball joint into the arm.
Figure 30-100-25
P111634
Install the retaining ring (Item 1) [Figure 30-100-25].

TIE ROD Figure 30-110-2
Description
The tie rods are the adjustable connection that links the
steering cylinder shaft to the spindle. The tie rods provide 1
a method of adjusting the “toe” position of the wheels.
3
Lift and block the machine. (See LIFTING AND 2


P-97868
NOTE: The tie rod end and boot are serviceable,
when replacing a tie rod, the tie rod must be
replaced as a complete unit. After the tie rod Remove the strap (Item 1) [Figure 30-110-2] securing
is replaced, the wheel alignment for toe the steering box side of the boot.
position must be checked.
Remove the clamp (Item 2) and slide the boot (Item 3)
Figure 30-110-1 [Figure 30-110-2] towards the spindle.

3
5
4
2
1
P111920
Remove the cotter pin (Item 1), nut (Item 2), bolt (Item 3)
and separate the outer tie rod end from the spindle (Item
4) [Figure 30-110-1]. Tighten the nut to 16 - 19 N•m (12 -
14 ft-lb) torque.
Loosen the nut (Item 5) [Figure 30-110-1] and turn the

tie rod end off of the tie rod. Count the number of turns it
takes to remove the tie rod end.
Installation: Turn the new tie rod end onto the tie rod the
same number of turns it took to remove the old tie rod
end.

TIE ROD (CONT’D) Figure 30-110-4
Toe Adjustment Procedure
Stop the machine on a flat level surface. Engage the

parking brake and stop the engine.
Turn the steering wheel so it is in the straight ahead

position.
Figure 30-110-3
NA5215
NOTE: Be sure the steering wheel is straight ahead

before determining which tie rod needs
1 adjustment.
If the toe alignment is incorrect, measure the distance

254 mm between the center of the vehicle and each wheel. This

(10.0 in) will determine which tie rod needs adjusting [Figure 30-
NA5216 110-4].
NOTE: During tie rod adjustment, make sure to use a

Place a chalk mark (Item 1) [Figure 30-110-3] on the wrench on both the tie rod end and the jam
center of the front tires at approximately 254 mm (10 in) nut. Tie rod end damage could occur if the tie
up from the floor (or as close to the centerline of the front rod end is not held securely while loosening
axle as possible. or tightening the tie rod jam nut.
NOTE: It is important that the height of both marks be Hold the tie rod end securely and loosen the jam nut.
equally positioned to get an accurate
measurement. Use a wrench on the flat spot on the tie rod and a wrench
on the tie rod end. Rotate the tie rod to shorten or
Measure the distance between the marks and record this lengthen until the alignment is as required to achieve the
measurement. (We will call this dimension A.) proper toe setting.
Move the gear selector out of PARK and roll the vehicle When alignment is correct, hold the tie rod end securely
ahead until the chalk marks are to the rear of the front and tighten the jam nut to torque.
tires (approximately at the centerline of the front axle.
Engage the parking brake.
Measure the distance between the chalk marks and

record the dimension. (We will call this dimension B.)
The difference between dimension A and B is the toe

alignment. The recommended toe tolerance is 3,17 - 6,35
mm (0.125 - 0.25 in) to out. (This means the
measurement: A: in front of the tire should be wider than
the measurement “B” at the rear of the tire.
Toe Out - 3,17 - 6,35 mm (0.125 - 0.25 in)

TAILGATE Figure 30-120-3
Figure 30-120-1
P-101136
1
Lift up and out on the left side of the tailgate first (Item 1)
[Figure 30-120-3].
P113484
Raise the latch (Item 1) [Figure 30-120-1] and lower the

tailgate.

Figure 30-120-2
P-101134
Pull out on the retaining clip (Item 1) [Figure 30-120-2]

and remove the tailgate cable from the cargo box.

TAILGATE (CONT’D) Figure 30-120-6
Latch Removal And Installation
Figure 30-120-4
1
1
1
1 P-101125
2 1
Remove the clips (Item 1) [Figure 30-120-6].
P-101126 Remove the latch.
Remove the screws (Item 1) and tailgate cap (Item 2)

[Figure 30-120-4].

Figure 30-120-5
1
P-101123
Remove the latch screws (Item 1) [Figure 30-120-5].

CARGO BOX Figure 30-130-3
Figure 30-130-1
1 2
P126822
Disconnect the tail light harness (Item 1) [Figure 30-130-

P-101085 3].
Support the cargo box and remove the nuts (Item 2)

Lift the handle (Item 1) [Figure 30-130-1] and tilt the [Figure 30-130-3] and bolts.
cargo box into the dump position.

Remove the cargo box.
Figure 30-130-2
1
2
P126790
Remove the shock clip (Item 1), washer, safety cable

(Item 2) (if equipped) and pin (Item 3) [Figure 30-130-2].


FENDER Removal And Installation (Rear)
Removal And Installation (Front) NOTE: Right rear fender shown. Procedures are the
same for the left side except where noted.
Removal And Installation on Page 30-30-1.) Figure 30-140-3
Remove the fender flares. (See Flare Removal And

NOTE: Right front fender shown. Procedures are the

same for the left front.
Figure 30-140-1 1
P111925
Remove the screw (Item 1) [Figure 30-140-3].

1
Figure 30-140-4

P110771 1
1
Remove the two screws (Item 1) and plastic rivet (Item 2)
[Figure 30-140-1].
Figure 30-140-2
P111926
2
1 Remove the two screws (Item 1) [Figure 30-140-4].
P110770
Remove the three screws (Item 1) and fender (Item 2)

[Figure 30-140-2].

FENDER (CONT’D) Figure 30-140-7
Removal And Installation (Rear) (Cont’d)
Figure 30-140-5
P111929

P111927 attaching the upper fender to the lower fender.
Figure 30-140-8
Remove the screws (Item 1) [Figure 30-140-5].
Figure 30-140-6

1
1 P111930
P111928 Remove the screw (Item 1) [Figure 30-140-8] attaching

the upper fender to the lower fender.
Remove the screw (Item 1) [Figure 30-140-6].

FENDER (CONT’D) Flare Removal And Installation
Removal And Installation (Rear) (Cont’d) NOTE: Right flare shown. Procedures are the same
for the left side.
Figure 30-140-9
Figure 30-140-11
P111931
P110769

attaching the lower fender to the frame. Remove the two screws (Item 1) [Figure 30-140-11].

(Operator’s side only) Slide the fender skirt forward to disengage the tabs from
the fender.
Figure 30-140-10
P111932
Reaching in from the rear of the fender, loosen the clamp

(Item 1) [Figure 30-140-10] and remove the filler hose.
Remove the fender.


ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-5
Fuse And Relay Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-5
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-3
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Current Draw - Key OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Break Even Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Alternator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-3
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-3
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-4
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
FUEL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Headlight Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Headlight Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-2
Tail Light / Brake Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-3
ELECTRONIC CONTROL MODULE (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
SWITCH (HEADLIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-2

SWITCH (BRAKE LIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-2
SWITCH (AWD / 2WD / TURF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-92-1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-92-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-92-2
SWITCH (KEY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-93-1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-93-1
Ignition Key Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-93-2
SWITCH (GEAR SELECTOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-94-1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-94-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-94-2

GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-2
DIFFERENTIAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
DIFFERENTIAL SOLENOID (REAR RELAY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-111-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-111-1
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
Fan Control Circuit Operation / Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-2
Fan Control Circuit Bypass Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-2

INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Information Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-3
Information Display Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-3
Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-10
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
DIAGNOSTIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1

Digital Wrench™ Diagnostic Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Digital Wrench™ Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-2
Digital Wrench™ SmartLink Module Kit - MEL1721 . . . . . . . . . . . . . . . . . . . . . . . . 40-160-2
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-3
Version And Update ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-3
Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-4
Digital Wrench™ Feature Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-6
Engine Controller Reprograming (Reflash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-7
ELECTRONIC POWER STEERING (EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1

EPS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Power Steering 30A Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
System Diagnosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
EPS Troubleshooting (Power Steering Non-Functional with MIL ON) . . . . . . . . . . 40-170-2
EPS Troubleshooting (Power Steering Non-Functional with MIL OFF) . . . . . . . . . . 40-170-3
EPS Troubleshooting (Using Digital Wrench™) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-4


ENGINE CONTROL UNIT EPS Power A BRN
(MODULE) (ECU/ECM) Start Solenoid TVS BRN LOW
Pin Function Fuel Solenoid/Pump TVS BRN BRN A A
LEFT
201 Start Solenoid Enable Headlight (-) Slice BRN GROUND A LIGHT DGR B B
WHT
202 ECMU Relay Enable (85) Engine Cooling Fan BRN SWITCH YEL
BRAKE C C
204 Fan Relay Enable Dash (-) Slice BRN PRESSURE 1 D D
2
RED/DBL
209 Key Switch Splice #1 (-) Slice BRN SWITCH DGR HIGH
3
211 Turf Enable Relay (-) Slice BRN
ORG/BLK
217 AWD Enable Rear Diff Relay BRN 4
RED/YEL HIGH
5 YEL
218 Rear Diff Relay Control D D
6
219 Hold/Pump Relay Enable (85) Vehicle Speed Sensor BRN YEL C C
BRN 8
RIGHT
Box Harness BRN 7 B B
223 Gear Switch BRAKE DGR
226 Glow Plug Relay Enable AWD Switch BRN GROUND B LIGHT
BRN A A
RED/YEL
ECM (-) Slice BRN ORG/BLK ORG/BLK
BRN
227 Crank Position Sensor (-) 25 5A 31 LOW
Dash (-) Slice BRN
ORG/BLK
228 AWD Switch Enable DASH Pin 8 YEL
230 Sensor Ground Crank Position Sensor Shield BRN
Fuel Level Sensor BRN START
235 Can Low TVS
RELAY
236 Can High 60 54 BRN C C BRN
237 Back-Up Alarm Enable 30 86 LEFT/RIGHT
ORG/BLK B B ORG/BLK
WHT/RED
WHT/RED
239 Crank Position Sensor (+) BRAKE
I RED/YEL A A RED/YEL
RED/YEL
244 Coolant Temp Sensor RED/WHT 6 6 B SPLICE
87 85 LEFT/RIGHT
LIGHTS
245 Vehicle Speed Sensor BATTERY 59 53 ORG 4 4 TAIL LIGHT
STARTER
247 Can High - + WHT/RED 2 2
ST
248 Can Low B M S RED/WHT 1 1
WHT/RED
250 Ground DRIVE MODE SWITCH
251 Ground 1
ECU Pin 201 WHT/RED SPLICE ECU Pin 253
WHT/DGN ECU Pin 211
RED/DBL 2
252 Ground ECU BRN
3
RELAY START GRY ECU Pin 228
253 ECU Relay Splice
RUN
68 RED/DBL
4
ALTERNATOR
ALTERNATOR
OFF
5
67
CONTROL
2 2 6
RELAY
RED 62 65
RED/WHT
WIRE COLOR LEGEND B 1 1 RED/BLK IGNITION RED/YEL 8
7
EXCITATION SWITCH
RED/DBL
RED/DBL
SPLICE
BRN
GLOW GLOW PLUG
RED RED ECU Pin 226 BRN 55
PLUGS SPLICE
BLACK BLK BRN SWITCHED
SPLICE
SWITCHED
WHITE WHT HR
BRN POWER 2
POWER 1
BROWN BRN ORG ORG RED/YEL
HR RED
ORANGE ORG 32 26 AWD
YELLOW YEL P4 P2 RED/BRN RED/WHT
HR SOLENOID A A SPLICE
PURPLE PUR 5A DRIVE
87 86
ORG
UNSWITCHED
ORG
RED/WHT
34 28
TURF SOLENOID
GRY B B GRY RED/GRN A A RED
ORG
PINK PNK GLOW PLUG BRAKE
POWER
SPLICE
30 86 LIGHT BRN/WHT C C ECU Pin 218 DGN/WHT B B GRN
GRAY GRY RELAY
RED/WHT
DRIVER
RED
TAN TAN 30 85 ALT.
D D BRN C C BRN
RED/WHT
ECU Pin 209

24 OHM
RELAY
DASH Pin 3
LIGHT BLUE LBU P1 SPLICE BRN/WHT ECU Pin 217
P3 87 85 RELAY BRN MIN. 11 VOLT
RED
DARK BLUE DBU GROUNDS 24 18 RED A A RED

33 27
LIGHT GREEN GRN FUSIBLE BRN BRN 30 86 LBL B B LBL
DARK GREEN DGN LINKS GLOW PLUG
P2 80A P1
RED/BLK Dealer Copy -- Not for Resale
ECU
RELAY
#5
RED/DBL 87 85 ENGINE OIL
ENGINE FAN 23 17 DASH Pin 10 PNK
RED PRESSURE
44 20A 38 ENGINE ON = OPEN SWITCH
#1 RED/DBL RED/DBL DGN/YEL ECU Pin 202 A A
42 48 DASH Pin 11 PUR/WHT B B FUEL EMPTY = 6k ohm
86 30 FUEL PUMP / BRN C C SENDER FULL = 102k ohm
DASH Pin 4
(UNSWITCHED
RED
RED FAN MOTOR HOLD SOLENOID BRN P2 P2 FUEL

POWER) P
RELAY RED RED/WHT PUMP
14 15A 20 RED P1 P1
BRN 85 87 36 30 TRANSMISSION
41 47 SWITCH
(SWITCHED 30 86 TVS
POWER) ECU Pin 204 BRN/RED FUEL HOLD / P1 P2 o 24 HIGH
PUMP RELAY
RED RED BRN
o 75 LOW
REAR
TERMINAL M
A A BRN 87 85 SPLICE
FUEL
ECU Pin 223 WHT B B o o 160 NEUTRAL
BLOCK B B ORG/BLK 35 29 1 2 ECU Pin 230 PUR PUR A A o 300 REV
FAN GRY/DGN ECU Pin 219
RED BRN o 620 PARK
ECU
BRN ECU Pin 250
MOTOR RED/DBL FUEL SOLENOID
UNSWITCHED ENGINE COOLANT
BRN BRN
ORG/WHT
ECU Pin 251

POWER SENSOR 25° C (77° F) =
RED BRN ECU Pin 252 t 29.9k ohm
#2 10 30A 4 PUR P2 P2
120° C (248° F) =
ORG ECU Pin 244 YEL P1 P1 1.22k ohm
CHASSIS SPLICE
ACCESSORIES ACC POWER #1
RED ORG/WHT PWR
#3 3 30A 9 WHT ORG/WHT ORG/WHT ECU Pin 227 BLK 2 2 CRANKSHAFT
6 22 20A 16 ORG/WHT GRD
12 BRN SHIELD BRN 3 3 POSITION
LIGHTS ECU Pin 237 BLK/WHT - + ORG/WHT SHIELD 2 SHIELD 1
86 30 SIG SENSOR
CHASSIS ECU Pin 239 WHT 1 1
WHT RED/YEL
RELAY 21 15A 15 BACK-UP ALARM HALL-EFFECT
85 87 (IF EQUIPPED) SENSOR
BRN
BRN
5 11 SPLICE
CHASSIS 12 VOLT ORG A A
PWR
TO SPLICE CHASSIS
POWER GRD SPEED
RELAY BRN WHT WHT RED/YEL PORTS BRN B B
GROUNDS 9 15A 3 SENSOR
SIG
ORG/WHT ECU Pin 245 GRN/RED C C
EPS
HALL-EFFECT
RED ORG SENSOR
#4 2 30A 8
66 RED/WHT
ORG/WHT
A B C D E F G H
72
86 30
4 3 2 1
EPS
POWER STEERING
RELAY
DGN DASH Pin 2
WIRING SCHEMATIC
ELECTRONIC
BRN BRN
85 87 ORG
ECU Pin 247 YEL
65 71 DGN DGN ECU Pin 248
TO SPLICE
BRN WHT A A
SPLICE ECU Pin 235 DGN 3400 D (S/N B3FK11001 AND ABOVE)
8 7 6 5
RELAY CAN LO
DGN
GROUNDS
BRN B B
YEL
3400XL D (S/N B3FM11001 AND ABOVE)
(UNSWITCHED
(SWITCHED
GROUND
Printable Version Click Here
POWER)
POWER)
YEL YEL ECU Pin 236 DIAGNOSTIC
SPLICE
CAN HIGH
YEL DASH Pin 1
CONNECTOR FRONT
TERMINAL
(PRINTED OCTOBER 2014)
Printed In U.S.A. BLOCK V-1592
281 of 481
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION
CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or

connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
electrical current to supply voltage to on switch application.
G the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION
COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
RUN
OFF
activated manually by a switch to
warn personnel.
BUZZER - Audible alarm. Sounds at a

1
SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

DIODE - Allows electrical current to
ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3700 3710 SPLICE (•) - Used to show when

3110
multiple wires are connected together
on the schematic. HOURMETER - Records the time the
+
H - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
C
-
B pressure. (Sender voltage rating is
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000 ohm
ohm rating is listed to show ohms at

high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
FUEL SENDER - Provides a variable

B
resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A
SPEED SENSOR - magnetic pickup -
detects rpm.
B

ELECTRICAL SYSTEM INFORMATION (CONT'D)
Troubleshooting WARNING
assistance in locating and correcting problems. Many of Instructions are necessary before operating or
the recommended procedures must be done by servicing machine. Read and understand the
authorized Bobcat Service Personnel only. Operation & Maintenance Manual and signs (decals)
death.
W-2408-0801
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4
Stator will not charge. 1, 3, 4
Starter will not turn the engine. 1, 2, 3, 5, 6, 7, 8
KEY TO CORRECT THE CAUSE

1. Battery connections are dirty or loose.
2. Battery is damaged.
3. The cable and wire connection are not making good contact.
4. The starter / alternator is damaged.
5. The engine is locked.
6. The starter is damaged.
7. The wiring or solenoid is damaged.
8. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 40-10-3
Description
The utility machine has a 12 volt, negative ground 1

5 9 11
charging system. The electrical system is protected by
2 23
fuses and relays. The fuses will protect the electrical 6 10 12
system when there is an electrical overload which could 3 7
lead to burned up harness or machine damage. The 19 21 22
20
reason for the overload must be found and corrected 4 8
before starting the engine again.
13 14 15 16 17 18
Fuse And Relay Location
P113556
The fuses and relays are located below the center of the
seat. (Front seat on 3400 Standard models and rear seat
on 3400XL models.) There is a decal [Figure 40-10-3] on the front of the relay
panel cover which shows the location of the relays.
Figure 40-10-1 Description of relays is also shown below.
Figure 40-10-4

1
P-97882 P113555
Remove the seat (Item 1) [Figure 40-10-1]. Under the cover (Item 1) [Figure 40-10-2] are the
following fuses / relays [Figure 40-10-4].
Figure 40-10-2
REF DESCRIPTION F REF DESCRIPTION
1 HEATER (if Equipped) 30 13 CHASSIS R

2 (EPS) ELECTRONIC 30 14 ECU R
POWER STEERING
3 CHASSIS 30 15 FUEL PUMP HOLD R
4 ECU 30 16 FAN R
5 DRIVE 15 17 START R
6 FUEL PUMP HOLD 15 18 EPS R
7 LIGHTS 15 19 ALTERNATOR R
1 8 ACCESSORIES 20 20 NOT USED R
9 BRAKE LIGHTS 5 21 NOT USED R
P113501 10 ALTERNATOR 15 22 NOT USED R
11 FAN 20 23 ALTERNATOR R
CONTROL
Remove the fuse / relay cover (Item 1) [Figure 40-10-2]. 12 ENGINE FAN 20
R = Relay


BATTERY NOTE: When removing and installing the battery, do
not touch any metal parts with the battery
Removal And Installation terminals.
Install the battery.
WARNING Install and tighten the battery hold down clamp and bolt.
Connect and tighten the battery cables. Connect the

negative (-) cable last to prevent sparks.
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
WARNING
and wash eye with clean, cool water for at least 15
minutes. BATTERY GAS CAN EXPLODE AND CAUSE
If electrolyte is taken internally drink large quantities Keep arcs, sparks, flames and lighted tobacco away
of water or milk! DO NOT induce vomiting. Get from batteries. When jumping from booster battery
prompt medical attention. make final connection (negative) at machine frame.
W-2065-0807
Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before

Figure 40-20-1 connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
4
1
P113507
Remove the passenger seat and the storage

compartment.
Disconnect the negative (-) cable (Item 1) [Figure 40-20-

1].
Disconnect the positive (+) cable (Item 2) [Figure 40-20-

1].
Remove the battery hold down bolt (Item 3) and battery

hold down clamp (Item 4) [Figure 40-20-1].
Remove the battery.

BATTERY (CONT’D)
Servicing
WARNING
contact. Wear goggles, protective clothing and

minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

Figure 40-20-2
P-09589 P-09590
Always clean the battery terminals and cable ends when

installing a new or used battery [Figure 40-20-2].
Check the electrolyte level in the battery (if needed). Add

distilled water as necessary.
Put grease on the battery terminals and cable ends to

prevent corrosion.

BATTERY (CONT’D) Figure 40-20-3
Using A Booster Battery (Jump Starting)
IMPORTANT
Do not use a running vehicle when jump starting as
high current loads may damage charging system.
• Bobcat recommends using a portable charge
pack or a stand alone battery when jump starting.
• If jump starting from a second vehicle is
necessary, make sure the engine of the second
P113506
vehicle is off before attempting to start the
vehicle with the dead battery.
I-2337-0610
Figure 40-20-4
If it is necessary to use a booster battery to start the

engine, BE CAREFUL!
NOTE: Do not jump start using a running vehicle.

Stop the engine on the vehicle being used for

the booster battery before attempting to start
the utility vehicle. 1
The key switch must be OFF. The booster battery must

be 12 volt.
WARNING P-97804
BATTERY GAS CAN EXPLODE AND CAUSE Using A Portable Power Pack
Keep arcs, sparks, flames and lighted tobacco away Remove the passenger seat and storage compartment.
from batteries. When jumping from booster battery
make final connection (negative) at machine frame. Connect the positive (+) cable (Item 1) [Figure 40-20-3]
of the booster pack to the positive (+) battery terminal.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before Connect the negative (-) cable (Item 1) [Figure 40-20-4]
connecting to a charger. Unplug charger before of the booster pack to a frame ground.
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging. Start the engine.
W-2066-0910
After the engine has started, remove the ground (-) cable
(Item 1) [Figure 40-20-4] first. Remove the cable from
the positive terminal (Item 1) [Figure 40-20-3].

BATTERY (CONT’D) Connect the end of the first cable (Item 1) [Figure 40-20-
7] to the positive (+) terminal of the booster battery.
Using A Booster Battery (Jump Starting) (Cont’d) Connect the other end of the same cable to the positive
(+) battery terminal (Item 2) [Figure 40-20-5] of the utility
Using A Second Battery Or Vehicle For Jump Starting vehicle.
Figure 40-20-5 Connect the end of the second cable (Item 3) to the
negative terminal of the booster battery. Connect the
other end of the same cable to a frame ground (Item 4)
[Figure 40-20-6] on the utility vehicle.
Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 40-20-6] first. Remove the cable from
2
the positive terminal (Item 2) [Figure 40-20-5]. Then
remove the cables from the booster battery.
P113506 IMPORTANT
Damage to the charging system can occur if:

Figure 40-20-6 • Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding. (Remove both cables
from the battery.)
• Extra battery cables (booster cables) are
connected incorrectly.
I-2217-0610
P-97804
Figure 40-20-7
1 3
P-39258
NOTE: Do not jump start using a running vehicle.

Stop the engine on the vehicle being used for
the booster battery before attempting to start
the utility vehicle.

CHARGING SYSTEM
Current Draw - Key OFF WARNING

Remove the seat base. (See Seat Base Removal And
Installation on Page 30-20-2.) AVOID INJURY OR DEATH
Figure 40-30-1 contact. Wear goggles, protective clothing and

minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
B-23982

If the charging system malfunctions check the following:
Check the electrolyte level in the battery. Add distilled

water as needed. (Does not apply to maintenance free
batteries.)
Verify the charge of the battery. Make sure battery is fully

charged.
Disconnect the battery cables (negative first, then

positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.
With the key off, connect an ammeter between the

negative battery post and the disconnected negative
cable clamp [Figure 40-30-1].
1. With the key OFF, current draw should not be more

than 0.01 DCA (10 MA).
2. If the draw is excessive, there is a short (drain) in the

electrical system of the utility work machine. The short
must be repaired before the charging system can be
checked.
3. Disconnect loads one by one until the draw is

isolated. Check component wiring as well as
components for shorts to ground.

CHARGING SYSTEM (CONT’D)
Break Even Test

The “break even” point of the charging system is the point

at which the alternator overcomes all system loads
(lights, etc.) and begins to charge the battery. Depending
on battery condition and system load, the break even
point may vary slightly. The battery should be fully
charged before performing this test.
Connect a tachometer to the engine.
Using an inductive amperage metering device, (set to DC

amps) connect to the negative battery cable.
With engine off and the key switch and lights in the ON
position, the ammeter should read negative amps
(battery discharge). Reverse meter lead if a positive
reading is indicated.

Shift transmission to neutral and start the engine. With
the engine running at idle, observe meter readings.
Increase engine rpm while observing ammeter and

tachometer.
Note rpm at which the batter starts to charge (ammeter

indication is positive).
With lights and other electrical loads off, the “break even”
point should occur at approximately 1500 rpm or lower.
With the engine running, turn the lights on and step on

the brake pedal to keep brake light on.
Repeat test, observing ammeter and tachometer. With

lights on, charging should occur at or below 2000 rpm.

CHARGING SYSTEM (CONT’D) Belt Adjustment
Alternator Removal And Installation Figure 40-30-4

2
Figure 40-30-2
1
3
1
2 P113558
Measure belt deflection at mid span (Item 1) [Figure 40-

P113558 30-4] of the belt with 89 N (20 lb) applied.
Deflection should not be more than 10 - 14 mm (0.375 -

Remove the top adjustment bolt (Item 1) [Figure 40-30- 0.500 in)
2].
If not, loosen the adjustment bolt (Item 2) and mount bolt
Remove the alternator belt (Item 2) [Figure 40-30-2]. (Item 3) [Figure 40-30-4].
Figure 40-30-3 Move the alternator (Item 4) [Figure 40-30-4] to tighten

the belt.
Tighten the adjustment and mounting bolt to 25 N•m (18

ft - lb) torque.
P120345
Remove the bottom bolt (Item 1) and the alternator (Item

2) [Figure 40-30-3].

CHARGING SYSTEM (CONT’D)
Belt Replacement
Figure 40-30-5
P113716
Remove the four plastic rivets (Item 1) and remove the

shield (Item 2) [Figure 40-30-5].
Loosen the mounting and adjustment bolts (Item 1 and 2)

[Figure 40-30-4] and move the alternator toward the
engine. Remove the belt.
Install the new belt and adjust as shown under Belt

Adjustment.
Reinstall the shield (Item 2) and the four plastic rivets

(Item 1) [Figure 40-30-5].

STARTER SYSTEM Testing
Operation The starter solenoid is non-serviceable. If found faulty,

replace the starter solenoid / motor unit.
The starter solenoid sits atop the starter motor. To
energize the starter solenoid the following must occur: Verify power is getting to the solenoid.
• The brake must be applied to close the brake Check resistance across the terminals. Starter solenoid
pressure switch and provide 12V power to the key terminal resistance should be 0.4ohmns.
switch and ECU.
• The key switch must be turned to the “start” position

to provide 12V power to the starter solenoid via the
White/Red wire.
• The starter solenoid then engages the starter gear to

the flywheel for the starter motor to turn the engine
over.

STARTER SYSTEM (CONT’D) Figure 40-40-3
Stop the engine and remove the passenger seat base.
Remove the negative (-) and positive (+) cables from the
battery.
Figure 40-40-1 1
1
P120003
Remove the bolts (Item 1) [Figure 40-40-3] attaching the

starter to the adapter plate.
Remove the starter motor.

P120187
Remove the wire (Item 1) [Figure 40-40-1] from the

solenoid.
Figure 40-40-2
P120188
Slide the protective boot (Item 1) [Figure 40-40-2] up the

wire and remove the nut and the battery wire.

FUEL SOLENOID Removal And Installation
Location Figure 40-50-2
Figure 40-50-1
2
P120206
P120205
Disconnect the wire harness connector (Item 1) [Figure
40-50-2] from the fuel solenoid.
The fuel solenoid (Item 1) [Figure 40-50-1] is located
under the cargo box after the fuel filter / water separator. Remove the fuel line (Item2) [Figure 40-50-2]

Remove the bolt (Item 3) [Figure 40-50-2] and the shut
off valve.

FUEL SOLENOID (CONT’D)
Testing
Figure 40-50-3
P120206

40-50-3] from the fuel solenoid.

Measure the resistance across the fuel solenoid pins.
FUEL SOLENOID RESISTANCE 12.6 

LIGHTS
Headlight Removal And Installation

Figure 40-60-1
P-97806

The high beam light bulb (Item 1) is to the inside and the
low beam light bulb (Item 2) [Figure 40-60-1] is to the
outside (both sides).
Figure 40-60-2
P-97333
Rotate the bulb socket (Item 1) [Figure 40-60-2]

approximately 1/8 turn counterclockwise to remove from
the light housing.
When installing the new bulb (Item 2) [Figure 40-60-2],

Do Not touch the bulb with bare fingers. The oil on your
skin will effect performance of the light bulb. Use a clean
cloth to grip the new bulb when inserting it into the
connector. (See instructions included with the bulb for
additional information).

LIGHTS (CONT'D) Figure 40-60-4
Headlight Adjustment
Figure 40-60-3
1
7,6 m (25 ft)
1
254 mm (10.0 in) 152 mm (6.0 in)

Low Beam High Beam
X X
P-97849
Locate the headlight adjusting screw (Item 1) [Figure 40-

P-97885A 60-4] on the headlight housing (one adjusting screw for
each light). The high beam light bulb is to the inside and
the low beam light bulb is to the outside (both sides).
When performing the headlight adjustment procedure,
there should be both an operator and passenger(s) in the Rotate the screw in or out as needed to adjust the

seat(s) for correct beam adjustment to simulate actual headlight.
vehicle operation [Figure 40-60-3]. (If using an
attachment for extended lengths of time, the attachment Repeat until the headlights are in correct adjustment.
should also be installed before adjusting lights. When the
attachment is removed, the lights will need to be Reinstall the front access cover.
readjusted.)
Place the vehicle on a flat and level surface with the

headlight approximately 7,6 m (25 ft) from a wall.
Move the gear selector lever to Park, stop the engine and
exit the vehicle.
Measure the distance (X) from the floor to the center of

the headlight. On the wall, directly in front of the vehicle,
make a mark (X) on the wall at the same height.
The most intense part of the light should be aimed

approximately 254 mm (10.0 in) for low beam, 152 mm
(6.0 in) for high beam, below the (X) mark placed on the
wall.


LIGHTS (CONT'D)
Tail Light / Brake Light Removal And Installation
Figure 40-60-5
1
2
P-97807
Remove the two screws (Item 1) and remove the rear

light assembly (Item 2) [Figure 40-60-5].

Figure 40-60-6
P-97862
Disconnect the harness from the rear light assembly

[Figure 40-60-6]. Replace the entire rear light assembly.


ELECTRONIC CONTROL MODULE (ECU) Removal And Installation
Description Remove the seat base.
Located under the center console. Signals to the ECU Connect the Vehicle Interface Cable to the Digital
include ignition power (on/off), engine coolant Wrench™ diagnostic connector. Go to the Special Tests
temperature, crankshaft position, engine speed (RPM) menu and select ECU Replacement. Carefully follow the
and battery voltage. The ECU stores the logic for hot ECU replacement instructions.
lamps, radiator fan, two-speed shift strategy, AWD
control, and starter lockout. During operation, the ECU Figure 40-70-1
continually performs a diagnostic check of itself, each of
the sensors and system performance. If a fault is
detected, the ECU turns on the “Check Engine” light on
the instrument cluster and stores a fault code in its fault
memory.
Digital Wrench™ also reports on the following items: 1
• AWD and Diff Lock Status 1
2
• Battery Voltage
• Brake Switch (on / off)
• Cooling Fan Relay Driver

P118744
• Crankshaft Signal Present
• Engine RPM, Temperature and Run-Time Remove the four screws (Item 1) [Figure 40-70-1]
securing the ECU to the center tray.
• Fuel Pump (on/off)
Installation: Tighten the screws to 2,7 N•m (24 in-lb)
• Gear Switch Voltage torque.
• Seat Switch (Operator Present) Input / Output With the ignition turned off, disconnect the wire harness
from the ECU. Lift the connecting locking lever (Item 2)
• Two-Speed Shift Coil Duty Cycle [Figure 40-70-1] and rotate it up until the connector is
free from the ECU.
• Vehicle Speed
NOTE: Upon removing the ECU connector, you
The ECM is a sealed component and cannot be tested. should hear a “click” when the connector is
fully open.
Remove the ECU.
NOTE: Upon installing the ECU connector, you

should hear a “click” when the connector is
fully closed.


VEHICLE SPEED SENSOR Testing
Location Disconnect the harness (Item 1) [Figure 40-80-1] from

the speed sensor and remove the sensor from the
Figure 40-80-1 transmission.
Connect the wires from the Static Timing Light Harness

to the sensor 3 pin connector using the Hall Sensor
Probe Harness.
Pass a screwdriver back and forth in front of the sensor

tip.
1
If the light flashes the sensor is good.
Figure 40-80-2
P118445
The speed sensor (Item 1) [Figure 40-80-1] is located on

the right side of the transmission, accessed through the
right rear wheel well.

P120351
Figure 40-80-3
P120350


SWITCH (HEADLIGHT) Removal And Installation
Location Remove the upper dash. (See Upper Dash Panel

Figure 40-90-1
Figure 40-90-2
P111181
P111180
The head lamp switch (Item 1) [Figure 40-90-1] is

located on the control panel. Disconnect the switch harness (Item 1) [Figure 40-90-2]

by depressing the connector locks and pulling on the
connector. Do not pull on the wiring.
Remove the switch (Item 1) [Figure 40-90-1].

SWITCH (HEADLIGHT) (CONT’D)
Testing
Figure 40-90-3

P111807
Disconnect the head lamp switch harness by depressing

the connector locks and pulling on the connector. Do not
pull on the wiring.
Test between the 3 sets of outputs (HIGH / LOW / OFF).

If any of the tests fail, replace head lamp switch assembly
[Figure 40-90-3].
Move the switch to HIGH. There should be continuity

between switch pins 2 and 3; 5 and 6 [Figure 40-90-3].
Move the switch to LOW. There should be continuity

Move the switch to OFF. There should be continuity

NOTE: Pins 7 and 8 provide power and ground to light

the switch lamp.

SWITCH (BRAKE LIGHT) Removal And Installation
Description Figure 40-91-1
The brake light switch senses pressure off the brake

master cylinder to determine if the brake pedal is
depressed. The switch is normally open.
Location
1 2
The brake light switch (Item 1) [Figure 40-91-1] is
located on the front brake line banjo bolt of the master
cylinder. The brake switch can be accessed through the
front left wheel well opening.
P111780
Disconnect the harness (Item 1) [Figure 40-91-1] from

the switch.
Remove the switch (Item 2) [Figure 40-91-1].

Installation: Perform brake bleeding procedures. (See
Bleeding / Fluid Removal And Installation on Page 20-10-
9.) (See Bleeding / Fluid Removal And Installation on
Page 20-10-9.)

SWITCH (BRAKE LIGHT) (CONT’D)
Testing
Connect an ohmmeter across switch contacts. Reading

should be infinite.
Apply the foot brake and check for continuity between

switch contacts. If there is no continuity or if resistance is
greater than 0.5 ohms, clean the switch contacts and re-
test. Replace switch if necessary.
Replace the switch if the correct readings are not

obtained.

SWITCH (AWD / 2WD / TURF) Removal And Installation
Location Remove the upper dash. (See Upper Dash Panel

Figure 40-92-1
Figure 40-92-2
P111181
P111180
The AWD / 2WD / TURF switch (Item 1) [Figure 40-92-1]

is located on the dash panel. Disconnect the AWD / 2WD / TURF switch harness (Item

1) [Figure 40-92-2] by depressing the connector locks
and pulling on the connector. Do not pull on the wiring.
Remove the switch from the panel.

SWITCH (AWD / 2WD / TURF) (CONT’D)
Testing
Test between the 3 sets of outputs (AWD / 2WD / TURF).

If any of the tests fail, replace the switch assembly.
Move the switch to AWD. There should be continuity

between switch pins 2 and 3; 5 and 6.
Move the switch to 2WD. There should be no continuity

between pins 1 through 6.
Move the switch to TURF. There should be continuity

between switch pins 1 and 2; 4 and 5.
NOTE: Pins 7 and 8 provide power and ground to

light the switch lamp.

SWITCH (KEY) Removal And Installation
Location Remove the upper dash panel. (See Upper Dash Panel
Figure 40-93-1
Figure 40-93-2
P111157
P111857
The key switch (Item 1) [Figure 40-93-1] in the lower

dash between the steering column and gear select lever. Disconnect the key switch harness (Item 1) [Figure 40-

93-2] by lifting the connector lock and pulling on the
connector. Do not pull on the wiring.
Figure 40-93-3
P111157
Remove the nut (Item 1) [Figure 40-93-3] from the front

of the key switch and remove the switch.

SWITCH (KEY) (CONT’D)
Ignition Key Switch Testing
Disconnect the key switch harness by lifting the

connector lock and pulling on the connector. Do not pull
on the wiring.
Test between the three sets of outputs (OFF / ON /

START). If any of the tests fail, replace ignition switch
assembly.
Turn the ignition key to ON. There should be continuity

between switch pins C and D.
Turn the ignition key to START. There should be

continuity between switch pins A and B; C and D.

SWITCH (GEAR SELECTOR) Removal And Installation
Location Figure 40-94-1
The gear selector switch is located on the right side of the

transmission. The switch can be accessed through the
right rear wheel well opening.
P111858
Disconnect the harness (Item 1) [Figure 40-94-1].
Figure 40-94-2

2
P111859
Remove the retaining clip (Item 1) and switch (Item 2)

[Figure 40-94-2].
NOTE: The gear selector switch is not adjustable. If

the indicator lights do not match the gear
selected adjust the shift cable.
Verify shift cable is adjusted correctly. (See Shift Cable

Adjustment on Page 20-20-6.)

SWITCH (GEAR SELECTOR) (CONT’D)
Testing
Figure 40-94-3
P111798
Disconnect the transmission switch harness by lifting the

connector lock and pulling on the 2-pin connector. Do not
pull on the wiring.
Test transmission switch for continuity in each gear

position and compare to the specifications in [Figure 40-
94-3].

GLOW PLUGS Removal And Installation
Location Raise the cargo box.
Figure 40-100-1 Figure 40-100-2
1
1
P120347
P120347 P120348
The glow plugs are located on the cylinder head just Disconnect the glow plug harness (Item 1) from the glow
below the intake manifold. (Item 1) [Figure 40-100-1] is plug (Item 2) [Figure 40-100-2].

located on the control panel.
Remove the glow plug (Item 2) [Figure 40-100-2]

GLOW PLUGS
(CONT’D) Testing
If the glow plug is suspected of being faulty, test the

current being drawn by the plug.
Glow plug current absorption should be 12 - 14 A.

DIFFERENTIAL SOLENOID Removal And Installation
The differential solenoid is located on the rear portion of

the transmission case. The solenoid actuates a shift fork
with an engagement dog, which locks and unlocks the
rear differential.
1
P117926
Disconnect the harness (Item 1) [Figure 40-110-1].
Figure 40-110-2

1
P117927
Remove the solenoid (Item 1) [Figure 40-110-2].


DIFFERENTIAL SOLENOID (REAR RELAY) Removal And Installation
The rear differential solenoid relay is attached to the rear

portion of the main frame under the cargo box.
When the switch is pushed to activate “TURF”, a ground

signal is provided to the ECU from the AWD switch.
1 3
Depending on engine speed and gear position criteria,
the ECU energizes the rear differential solenoid relay
allowing it to enable the differential solenoid.
If the rear differential fails to switch from operational 2

modes:
• Check the solenoid and relay contacts. Look for loose P117928
wires or bad connections.
• Check the power from the relay connector to verify the Disconnect the harness (Item 1) [Figure 40-111-1].
solenoid has power to be activated.
Remove the screw (Item 2) and relay (Item 3) [Figure 40-
• Check the AWD switch wires for loose connections. 111-1].

• Remove the solenoid from the rear differential and
verify the plunger is actuating.
NOTE: Do not power the solenoid with 12 volts for

more than 1 second or damage may occur to
the solenoid.


BACK-UP ALARM SYSTEM Inspect the back-up alarm electrical connections and the
wire harness for tightness and damage. Repair or replace
Description any damaged components.
This utility vehicle may be equipped with a back-up alarm Figure 40-120-3
system. The back-up alarm will sound when the key
switch is in the ON position and the operator moves the
Gear Selector Lever to the reverse travel position.
Inspecting
Figure 40-120-1
1
1 P111163
The back-up alarm activation switch is an integral part of

the Gear Selector Lever (Item 1) [Figure 40-120-3].

P113550
If the back-up alarm does not sound, [with the key switch
in the ON position, engine not running and the Gear
Inspect for damaged or missing back-up alarm decal Selector Lever (Item 1) [Figure 40-120-3] is in the
(Item 1) [Figure 40-120-1] located on the panel below reverse travel position], check for 12 volt power at the
operator’s seat. Replace if required. electrical connector at the back-up alarm (Item 1) [Figure
40-120-2].
Turn the key switch to the ON position but do not start the
engine. If no power is detected, check harness connectors to
make sure all connections are correct.
Move the Gear Selector Lever (Item 1) [Figure 40-120-3]
to the reverse travel position. The back-up alarm must Repair or replace components as needed.
sound.
Figure 40-120-2
P120435
The back-up alarm (Item 1) [Figure 40-120-2] is located

on the frame by the left rear tire.

BACK-UP ALARM SYSTEM (CONT’D)
Figure 40-120-4
1 2
3
P112109
Disconnect the back-up alarm electrical connector (Item

1) [Figure 40-120-4] from the main harness.

Remove the nut (Item 2) and remove the back-up alarm
(Item 3) [Figure 40-120-4] from the vehicle.

TEMPERATURE SENSOR Removal And Installation
Description Raise the cargo box.
Mounted in the thermostat housing, the engine coolant Drain the coolant so the level is below the sensor. (See
temperature sensor measures coolant temperature. the Removing And Replacing Coolant on Page 10-70-3.)
engine temperature sensor is a Negative Temperature
Coefficient (NTC) type sensor, as the temperature Figure 40-130-1
increases the resistance decreases.
Coolant passes through the thermostat and by the

sensor probe, varying a resistance reading which is
relayed to the ECU. This signal is processed by the ECU
and compared to its programming for determining the fuel
and ignition requirements during operation. The ECU
also uses this signal to determine when to activate the
fan during operation. If for any reason the engine
temperature sensor circuit is interrupted, the fan will 2
default to “ON”.
Testing
1
To quickly rule out other components and wiring related P120202
to the ECT, disconnect the harness from the ECT sensor

and start the engine. After a few seconds, the fan should
turn on and the “Check Engine” indicator should display Disconnect the harness (Item 1) from the sensor (Item 2)
on the instrument cluster. This indicates all other [Figure 40-130-1].
components are working properly
Remove the sensor (Item 2) [Figure 40-130-1].
The temperature sensor can be tested with the Digital
Wrench™ Diagnostic Software or by using an ohmmeter. Installation: Torque the sensor to 25 N•m (18.5 ft-lb)
torque.
With the engine and temperature sensor approximately
25°C (77°F), disconnect the harness. NOTE: Bypass hose removed for photo clarity.
With a multimeter set to ohms, place the meter leads

onto the sensor contacts.
Use the Temperature / Resistance table to determine if

the sensor needs to be replaced.
TEMPERATURE °C (°F) RESISTANCE

20° C (68°F) 
30° C (86°F) 
40° C (104°F) 
50° C (122°F) 
60° C (140°F) 
70° C (158°F) 
80° C (176°F) 
90° C (194°F) 
100° C (212°F) 

TEMPERATURE SENSOR (CONT’D) Fan Control Circuit Bypass Test
Fan Control Circuit Operation / Testing Disconnect harness from coolant temperature sensor.
Power is supplied to the fan via the Orange / Black wire Turn the key on. After a few seconds, the fan should start
when the relay is ON. The ground path for the fan motor running and the “Check Engine” indicator should display
is through the brown harness wire. on the instrument cluster. This indicates all other
components are working properly.
NOTE: The fan may not function or operation may be
delayed if coolant level is low or if air is If the fan does not run or runs slowly, check the fan motor
trapped in the cooling system. Be sure wiring, ground, motor condition, circuit breaker and relay
cooling system is full and purged of air. for proper operation. Repair or replace as necessary.
If the fan runs with the sensor harness disconnected, but

will not turn on when the engine is hot, check the coolant
temperature sensor and connector terminals.

INSTRUMENT CLUSTER
Information Display

P111218

INSTRUMENT CLUSTER (CONT’D) 13. Gear Position Indicator - Displays gear selector posi-
tion.
Information Display (Cont’d)
H = High
The rider information display is located in the instrument
cluster. All segments will light up for 1 second at startup. L = Low
NOTE: If the instrument cluster fails to illuminate, a N = Neutral

battery over-voltage may have occurred and
the instrument cluster may have shut off to R = Reverse
protect the electronic speedometer.
P = Park
1. Vehicle Speed Display - Analog display of vehicle
speed in MPH or km/h. -- = Gear Signal Error (shifter stuck between gears)
2. Information Display Area - Service Info - LCD display of 14. Power Steering System MIL - LED icon illuminates
the service hour interval, total vehicle miles or km., total when a fault has occurred with the power steering system.
engine hours, a trip meter, engine RPM and engine tem- This indicator illuminates when the key is turned to the ON
perature. position and goes off when the engine is started (EPS Op-
tion Only)
3. MPH / KM/H Display - MPH is displayed when the in-
strument cluster is in the Standard mode. KM/H is dis- 15. Turn Signal / Hazard lamp Indicator - LED icon illumi-
played when the instrument cluster is in the Metric mode. nates whenever the LH, RH or hazard lamps are activated
(INT’L Models Only) the glow plugs are active. Light goes

4. High Beam Indicator - LED icon illuminates whenever out when the engine is ready to start.
the Head lamp switch is in the high beam position.
16. Helmet / Seat Belt Indicator - LED icon illuminates for
5. Fuel Level Indicator - LCD bar graph indicating current several seconds when the key is turned to the ON posi-
fuel level. All segments will flash when the last segment is tion. The lamp is a reminder to the operator to ensure all
cleared indicating a low fuel warning. riders are wearing helmets and seat belts before operat-
ing the vehicle.
6. Clock - Displays current time in either 12-hour or 24-
hour formats.
7. Engine Temperature Indicator - LED icon illuminates

when the ECM determines the engine is overheating. The
indicators will initially flash to indicate the engine is over-
heating. The indicators will stay lit and not flash if a severe
overheating condition exists.
8. Service Interval Indicator - Preset at the factory and ad-

justable by the user, a flashing wrench symbol alerts the
operator that the preset service interval has been reached
and maintenance should be performed. The wrench icon
will flash for 10 seconds upon startup once it reaches 0.
9. Check Engine MIL - Illuminated when the ECM has de-

tected a Diagnostic Trouble Code in the engine manage-
ment system.
10. AWD Indicator - Illuminated when the AWD / TURF

switch is in the AWD position.
11. TURF Indicator - Illuminated when the AWD / TURF

switch is in the TURF position.
12. Neutral Gear Indicator - LED icon illuminates when

gear selector is in the neutral (N) position.

INSTRUMENT CLUSTER (CONT’D) Units Of Measurement
Pinouts Distance Miles (MPH) Kilometers (KM/H)
Figure 40-140-1 Temperature Fahrenheit Celsius

Time 12-Hour Clock 24-Hour Clock
Figure 40-140-2
P111819
FUNCTION PIN
P111816
CAN High 1
CAN Low 2

Figure 40-140-3
Switched Power (Vdc) 3
Constant Power (Vdc) 4
Ground 5
High Beam Input 8
Fuel Level Sensor 11
NOTE: The pin numbers read from left to right starting

with the bottom row (Item 1) [Figure 40-140-1].
Information Display Area
The LCD portion of the instrument cluster is the

information display area. Information displayed in this P111813
area includes: odometer, trip meter, engine RPM, engine
hours, service interval, clock, engine Diagnostic Trouble
Codes (DTC’s) and power steering DTC’s. To change between Standard [Figure 40-140-2] and
Metric units [Figure 40-140-3] of measurement, follow
these steps:
• Turn the key to the OFF position.
• Press and hold the MODE button while turning the

key to the ON position.
• When the display flashes the distance setting, tap the

MODE button to advance to the desired setting.
• Press and hold the MODE button to save the setting

and advance to the next display option.
• Repeat the procedure to change remaining display

settings.

INSTRUMENT CLUSTER (CONT’D) Trip Meter
Information Display Area (Cont’d) Figure 40-140-5
Odometer
Figure 40-140-4
P118711
The trip meter records the miles traveled by the vehicle

P118708 on each trip [Figure 40-140-5]. To reset the trip meter:
• Toggle the MODE button to TRIP 1.

The odometer records and displays the total distance
traveled by the vehicle. The odometer can not be reset • To reset to 0, push and hold the MODE button until
[Figure 40-140-4]. the distance display changes to 0.
Engine Hours
Figure 40-140-6
P118706
Engine hours are logged anytime the engine is running.

Total hours can not be reset [Figure 40-140-6].

INSTRUMENT CLUSTER (CONT’D) Clock
Tachometer (RPM)
Figure 40-140-7
P118701
The clock displays the time in a 12-hour or 24-hour

P118709 format [Figure 40-140-9]. (See Units Of Measurement
on Page 40-140-3.) to change the format (Standard 12-
hour / Metric-24 hour). To set the clock:

Engine rpm can be displayed digitally [Figure 40-140-7].
• Toggle the MODE button until the odometer is
Engine Temperature displayed.
Figure 40-140-8 • Press and hold the MODE button until the hour
segment flashes. Release the button.
• With the segment flashing, tap the MODE button to

advance to the desired setting.
• Press and hold the MODE button until the next

segment flashes. Release the button.
• Repeat steps 3 - 4 twice to set the 10 minute and 1

minute segments. After completing the 1-minute
segment, step 4 will save the new settings and exit
the clock mode.
P118704
Shows current engine temperature [Figure 40-140-8].

Engine temperature can be displayed in Fahrenheit or
Celsius (See Units Of Measurement on Page 40-140-3.)
to change the format.

INSTRUMENTATION CLUSTER (CONT’D) Programmed Service Interval
Battery Under / Over Voltage
This warning indicates that the vehicle is operating at an

RPM too low to keep the battery charged, the electrical
loads are too high, or there is a charging system failure.
Battery Voltage Low
Figure 40-140-10
P118710
The initial factory service interval setting is 50 hours.

Each time the engine is started, the engine hours are
subtracted from the service interval hours. When the
service interval reaches 0, the LCD wrench icon will flash

for approximately 10 seconds each time the engine is
started [Figure 40-140-12].
P118707 To change the hour setting or reset the function, follow

these steps:
If battery voltage drops below 11 volts, a warning screen • Toggle the MODE button until the wrench icon is
will display [Lo] and provide the present battery voltage displayed in the information area.
[Figure 40-140-10]. If voltage drops below 8.5 volts, LCD
backlighting and icons will turn off. • Press and hold the MODE button until the information
display area begins to flash.
Battery Voltage High
• Toggle the MODE button to increase the service
Figure 40-140-11 interval hours in 5 hour increments to a maximum of
100 hours.
• To turn off the service interval function, toggle the

MODE button until [OFF] is displayed.
P118705
If battery voltage rises above 15 volts, a warning screen

will display [OV] and provide the present battery voltage
[Figure 40-140-11]. If voltage rises above 16.5 volts,
LCD backlighting and icons will turn off.

INSTRUMENTATION CLUSTER (CONT’D) Figure 40-140-15
Information Display Area (Cont’d)
Check Hydraulic
Figure 40-140-13
P118703
Press and hold the MODE button to enter the diagnostics

code menu.
P111783
A set of three numbers will appear in the information area
[Figure 40-140-15].
Indicates too low of hydraulic oil pressure caused by a

plugged / blocked hydraulic oil filter or too high of The first number (located far left) can range from 0 to 9.
hydraulic oil temperature [Figure 40-140-13]. The Oil or This number represents the total number of trouble codes
Temperature light will illuminate along with this message. present (example: 2 means there are 3 codes present).
Check Engine / Trouble Code Display The second number (located top right) can be 2 to 6
digits in length. This number equates to the suspected
The diagnostic mode is accessible only when the check area of fault (SPN).
engine MIL has been activated [Figure 40-140-14].
The third number (located bottom right) can be 1 to 2
Use the following procedure to display diagnostic trouble digits in length. This number equates to the fault mode
codes that were activated during current ignition cycle (FMI).
causing the MIL to illuminate. Diagnostic trouble codes
will remain stored in the gauge (even if MIL turns off) until Use the Diagnostic Trouble Code Table on the following
the key is turned off. pages for a description of each code.
Figure 40-140-14 If more than one code exists, press the MODE button to
advance to the next trouble code.
To exit the diagnostic mode, press and hold the MODE

button or turn the ignition key OFF once the codes are
recorded.
P118702
If the trouble codes are not displayed, use the MODE

button to toggle until [CK ENG] displays on the
information display area.

INSTRUMENTATION CLUSTER (CONT’D)
Diagnostic Trouble Codes
DIGITAL
COMPONENT CONDITION SPN FMI WRENCH™
P-CODE
Vehicle Speed Signal Data Erratic or Intermittent (or 84 2 P0503

missing)
Engine Temperature Sensor Voltage Too High 110 3 P0118
(ECT)
Voltage Too Low 4 P0117
Temperature Too High 16 P0217
System Power Voltage Too High 168 3 P0563
(Battery Potential / Power
Voltage Too Low 4 P0562
Input)
Gear Sensor Signal Voltage Too Low 523 4 P0916
Crankshaft Position Sensor Plausibility Fault 636 2 P0335
(CPS)
Rear Differential Output Driver Circuit Open / Grounded 746 5 P1691

Driver Circuit Short to B+ 3 P1692
Driver Circuit Grounded 4 P1693
Fan Relay Driver Circuit Driver Circuit Open / Grounded 1071 5 P1481
Fuel Pump Driver Circuit Driver Circuit Open / Grounded 1347 5 P0230
PTO Solenoid Driver Circuit Driver Circuit Open / Grounded 1888 5 P1310
ECU 3.3V Output Supply Voltage Too High 3597 3 P16A2
Voltage
Voltage Too Low 4 P16A1
ECU 5V Output Supply Voltage Too High 3598 3 P16A9
Voltage
Voltage Too Low 4 P16A8
Hydraulic Oil Temperature Temperature Too High 5536 16 P1218
Sensor
Hydraulic Over-temp Shutdown 0 P121A
Received Hydraulic Oil Temp Has 19 P121B
Error

INSTRUMENTATION CLUSTER (CONT’D)
Diagnostic Trouble Codes (Cont’d)
DIGITAL
COMPONENT CONDITION SPN FMI WRENCH™
P-CODE
All Wheel Drive Control Circuit Driver Circuit Open / Grounded 520207 5 P1836
(AWD)
Glow Plug Relay Driver Circuit Driver Circuit Open / Grounded 520272 5 P1385
Fuel Pull Solenoid Relay Driver Circuit Open / Grounded 520273 5 P125A
Driver Circuit
Driver Circuit Short to B+ P125D 3
Driver Circuit Grounded 4 P125C
Two-Speed Shift Coil Driver Driver Circuit Open / Grounded 520274 5 P1750
Circuit

Operator Presence Switch Voltage Too High 524070 3 P251C
Hydraulic Oil Pressure Sensor Hydraulic Oil Filter Plugged 524075 17 P150F
/ Switch
Engine Oil Pressure Sensor / Oil Level Low 524076 17 P151F
Switch

INSTRUMENTATION CLUSTER (CONT’D) Figure 40-140-18
NOTE: Do not allow alcohol or petroleum products to

come in contact with the instrument cluster
lens.
Remove the upper dash. (See Upper Dash Panel

Figure 40-140-16
P111831A
Installation: Spray a soap and water mixture onto the

outer surface area of the instrument cluster. This will help
the instrument cluster slide into the rubber mount more
easily [Figure 40-140-18].

1 P111829

40-140-16] from the back side of the instrument cluster.
Figure 40-140-17
3
1
P111830
Push the instrument cluster (Item 1) out of the lower dash

panel, while securely holding the panel and rubber mount
(Item 2) [Figure 40-140-17].
NOTE: The instrument cluster bezel (Item 3) [Figure

40-140-17] is a snap-on assembly and is a
serviceable part.

FUEL SENDER
Testing
Remove the fuel level assembly from the fuel tank. (See
Fuel Pump on Page 50-70-4.)
Using an ohmmeter, measure the resistance of the fuel

sender as shown below.
Allow the sender float to sit in the empty position and

compare to specification.
Fuel Sender Empty 15 ± 2 Ω
Slowly move the sender float to the full position and

compare to specification.
Fuel Sender Full 95 ± 2 Ω
If the readings are out of specification, or if the reading is

erratic or LCD display “sticks”, check the following before
replacing the fuel level assembly:

• Loose float
• Float contact with tank
• Bent float rod
If none of the conditions exist, the fuel sender assembly

is faulty. Replace the fuel level sender assembly. (See
Fuel Pump on Page 50-70-4.)


DIAGNOSTIC TESTING ECU Replacement
Digital Wrench™ Diagnostic Software Although the need for ECU replacement is unlikely, a
specific replacement procedure is required to ensure that
Description all essential data contained within the original ECU is
transferred to the replacement ECU. All replacement
This software installs on laptop computers equipped with ECU’s are shipped with no programming and must be
a CD drive and serial port connection. It is for use by programmed prior to vehicle use or the vehicle will not
Bobcat authorized dealership personnel only to perform start.
the following tests and observations:
Refer to procedure and carefully follow all instructions
View or clear trouble codes provided in Digital Wrench™.
Analyze real-time engine data Guided Diagnostic Available
Re flash ECU calibration files Guided diagnostics are available within Digital Wrench™
for all supported Trouble Codes (that is, any fault that will
Perform guided diagnostic procedures turn on the ‘Check Engine’ indicator).
Create customer service account records In addition guided diagnostics are also available for many
other electrical sub systems.
Perform output state control tests
Diagnostic procedures are added to subsequent versions
Diagnostic Software Version of Digital Wrench™ as they become available. check your

release version often and upgrade when available to be
Always use the most current version of the Digital sure you are using the most current software available.
Wrench™ software to ensure you have the latest updates
or enhancements. New reprogramming files and guided Digital Wrench™ Communication Errors
diagnostic procedures are added to these updates as
they become available. For information on how to If you experience problems connecting to a vehicle or any
determine if you have the latest update available, refer to Digital Wrench™ related problem, visit the digital
“Digital Wrench™ Version and Update ID”. Wrench™ Knowledge Base for the most current
troubleshooting information. FAQs, downloads and
software updates at BobcatDealerNET.com.

DIAGNOSTIC TESTING (CONT’D) Digital Wrench™ SmartLink Module Kit - MEL1721
Digital Wrench™ Diagnostic Connector This module kit contains the necessary cables and
hardware to communicate between the vehicle ECU and
Figure 40-160-1 the Digital Wrench™ diagnostic software. It also includes
a card with the license number required to install Digital
Wrench™ software. Keep this card in a safe place.
1 Figure 40-160-2
P120116
The diagnostic connector (Item 1) [Figure 40-160-1] is

located on the frame rail with battery compartment.
P120118

Assemble the SmartLink Module (Item 1) [Figure 40-
160-2] and attach the PC Interface Cable to your laptop.
Remove the protective cap from the Digital Wrench™

connector on the vehicle.
Connect the Vehicle Interface Cable to the Digital

Wrench™ diagnostic connector.
Turn the ignition key to the ‘ON’ position, select the

appropriate vehicle and wait for the status to display
‘Connected’ in the lower left corner of the screen.

DIAGNOSTIC TESTING (CONT’D) Version And Update ID
Serial Number Location Figure 40-160-4
Figure 40-160-3
P-99640
P-99639
Open the Digital Wrench™ software. Locate the version
ID shown on the lower right side of the Digital wrench™
Open the configuration screen by clicking on the wrench startup screen. In this case, the version number is 1.0
icon. The serial number is located on the right side of the with a 06/02/10 revision [Figure 40-160-4].

screen [Figure 40-160-3].

DIAGNOSTIC TESTING (CONT’D) Figure 40-160-6
Updates
NOTE: Only authorized Bobcat dealers and

distributors can access the dealer website.
Figure 40-160-5
P-99641
Log onto BobcatDealerNET.com.
Locate the “Service Homepage” link on the main home

screen [Figure 40-160-6].
P-99639
Figure 40-160-7

The best way to ensure that your version of Digital
Wrench™ is always up to date, is by using the auto
update feature. Internet access is required for this feature
to work properly. Open the configuration screen by
clicking on the wrench icon. Move the “Auto Updates”
button to the ON (green) position [Figure 40-160-5].
If Internet access is not available, proceed to the service

software page on BobcatDealerNET.com to manually
check for updates.
P-99642
Locate the “Service Software” link in the left margin

[Figure 40-160-7].

DIAGNOSTIC TESTING (CONT’D)
Updates (Cont’d)
Figure 40-160-8
P-99643
Locate the “Bobcat Digital Wrench™” link from the list of

topics [Figure 40-160-8].

Figure 40-160-9
P-99644
The latest version will be shown at the top of this screen.

If your version is different, download and install the latest
update file [Figure 40-160-9].
NOTE: Do Not “run” or “open” the file. (Copy the

statement you already wrote).

DIAGNOSTIC TESTING (CONT’D)
Digital Wrench™ Feature Map
P101443

DIAGNOSTIC TESTING (CONT’D) CLOSE NON-ESSENTIAL PROGRAMS: Bobcat
recommends that you DO NOT install non-essential
Engine Controller Reprograming (Reflash) programs on a Service Department laptop. Camera
detection software, Virus Scanners, Tool Bars, etc. may
Process Overview use up memory if running in the background and make it
harder for the diagnostic software to operate.
The reprogramming features is in the Special Tests menu
on the Digital Wrench™ screen. Start Digital Wrench™ KNOW THE PROCESS: If you are not familiar with the
and click on the Special Tests menu icon (red tool box). A entire reprogramming process, review the HELP section
technician should be familiar with the process and with of the diagnostic software before you attempt
computer operation in general before attempting to reprogramming. Click on the? on the tool bar or press
reprogram an ECU. F11. The information in the on-line help is the most
current and complete information available. This should
The Digital Wrench™ Engine Controller Reprogramming be your first step until you are familiar with the process.
(or “Reflash”) feature allows reprogramming of the ECU,
and authorization Key must be obtained by entering a COMMUNICATION PROBLEMS: If you have had
Request Code in the box provided on the Reflash problems communicating with a vehicle while performing
Authorization site. The Request Code is automatically diagnostic functions, do not attempt reprogramming until
generated by Digital Wrench™ during the reprogramming the cause has been identified and fixed. Check all
process. The Reflash authorization site is located on the connections, and be sure battery voltage is as specified.
Doosan Passport list of available applications. Access to
the Reflash authorization site is only available to Figure 40-160-10
authorized Bobcat dealer locations with a Utility Vehicle
contract.

IMPORTANT
Failure to follow the reprogramming instructions
completely and correctly can result in an engine that
does not run! Replacement ECUs are programmed as
“no-start” and require a reflash for them to work.
I-2335-0710
Reprogramming (Reflash) Tips:
BATTERY VOLTAGE: The majority of problems with

reprogramming can be attributed to a low battery. Be sure P-99644
the battery voltage (no load) is at least 13 volts and at
least 12.5 volts with the key ON. Connect a battery
charger if necessary to bring voltage level above Proceed to www.BobcatDealerNET.com for specific
minimum. Fully charge the battery before you attempt to information and FAQs on how to troubleshoot
reprogram. communication problems [Figure 40-160-10].
DEDICATED LAPTOP: Best results are obtained using a DON’T DISTURB THE PC: While reprogramming is in
laptop computer that is dedicated to service software, progress, don’t move the mouse and don’t touch the
such as Digital Wrench™, BATS, Service Analyzer, etc. keyboard. The process only takes a few minutes, and is
only. A laptop that is used by a variety of people and in best left alone until complete. Additional troubleshooting
several applications around the dealership is more likely information can be found in the Bobcat Call Trac system
to cause a reprogramming problem than one dedicated to by searching for solutions using the keywords “Smart
service software only. Link” or “Digital Wrench”.
OPTAINING THE LATEST UPDATE: Reprogramming

updates are provided periodically and contain the most
recent calibrations. (See Updates on Page 40-160-4.)

Engine Controller Reprograming (Reflash) (Cont’d)
Reprogramming (Reflash)
If you are not familiar with the reprogramming process,

review the “Reprogramming (Reflash) Tips” before you
begin. Follow the on-screen instructions as you progress
through the steps. If you encounter a problem, always
check the On-Line help for current tips and information.
Verify the most current update has been downloaded and

loaded into Digital Wrench™. (See Version And Update
ID on Page 40-160-3.)
P101426
Connect the SmartLink Module cables to the PC and
vehicle. (See Digital Wrench™ Diagnostic Connector on
Page 40-160-2.) Select the “Special Tests” icon [Figure 40-160-12].
Figure 40-160-11 Figure 40-160-13

P101423 P101432
Open the Digital Wrench™ program. Select “Engine Controller Reprogramming” [Figure 40-
160-13].
Select the model year, product line and vehicle
description by selecting the “Change Vehicle type” icon
[Figure 40-160-11].

Reprogramming (Reflash) (Cont’d)
Figure 40-160-14
P-99885
Go to the Doosan Passport main screen and choose the

application called “Utility Vehicle ECU Reflash
Authorization” [Figure 40-160-16].
P101437
Figure 40-160-17

Select the file you want to load into the ECU then click
the “Continue” icon to proceed to the Integrity Check and
obtain a Request Code [Figure 40-160-14].
The Request Code is available on Doosan Passport.
Figure 40-160-15
P101433
Enter or paste (CTRL+V) the Request Code into the box

[Figure 40-160-17].
P101427
Copy (CTRL +C) the Request Code that will be required

on the dealer web site in the next step. DO NOT CLOSE
Digital Wrench™ or the Request Code will be invalid
[Figure 40-160-15].
NOTE: All characters are letters; there are no

numbers in a request code.

Programming (Reflash) (Cont’d)
Figure 40-160-18
P101428
Enter or paste (CTRL+V) the Authorization Key in the box

located on the Digital Wrench™ screen. Click the
“continue” button and follow instructions provided on the
P101434 screen to complete the reprogramming procedure
[Figure 40-160-20].

Select the same file type from the list that you selected Figure 40-160-21
previously while in Digital Wrench™. Enter the serial
number along with the customer’s name and address.
When completed click the authorize button once to
proceed [Figure 40-160-18].
Figure 40-160-19
P101427
At this point the reflash process will begin. Do not disturb

the vehicle or PC during the process.
P101435 Once the ECU reprogramming procedure is complete,

click the “Finish” button on the screen. Verify the reflash
was success by starting the vehicle.
An “Authorization Key” will appear in the upper left corner
of the screen. Copy (CTRL+C) this key exactly as it
appears [Figure 40-160-19].

ELECTRONIC POWER STEERING (EPS) System Diagnosing
EPS Operation NOTE: Verify the EPS unit has the latest software
version and calibration loaded before
The EPS module is an intelligent electronic power replacing the EPS unit. If not, update the latest
steering system that operates off of the vehicles 12V version for each and follow the guided
electrical system. It calculates steering assist by sensing diagnostic procedure (s) available in Digital
the difference between the input torque of the steering Wrench™.
post and the output torque required to turn the wheels,
and then provides assist by energizing an electric motor. WIRE COLOR FUNCTION
This process provides a smooth, seamless assist.
ORANGE (2 Pin) Main Power (30A Protected
The system is continuously running diagnostic checks BROWN (2 Pin) Ground
and monitoring factors such as battery voltage, ground ORANGE (8 Pin) Key-On Battery Voltage
speed and engine speed. In the event that an internal or
external issue the effects the EPS system s detected, the YELLOW (8 Pin) CAN High Signal
system will illuminate a fault indicator and transition to a GREEN (8 Pin) CAN Low Signal
normal mechanically coupled steering system. The
system is Digital Wrench™ compatible for simplified
diagnostics and system troubleshooting through the
vehicles diagnostic port.
With the engine off and the key on, the power steering
unit will operate for up to five minutes. After the five

minutes, you will need to cycle the key switch and restart
the engine to regain power steering operation.
NOTE: To conserve battery power, the EPS unit will

shut down 5 minutes after the engine has
stopped if the key remains in the ON position.
At this point, the EPS malfunction indicator
Light will illuminate to indicate the EPS has
shut down and will set a fault code in Digital
Wrench™.
Power Steering 30A Fuse
If the fuse fails, the Power Steering Malfunction Indicator

Light (MIL) on the instrument cluster will illuminate.
During this time, the vehicle will have no power steering.
You will be able to connect and communicate with the
vehicles Engine Controller, but not the Power Steering
Controller, while using Digital Wrench™.
NOTE: DO NOT SPLICE OR CUT INTO THE CAN

CICUITS.

ELECTRONIC POWER STEEERING (EPS) (CONT’D)
EPS Troubleshooting (Power Steering Non-Functional with MIL ON)
NA9466

EPS Troubleshooting (Power Steering Non-Functional with MIL OFF)
NA9467

EPS Troubleshooting (Using Digital Wrench™)
NA9468

ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-7
Accessible Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-14
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-15
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-21
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-22
Compression And Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-23
Cylinder Head Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-24
Fuel Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-24
Idle Speed Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-25
Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-26
THROTTLE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Throttle Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Throttle Cable Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Throttle Freeplay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-4

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-4
Throttle Freeplay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-4
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Cooling System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Radiator Cap Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Radiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-3
Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-4
Cooling Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-6
Thermostat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-7
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-8
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-3
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-3
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-4

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Initial Priming / Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Fuel Line Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-4
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-6
Injector Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-8
ENGINE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Crankcase Vacuum Regulator Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Intake Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Exhaust Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Drive Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Timing Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-4
Timing Pulleys Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-5
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-6
Speed Governor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-6

Rocker Arm Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-7
Fuel Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-8
Unit Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-8
Rocker Arm Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-9
Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-10
Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-11
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-12
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-12
Valve And Spring Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-13
Pre-Combustion Chamber Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-15
Piston And Connecting Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-16
Piston And Piston Ring Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-17
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-18
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-19
Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-20
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-21

ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Piston And Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Pre-Combustion Chamber Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-5
Camshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-6
Rocker Arm Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-7
Valve / Rocker Arm Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-7
Speed Governor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-8
Unit Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-9
Fuel Rail Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-10
Rocker Arm Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-10
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-11
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-12
Timing Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-12
Timing Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-13
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-16
Drive Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-16
Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-17

Exhaust Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-18
Intake Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-18
Crankcase Vacuum Regulator Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-19


ENGINE INFORMATION
Description
Figure 50-10-1
P120248
The engine is a Kohler, water cooled, 3-cycle, DOHC,

three cylinder diesel engine [Figure 50-10-1].

ENGINE INFORMATION (CONT’D)
Specifications
Cylinder Head
Item Factory Specification Allowable Limit

Cylinder Warpage Limit 0,10 mm (0.0039 in)
Compression Pressure 2758 - 3103 kPa 2413 - 2758 kPa
(27,58 - 34,47 bar) (400 - 500 psi)
(24,31 - 27,59 bar) (350 - 400 psi)
Valves

Valve Head Diameter IN. 34,4 mm (1.354 in)
EX. 130,20 mm (1.189 in)
Valve Head Angle IN. 60°
EX. 45°
Valve Seat Housing I.D. IN. 35,2200 - 35,245 mm -
(1.387 - 1.388 in)
EX. 31,220 - 31,241 mm -

(1.229 - 1.230 in)
Valve Seat O.D. IN. 35,306 - 35,31 mm
(1.232 - 1.233 in)
EX. 31,308 - 31,316 mm
(1.232 - 1.233 in)
Valve Seat Angle IN. 60° -
EX. 45°
Valve Guide Diameter 7,005 - 7,020 mm -
(0.276 - 0.276 in)
Valve Guide Stem Diameter 6,96 - 6,99 mm -
(0.274 - 0.275 in)
Valve Guide Clearance 0,10 mm 
(Max) (0.0039 in)
Valve Recess 0,7 - 0,1 mm (0.028 - 0.039 in) 1,3 mm (0.051 in)
Valve Seat Width 1,6 mm (0.063 in)
2.0 mm (0.079 in)
Valve Springs

Valve Spring (Overall Length) 46mm (1.81 in) 43,5 mm (1.71 in)

Specifications (Cont’d)
Cylinder

Cylinder (Piston Clearance) 0,050 - 0,070 mm
(0.0020 - 0.0028 in)
Rocker Arms

Rocker Shaft Oil Clearance 0,15 mm
(0.0059 in)
Camshaft

Cam Lobe Wear IN. 0,10 mm
Limit (0.039 in)
EX. 39,13 ± 0,097 mm 32,426 mm

(1.5405 ± 0.0038 in) (1.2766 in)
Camshaft Journal All (Standard) 36,975 - 37,000 mm -
O.D. (1. 456 - 1.457 in)
Camshaft Journal All (Standard) 37,035 - 37,060 mm -
Bore I.D. (1.458 - 1.459 in)
Camshaft Oil Clearance 0,170 mm
(0.0067 in)

Piston

Outer Diameter (Std) (Class A) 74,930 - 74,940 mm -
(2.9500 - 2.9504 in)
Outer Diameter (Class B) 74,940 - 74,950 mm -
(2.9504 - 2.9508 in)
Outer Diameter (Class C) 74,950 - 74960 mm -
(29.508 - 2,95129 in)
Piston Pin

Outer Diameter 19,996 - 20,000 mm
(0.7872 - 0.7874 in)
Piston Pin Clearance - (Max) 0,060 mm -
(0.0024 in)

Degree Of Fit Piston pin must be a push (by hand) -
fit at 20°C (68°F)
Piston Rings

Piston Ring Installed Gap (Top Ring) 0,250 - 0,450 mm 1,0 mm
(0.0098 - 0.0117 in) (0.039 in)
Piston Ring Installed Gap (Second Ring) 0,250 - 0,450 mm 1,0 mm
(0.0098 - 0.0117 in) (0.039 in)
Piston Ring Installed Gap (Oil Ring) 0,250 - 0,450 mm 1,0mm
(0.0098 - 0.0117 in) (0.039 in)
Standard Clearance - Piston Ring To Ring Groove 0,090- 0,125 mm
(Top Ring) (0.0035 - 0.0049 in)
Standard Clearance - Piston Ring To Ring Groove 0,020 - 0,76 mm
(Second Ring) (0.0020 - 0.0033 in)

Connecting Rod

Connecting Rod Small End I.D. 20,015 - 20,025 mm
(0.8665 - 0.8670 in)
Crankshaft

Crankshaft Runout Limit - 0,130 - 0,313 mm
(0.0051 - 0.0120 in)
Oil Pump

Engine oil pressure At rated speed 400 - 450 kPa (4.0 - 4.48 bar) 100 kPa (0,99 bar)
at 5500 rpm (Engine (58 - 60 psi) (14.5 psi)
Hot)

Rotor Tip Clearance 0,25 mm 0,25 mm
(0.0098 in) (0.0098 in)
Thermostat
Valve opening temperature at beginning 80°C

(176°F)
Opened completely (height 8,0 mm (0.315 in) 96°C
(205°F)
Radiator
Radiator Tightness Retain 69 kPa (0,69 bar) (10 psi) for five minutes or longer
Radiator Cap Pressure 90 kPa (0,90 bar) (13 psi)

ENGINE INFORMATION (CONT’D) Crankshaft Center Drive Pulley 360 (266)
Bolt
Torque Values
Alternator 25 (18)
Fastener N•m (ft-lb) Starter Motor 40 (30)
Thermostat Cover Bolts 25 (18) Exhaust Manifold 25 (18)
Coolant Bleed Screw 4,75 - 5,15 (42 - 46 Intake Manifold Duct Elbow 22 (16)
in-lb)
Water Pump 25 (18)
Water Pump Impeller Finger Tight
Rocker Arm Cover 9 (6.6)
Engine Mount Plate 25 (18)
Pre Combustion Chamber 1st 100 (74)
Torque
Pre Combustion Chamber 2nd 180 (133)
Torque
Exhaust Head Pipe bolts 27 (20)
Exhaust Silencer Mount Bolts 23 (17)

Starter Motor 40 (30)

Oil Pump 25 (18)
Oil Plug 40 (29.5)
Oil Pan 10 (7)
Intake Manifold 25 (18)
Injector 20 (15)
Camshaft Timing Pulley 80 (59)
Camshaft End Cover 10(7)
Glow Plug 20 (14)
Injector Control Rod 1,1 (9.7 in - lb)
Cylinder Head Step 1 50 (37)
Cylinder Head Step 2 90°CW
Cylinder Head Step 3 90°CW
Fuel Rail 4 (3)
Oil Pump Backplate 10 (7)
Alternator Bracket 25 (18)
Crankcase Main Journal Cap 60 (44)
Forward and Rear Main Bearing 60 (44)
Cap
Connecting Rod End Cap 40 (30)
Speed Governor 10 (7)
Flywheel 80 (59)
Timing Belt Preload 20 (15)
Timing Belt Idler Pulley 40 (30)
Timing Belt Cover 10 (7)
Crankshaft Outer Drive Pulley 10 (7)
Bolts

Troubleshooting
CAUSE
Engine System
Improper Seized Worn
TROUBLE SYMPTOM Compression Intake / Cylinder Seized Improper
Intake / Or Piston
Leakage Exhaust Head Crankpin Arrangement
Exhaust Broken Ring,
From Valve Valve Gasket Metal Or Of Piston
Valve Piston Piston Or
Seat Seizure Blowout Bearing Ring Gaps
Clearance Ring Cylinder
Engine Does Not Start
Engine None
Starting Starts Little
Exhaust
Problem But
Smoke
Stops Much
Soon
Insufficient Ordinary
Exhaust
Engine White
Color
Output Black
Poor White
During
Exhaust
Work Black
Color
High Knocking Sound During

Combustion
Abnormal Engine Sound
Uneven Combustion Sound
Engine During Idling
Surging During Work Operation
Excessive Engine Vibration
Difficulty In Returning To Low
Speed
Excessive Fuel Consumption
Excessive Oil
Consumption
Engine Oil Dilution By Diesel Fuel
Oil With Water
Low Oil Pressure
Excessive Blow-by Gas
Overheat
Engine
Low Coolant
Coolant
Temperature
Pressure Drop
Air Intake
Pressure Rise
Exhaust Temperature Rise
Correct
Perform
or Replace
Adjust the Replace Honing Correct the
Lap the Replace the Repair or
Corrective Action Valve the and Use Ring Joint
Valve Seat. Intake / Piston Replace.
Clearance. Gasket. Oversize Positions.
Exhaust Ring.
Parts.
Valve.

Troubleshooting (Cont’d)
CAUSE
Engine System
Improper
Worn Foreign Worn Open /
TROUBLE SYMPTOM Reverse Crankpin Loose Matter Excessive Intake / Governor Close
Assembly Of And Connecting Trapped in Gear Exhaust Adjusted Timing Of
Piston Rings Journal Rod Belt Combustion Backlash Valve Incorrectly Intake /
Bearing Chamber Guide Exhaust
Valves
Engine None
Starting Starts
Exhaust Little
Problem But
Smoke
Stops Much
Soon
Exhaust
Engine White
Color
Output Black
Poor White
During
Exhaust
Work Black
Color

Combustion
Difficulty In Returning To Low Speed
Excessive Oil
Consumption
Oil With Water
Low Oil Pressure
Engine Overheat
Coolant Low Coolant Temperature
Pressure Drop
Air Intake
Pressure Rise
Tighten to
Measure Adjust Measure Adjust the
Reassemble the Disassemble Make
Corrective Action Correctly.
and
Specified and Repair.
Gear and
Adjustment.
Valve
Replace. Meshing. Replace. Clearance.
Torque.

CAUSE
Engine Coolant System
TROUBLE SYMPTOM Excessive Insufficient Cracked Stretched
Insufficient Defective
Radiator Engine Coolant Coolant Coolant
Radiator Cooling Thermostat
Cooling Level Jacket Pump V-Belt
Engine None
Starting Starts
Exhaust Little
Problem But
Smoke
Stops Much
Soon
Exhaust
Engine White
Color
Output Black
Poor White
During
Exhaust
Work Black
Color
Combustion

Excessive Oil
Consumption
Oil With Water
Low Oil Pressure
Engine Overheat
Pressure Drop
Air Intake
Pressure Rise
Replace Check Coolant
Replace Thermostat or Leakage from Repair or Adjust the Check or
Corrective Action
Thermostat. Check for Loose Engine Coolant Replace. Belt Tension. Replace.
Coolant Pump Belt. System.

CAUSE
Engine Oil System
TROUBLE SYMPTOM Engine Insufficient Defective
Incorrect Clogged Insufficient Overfilled
Oil Delivery Pressure
Engine Engine Oil Engine Oil Engine
System Capacity of Regulating
Oil Filter Level Crankcase
Leakage Trochoid Pump Valve
Engine None
Starting Starts
Exhaust Little
Problem But
Smoke
Stops Much
Soon
Exhaust
Engine White
Color
Output Black
Poor White
During
Exhaust
Work Black
Color
Combustion

Excessive Oil
Consumption
Oil With Water
Low Oil Pressure
Engine Overheat
Pressure Drop
Air Intake
Pressure Rise
Use
Add
Correct Check and Clean or Clean, Adjust Check
Corrective Action Repair. Correct
Engine Repair. Replace. or Replace. Engine Oil.
Engine Oil.
Oil.

CAUSE
Fuel System
TROUBLE SYMPTOM Too Early Too Late Timing
Incorrect Diesel Water in Fuel Clogged Fuel
Timing of Fuel of Fuel Injection
Fuel System Filter
Injection Pump Pump
Engine None
Starting Starts
Exhaust Little
Problem But
Smoke
Stops Much
Soon
Exhaust
Engine White
Color
Output Black
Poor White
During
Exhaust
Work Black
Color
Combustion

Excessive Oil
Consumption
Oil With Water
Low Oil Pressure
Engine Overheat
Pressure Drop
Air Intake
Pressure Rise
Check and Check and Use Correct Fuel Drain the Fuel Clean or
Corrective Action
Adjust. Adjust. Oil. Filter. Replace.

CAUSE
Fuel System
Poor
Uneven Spray Clogged
Insufficient
TROUBLE SYMPTOM Clogged Injection Excessive
Air in Fuel Supply Pattern Strainer
or Volume Fuel Priming
Fuel to Fuel from at Feed
System
Cracked
Injection
from Fuel Injection Failure
Fuel Line Injection Volume Fuel Pump
Pump Injection Inlet
Pump
Nozzle
Engine None
Starting Starts
Exhaust Little
Problem But
Smoke
Stops Much
Soon
Exhaust
Engine White
Color
Output Black
Poor White
During
Exhaust
Work Black
Color

Combustion
Excessive Oil
Consumption
Oil With Water
Low Oil Pressure
Engine Overheat
Pressure Drop
Air Intake
Pressure Rise
Foreign
Check the Matter
Fuel Tank Trapped in the
Cock, Fuel Check Check Check Clean
Bleed Clean or Valve Inside
Corrective Action Filter, Fuel and and and the
the Air. Replace. the Priming
Line and Adjust. Adjust. Adjust. Strainer.
Fuel Feed Pump
Pump. (Disassemble
and Clean).

CAUSE
Air / Exhaust Gas System Electrical System
Engine Used
TROUBLE SYMPTOM at High Clogged Starting Open-
Clogged Alternator Battery
Temperatures Exhaust Motor Circuit in
Air Filter Defect Voltage Drop
or at High Pipe Defect Wiring
Altitude
Engine None
Starting Starts
Exhaust Little
Problem But
Smoke
Stops Much
Soon
Exhaust
Engine White
Color
Output Black
Poor White
During
Exhaust
Work Black
Color
Combustion

Excessive Oil
Consumption
Oil With Water
Low Oil Pressure
Engine Overheat
Pressure Drop
Air Intake
Pressure Rise
Study Output Repair or
Clean Repair or Repair Inspect and
Clean Air Drop and Replace
Corrective Action Exhaust Replace Open Change the
Filter. Load Stater
Pipe. Alternator. Circuit. Battery.
Matching. Motor.

Accessible Engine Components
The following components can be serviced or removed

with the engine installed in the frame:
• Camshaft / Valve Train
• Fuel Injectors, Fuel Rail
• Timing Components (Belt, Pulleys)
• Alternator
• Water Pump
• Starter Motor
• Governor
• Cylinder Head
• Glow Plug / Pre-Combustion Chamber

The following components require engine removal for
service:
• Pistons
• Connecting Rods
• Crankshaft
• Crankcase
• Oil Pan
• Flywheel

Engine Removal And Installation

WARNING
NOTE: Before removing engine, the fuel pressure
must be relieved from the system.
Always wear safety glasses and proper shop clothing
when performing the procedures in the manual.
NOTE: Some engine repair procedures can be
Failing to do so may lead to possible injury or death.
performed without removing the engine. (See W-2847-0710
Accessible Engine Components on Page 50-
10-14.) for further information.
Figure 50-10-2
NOTE: The use of an overhead or portable engine
hoist is the only recommended method for
removing and installing the engine. Have an
assistant help guide the engine in and out of
the vehicle while using an engine hoist to
2
prevent personal injury or damage to vehicle
components.
1
Clean the work area.
Thoroughly clean the engine and chassis. 1

P120208
Disconnect the negative (-) battery cable.
Remove the fasteners (Item 1) and heat shield (Item 2)
Raise and remove the cargo box.
[Figure 50-10-2].
Drain the oil from the engine.
Figure 50-10-3
Drain the engine coolant from the cooling system. (See
Removing And Replacing Coolant on Page 10-70-3.)

Remove the drive belt. (See Removal on Page 20-30-1.) 1 1
Remove the drive clutch. (See Removal And Installation 1

2
on Page 20-41-1.)
Remove the driven clutch. (See Removal And Installation

on Page 20-42-1.)
P120207
Remove the inner CVT cover. (See CVT (Inner) Cover
Remove the exhaust system. [Figure 50-10-3].
Remove the Alternator.

ENGINE INFORMATION (CONT’D) Figure 50-10-6
Engine Removal And Installation (Cont'd)
Figure 50-10-4
1
P120184

P120200 the oil pressure sensor.
Figure 50-10-7
Loosen the clamp (Item 1) and remove the bypass hose
(Item 2) [Figure 50-10-4].

Figure 50-10-5
P120191
1
P120202 the Crankshaft Position Sensor (CPS).
Disconnect the harness from the Coolant Temperature

Sensor (CTS) (Item 1) [Figure 50-10-5].

Figure 50-10-8
1
P120187
Disconnect the solenoid wire (Item 1) [Figure 50-10-10]

P120186 from the starter.
Figure 50-10-11
Disconnect the glow plug harness (Item 1) [Figure 50-
10-8].

Figure 50-10-9
1
1
2 P120188
Remove the protective boot (Item 1) nut and positive

P120189 battery cable (Item 2) [Figure 50-10-11] from the starter.
Remove the nut (Item 1) and the engine ground (Item 2)

[Figure 50-10-9] wire.

Figure 50-10-12
1
2
P120183
Remove the nut (Item 1) bolt and the air box (Item 2)
P120182 [Figure 50-10-14].
Figure 50-10-15
Remove the cable tie (Item 1) [Figure 50-10-12] from the
top of the air box.

Figure 50-10-13
2
1 3
P120190
2
P120181 [Figure 50-10-15].
Loosen the clamp (Item 1) and remove the air box hose
(Item 2) [Figure 50-10-13].
Loosen the jam nut (Item 3) and remove the throttle cable
(Item 4) [Figure 50-10-13] from the bracket.

Figure 50-10-16
1
1
3
2
P120199
Remove the nuts (Item 1) [Figure 50-10-18] and bolts

P120185 from the operator side of the engine.
Installation: Tighten the right side engine mount nuts to

Loosen the clamps (Item 1) and remove the fuel supply 64 N•m (47ft-lb) torque.
(Item 2) and return line (Item 3) [Figure 50-10-16].

Figure 50-10-19
Figure 50-10-17
1 1
P120203
P120201
Remove the nuts (Item 1) [Figure 50-10-19] and bolts

Install a lifting strap or chain (Item 1) [Figure 50-10-17], from the passenger side of the engine.
and apply slight upward pressure.
Installation: Tighten the left side engine mount nuts to
Place a block under the transmission to prevent it from 74,5 N•m (55 ft-lb) torque.
falling to the floor when the coupler bolts are removed.

Figure 50-10-20
P120204
With the help of an assistant, raise the engine vertically

P120197 out of the vehicle frame [Figure 50-10-22].
NOTE: Use caution when lifting the engine out of the

Figure 50-10-21 frame. Use an engine lift or other means if the
engine appears too heavy to be lifted

manually.
Install the engine on a suitable engine stand for

disassembly and assembly.
P120198
Remove the nut (Item 1) [Figure 50-10-20] and [Figure

50-10-21] and bolt from the forward engine mount.
Installation: Tighten the front engine mount nuts to 54


ENGINE INFORMATION (CONT’D) Exhaust
Engine Installation Notes Replace exhaust gaskets. Seal connections with high
temp silicone sealant.
After the engine is installed in the frame, review this
checklist and perform all steps that apply: Check to be sure all springs are in good condition.
General Items Bleed Cooling System
Repeat steps in reverse order in the “Engine Removal” Remove radiator cap and slowly add coolant to top of
section above to reinstall the engine. filler neck.
Install previously removed components using new Fill coolant reservoir tank to full mark.
gaskets, seals, and fasteners
Install radiator cap and squeeze coolant lines to force air
Perform regular checks on fluid levels, controls, and all out of system.
important areas on the vehicle as outlined in the daily
pre-ride inspection checklist. (See SERVICE SCHEDULE Again remove radiator cap and slowly add coolant to top
on Page 10-50-1.) of fill neck.
CVT System Start engine and observe coolant level in the radiator.
Allow air to purge and top off as necessary. Reinstall
Adjust center distance of drive and driven clutch. radiator cap and bring engine to operating temp. Check
level in reservoir tank after engine is cool and add coolant

Clean clutch sheaves thoroughly and inspect inlet and if necessary.
outlet ducts for proper routing and sealing.
Engine Break In Period
Transmission
Diesel Engine Break-In Period is defined as the first 50
Inspect transmission operation and adjust shift cable if hours of engine operation or 2 full tanks of fuel.
necessary. (See Shift Cable Adjustment on Page 20-20-
6.) Use only Bobcat synthetic engine oil 2W-50. Never
substitute or mix oil brands. Serious engine damage can
result.
Use fuel with a minimum octane of 87 (R+M) / 2 method.
Change break-in oil and filter at 50 hours.

Engine Mount Replacement
Figure 50-10-23
P110878
The engine mount (Item 1) [Figure 50-10-23] consists of

a one piece molded design.

Use the following procedure to install new engine
mounts:
Remove the existing mount from the engine. Refer to

engine removal and installation for engine mount
locations.
Replace all three engine mounts two front and one rear.
Installation: Tighten the front engine mount bolts to 41

Installation: Tighten the rear engine mount nuts to 30


ENGINE INFORMATION (CONT’D) Press the brake and crank the engine with the starter
cranking rpm.
Compression And Leakage Test
Cylinder Compression
Smooth idle generally indicates good compression. Low
New 2758 -3103 Kpa (400 - 500 psi)
engine compression is rarely a factor in running condition
problems above idle speed. Abnormally high Broken - In 2413 - 2758 Kpa (350 - 400 psi)
compression can be caused by a decompressor Cylinder to Cylinder 345 Kpa (50 psi)
malfunction, or worn or damaged exhaust cam lobes. variance
Inspect camshaft and automatic decompression
Leak down Service 15%
mechanism if compression is abnormally high.
Limit
A cylinder leakage test is the best indication of engine
condition on models with automatic decompression. Figure 50-10-25
Follow manufacturer’s instructions to perform a cylinder
leakage test (never use high pressure leakage testers as
crankshaft seals may dislodge and leak).
Figure 50-10-24

1
P-99369
Push the button on the compression gauge to release

pressure [Figure 50-10-25].
P-99368 Installation: Tighten the glow plugs to 20 N•m (14 ft-lb)

torque.
The engine must be at operating temperature.
Remove the glow plugs. Connect the compression gauge

(Item 1) [Figure 50-10-24] to the cylinder to be tested.

ENGINE INFORMATION (CONT’D) Fuel Limiter
Cylinder Head Diagnostics Figure 50-10-27
Figure 50-10-26
P120329
P120328
It is against US EPA regulations to adjust the fuel limiter
nut (Item 1) [Figure 50-10-27]. The nut is marked to
It is possible, if necessary, to diagnose components in the prevent tampering.
cylinder head while the rocker arm cover is removed.

Only run the engine on a limited basis with the oil supply
plugged.
Before starting the engine remove the rocker arm cover.
Insert a 10 mm x 1.5 mm long bolt to plug the supply hole

(Item 1) [Figure 50-10-26] to prevent oil from spraying
during running.

Idle Speed Setting
Figure 50-10-28
P120331
The idle speed adjustment screw (Item 1) and the

maximum engine speed adjustment screw (Item 2)

[Figure 50-10-28] are marked to prevent tampering. DO
NOT adjust the maximum engine speed adjustment
screw. If necessary, the idle speed screw can be
adjusted.
Start the engine and let it warm up for ten minutes.
Turn the screw to adjust the idle speed to 1250RPM.
Tighten the nut to secure the idle speed screw.

Timing Belt Inspection
NOTE: Do NOT remove the timing belt for inspection

purposes. Once the belt is removed it must be
replaced.
Figure 50-10-29
P120004
1
Remove the bolts (Item 1) and the timing belt cover (Item
2) [Figure 50-10-31].
Figure 50-10-32
P118970

Remove the center bolt (Item 1) [Figure 50-10-29].
Installation: Tighten the bolt to 360 N•m (265 ft-lb)

torque.
NOTE: The center bolt is reverse threaded. Turn

clockwise to remove from the pulley.
Figure 50-10-30
P120006
Inspect the belt for any cracks on the smooth outer

surface of the belt. Look for any missing teeth. Oil on the
belt will shorten its life and must be replaced if seals are
leaking [Figure 50-10-32].
1 1
P118969
Remove the outer bolts (Item 1) and pulley (Item 2)

[Figure 50-10-30].

THROTTLE SYSTEM Figure 50-20-3
Throttle Pedal Removal And Installation
Figure 50-20-1
1 2
2 1
P-99328
Lift the spring (Item 1) and remove the pedal assembly

P-99326 (Item 2) [Figure 50-20-3] from the machine.
Figure 50-20-4
Compress the tabs (Item 1) and remove the cable from
the slot (Item 2) [Figure 50-20-1].

Figure 50-20-2
2
P-99329
Remove the plastic bushing (Item 1) [Figure 50-20-4]

P-99327 from the shaft.
Remove the clip (Item 1) and remove the plastic bushing

(Item 2) [Figure 50-20-2].

THROTTLE SYSTEM (CONT’D) Throttle Cable Removal And Installation
Throttle Pedal Removal And Installation (Cont’d) Remove the seat. (See Seat Base Removal And
Figure 50-20-5
Figure 50-20-7
2
1
2
P-99331
P-99326
Remove the clip (Item 1) and washer (Item 2) [Figure 50-

20-5]. Compress the tabs (Item 1) and remove the cable

through the slot (Item 2) [Figure 50-20-7].
Figure 50-20-6
Figure 50-20-8
P-99332
P-99333
Lift the spring (Item 1) and remove the pedal (Item 2)

[Figure 50-20-6]. Compress the tabs (Item 1) [Figure 50-20-8] and feed
the cable through the hole.
Check all components for wear or damage and replace
as needed.

THROTTLE SYSTEM (CONT’D) Figure 50-20-11
Throttle Cable Removal And Installation (Cont’d)
Figure 50-20-9
P-99655
2 3
Remove all tie straps securing the cable (Item 1) [Figure

P-99654 50-20-11].
Remove the speed control cable.

Loosen the nut (Item 1) and remove the cable (Item 2)
[Figure 50-20-9] from the bracket. Installation: Secure the cable with new tie straps.

Disconnect the cable end (Item 3) [Figure 50-20-9] from After installing the throttle cable, the throttle freeplay
the speed control. must be checked. (See Throttle Freeplay on Page 50-20-
4.)
Figure 50-20-10
1
1
1
2
P-99656
Remove the screws (Item 1) and remove the floor cover

(Item 2) [Figure 50-20-10] from the vehicle.

THROTTLE SYSTEM (CONT’D) Throttle Freeplay Adjustment
Throttle Freeplay Figure 50-20-13

If the throttle pedal has excessive play due to cable
stretch or mis-adjustment, it will cause a delay in the
throttle response, especially at low engine speed. The
throttle may also not open fully. If the throttle pedal has
no freeplay, the throttle may be hard to control, and idle
speed may be erratic.
1
Adjust freeplay as necessary.
Inspection And Maintenance
Figure 50-20-12
P113563
Figure 50-20-14
1
1,6 - 3,4 mm 2

1
(0.06 - 0.12 in)

P-97344

P113564
the park brake, place the gear selector lever in neutral.
Start the engine and allow to warm to operating
temperature.
the park brake and stop the engine. Exit the utility
Measure the distance the throttle pedal (Item 1) [Figure
vehicle.
50-20-12] moves before the engine picks up speed.
The adjustment for the throttle cable is located under the
The correct throttle pedal freeplay is 1,6 - 3,2 mm (0.06 - boot (Item 1) [Figure 50-20-13]. Squeeze the end of the
0.12 in). rubber boot and slide it far enough to expose the end of
the in line cable adjuster.
Remove the seat. (See Seat Base Removal And
Installation on Page 30-20-2.) Loosen the adjuster locknut (Item 1) [Figure 50-20-14].
Rotate the adjuster (Item 2) [Figure 50-20-14] until the

correct amount of throttle pedal freeplay is achieved.
NOTE: While adjusting, lightly flip the throttle pedal

up and down.
Tighten the locknut (Item 1) [Figure 50-20-14] and slide

the rubber boot (Item 1) [Figure 50-20-13] back to its
original location.

MUFFLER
Figure 50-30-1
2
1
3
P110943
Remove the springs (Item 1) that secure the muffler (Item

2) to the exhaust pipe (Item 3) [Figure 50-30-1].
Figure 50-30-2
P110944
Remove the nuts (Item 1), washers (Item 2), [Figure 50-
30-2] and bolts.
Remove the muffler.


AIR CLEANER
Housing Removal And Installation
Figure 50-40-1
P120179
Loosen the clamps (Item 1) and disconnect the hoses

(Item 2) [Figure 50-40-1] from the air cleaner housing.
Figure 50-40-2
P120155
Remove the bolt (Item 1) and air cleaner housing (Item 2)

[Figure 50-40-2].
Plug the hoses to prevent dirt and debris from entering

the engine.


ENGINE COOLING SYSTEM Radiator Cap Pressure Test
Cooling System Pressure Test Remove the front access cover.
Remove the front access cover.
WARNING
WARNING Never remove radiator cap when engine is warm or
hot. The cooling system is under pressure and
Never remove radiator cap when engine is warm or serious burns may result. Allow the engine and
hot. The cooling system is under pressure and cooling system to cool before servicing.
serious burns may result. Allow the engine and W-2867-0510
cooling system to cool before servicing.
W-2867-0510
Remove the radiator pressure cap and test using a cap
tester (Commercially available).
Remove the pressure cap from the radiator and pressure
test the cooling system using a commercially available The radiator cap relief pressure is 0,90 bar (13 psi).
tester. Replace cap if it does not meet this specification.
The system must retain 69 kPa (0,69 bar) (10 psi) for five
minutes or longer. If pressure loss is evident within five

minutes, check radiator, all cooling system hoses and
clamps and water pump seal for leakage.

System Bleeding
Remove the front access cover.
NOTE: If coolant level is very LOW in the radiator, or

if there are leaks in the system, the coolant
system will not draw coolant from the
recovery bottle. It may be necessary to raise
the front of the vehicle (12 in) to bleed the
system.
1
WARNING P113499
Remove the pressure cap (Item 1) [Figure 50-50-2] and

Never remove radiator cap when engine is warm or
top off coolant. Leave the pressure cap off at this point.
serious burns may result. Allow the engine and
cooling system to cool before servicing.
W-2867-0510
Figure 50-50-3

Figure 50-50-1
MAX
P120207
P118559
Open the bleed screw (Item 1) [Figure 50-50-3] on the
thermostat housing to allow any trapped air to escape.
Remove recovery bottle fill cap (Item 1) [Figure 50-50-1]
and fill the bottle to the “MAX” line. Reinstall the recovery Fill the radiator until a steady stream of coolant begins to
bottle cap. drain out of the bleed screw.
Tighten the bleed screw to 4,75 - 5,15 N•m (42 - 46 in-lb)

torque.
Start the engine and allow it to idle for 5 - 10 minutes until

the coolant fan has cycled.
NOTE: When the thermostat opens the radiator

coolant level will drop significantly.

ENGINE COOLING SYSTEM (CONT’D) Radiator Cleaning
System Bleeding (Cont’d) Check radiator air passages for restrictions or damage.
Stop the engine and allow it to cool. Top off the radiator Carefully straighten any bent radiator fins.
with coolant. If the coolant level drops indicating that
coolant has been pulled into the system, fill the radiator Remove any obstructions with compressed air or low
first then fill the recovery bottle. pressure water. Flush radiator fins from the fan side.
Open the bleed screw to allow any trapped air to escape.

Close the bleed screw once a steady stream of coolant
begins to drain out.
Tighten the bleed screw to 4,75 - 5,15 N•m (42 - 46 in-lb)

torque.
Fill the recovery bottle to the MAX line.
Lower the cargo box and install the front access cover.

Radiator Removal And Installation

WARNING
1
Never remove radiator cap when engine is warm or
serious burns may result. Allow the engine and
cooling system to cool before servicing. P118560
W-2867-0510
Slide the clamp (Item 1) [Figure 50-50-5] back and

Figure 50-50-4 remove the lower radiator hose.
Allow the coolant to drain. Properly dispose of the used

coolant.

Figure 50-50-6
1
1
3
2
P113499
Remove the radiator cap (Item 1) [Figure 50-50-4] to

relieve any system pressure.
P118401
Place a drain pan under the lower radiator hose.
Remove the bolt (Item 1), plastic rivet (Item 2) and

reposition the bracket (Item 3) [Figure 50-50-6] (both
sides).

Radiator Removal And Installation (Cont’d)
Figure 50-50-7
1
P118543
Figure 50-50-10
P113499
1
Remove the recovery bottle return line (Item 1) [Figure
50-50-7] from the radiator.

Figure 50-50-8
1 P118542
2 Remove the bolts (Item 1) [Figure 50-50-9] and [Figure

50-50-10] securing the fan shroud to the radiator.
Lift up on the radiator / fan assembly to separate the fan

P118541 shroud from the radiator.
Slide the clamp (Item 1) back and remove the upper

radiator hose (Item 2) [Figure 50-50-8].

ENGINE COOLING SYSTEM (CONT’D) Cooling Fan Removal And Installation
Radiator Removal And Installation (Cont’d) Remove the front access cover. (See Front Access Cover
Figure 50-50-11
Figure 50-50-12
1
1
P118537
P118401
Carefully pull the radiator (Item 1) [Figure 50-50-11] up

through the flexible portion of the hood liner. Take care Remove the bolt (Item 1), plastic rivet (Item 2), and

not to damage the radiator cooling fins. reposition the bracket (Item 3) [Figure 50-50-12] (both
sides).
Figure 50-50-13
1
2
P118558
Remove the four bolts (Item 1) securing the cooling fan

(Item 2) [Figure 50-50-13] to the shroud.
Disconnect the cooling fan harness (Item 2) [Figure 50-

50-13].
Lift up on the radiator / fan assembly to separate the fan

shroud from the radiator.
Carefully pull the fan up through the flexible portion of the

liner taking care not to damage the radiator cooling fins.

Thermostat Removal And Installation


1
Figure 50-50-14
P120250
1 Remove the thermostat (Item 1) and seal (Item 2)

[Figure 50-50-16].

P113499
Remove the radiator cap (Item 1) [Figure 50-50-14] to

relieve any system pressure.
Drain coolant to a level thats below the thermostat

housing.
Figure 50-50-15
1 1
P120249
Remove the bolts (Item 1) and the thermostat cover (Item

2) [Figure 50-50-15].
Installation: Tighten the bolts to 25 N•m (18 ft-lb) torque.

Water Pump Removal And Installation 2
NOTE: The water pump assembly is non-serviceable.

If any part (including the pulley) is found
faulty, replace the entire assembly.
Disconnect the (-) negative battery cable.
Drain the coolant from the radiator. (See Cooling System 1

1
Pressure Test on Page 50-50-1.)
Remove the timing belt.
Raise and support the vehicle. Remove the right rear P120018
wheel.
Figure 50-50-17 Remove the bolts (Item 1) and water pump (Item 2)
[Figure 50-50-18]
Installation: Tighten the water pump cover bolts to 25


1
P120017
Remove the bolts (Item 1) [Figure 50-50-17] attaching

the alternator mount bracket to the engine block.
Installation: Tighten the alternator mount bracket cover

bolts to 25 N•m (18 ft-lb) torque.

LUBRICATION SYSTEM Figure 50-60-3
Oil Pan Removal And Installation
Figure 50-60-1
1
1
P118983
2
Before removing the oil pan from the engine block, run a
P118981 flexible blade at either end of the oil pan to ensure that no
silicon is attached to the oil pan and the forward and rear
main bearing seals.
Remove the bolts (Item 1) and CVT cover mounting plate
(Item 2) [Figure 50-60-1]. Remove the oil pan (Item 1) [Figure 50-60-3].

NOTE: Removal of the CVT cover is not mandatory for NOTE: The oil pick-up is attached to the base of the oil
removal of the oil pan but makes the task pan. Use care during oil pan removal to avoid
easier.
damaging the pick-up.
Figure 50-60-2
1 1
1
P118982
Remove the oil pan bolts (Item 1) [Figure 50-60-2].
Installation: Tighten the oil pan bolts to 10 N•m (7 ft-lb)

torque.

LUBRICATION SYSTEM (CONT’D) Figure 50-60-5
Oil Pump Removal

1
The oil pump is non-serviceable. If any part is found
faulty, replace with a new pump assembly. The pump
rotor is keyed to the crankshaft6. Rotate the crankshaft
until the crankshaft timing pulley keyway is at 12 o’clock
position. When the crankshaft timing pulley keyway is in
position, the oil pump drive keyway will be at the 3 o’clock
position allowing removal of the oil pump assembly. 2
NOTE: If the oil pump must be replaced, replace it as

an assembly only. Do not replace individual 3
components.
P118985
Figure 50-60-4
With the crankshaft properly positioned (crankshaft

timing pulley keyway (Item 1) at 12 0’clock and oil pump
drive keyway (Item 2) at 3 o’clock) remove the oil pump
(Item 3) [Figure 50-60-5].

1
P118984
Remove the bolts (Item 1) [Figure 50-60-4] securing the

oil pump to the engine block.

LUBRICATION SYSTEM (CONT’D) Oil Pump Installation
Oil Pump Inspection Figure 50-60-8
NOTE: If any oil pump component clearance exceeds

its limit, the oil pump must be replaced as an
assembly.
Figure 50-60-6
1
P120247
1
Position the backplate (Item 1) and install the bolts (Item

2), [Figure 50-60-8].
P120247
Place a new oil pump gasket on the engine.

Rotate the crankshaft until the crankshaft timing pulley
Remove the bolts (Item 1) and backing plate (Item 2) keyway is in the 12 o’clock position. Install the key.
[Figure 50-60-6].
Figure 50-60-9
Inspect the pump rotor for any damage or debris.
Figure 50-60-7
2
1
P118984
P118986
Position the oil pump assembly (Item 1) and install the
bolts (Item 2) [Figure 50-60-9].
Using a feeler gauge, measure the distance between the Installation: Tighten the oil pump bolts to 25 N•m (18 ft-
teeth on the rotors (Item 1) [Figure 50-60-7]. lb) torque.
Record the measurements.
Oil Pump Teeth Clearance 0,25 mm

(Max) (0.0098 in)

LUBRICATION SYSTEM (CONT’D)
Engine Oil Pressure - Testing
Figure 50-60-10
P118998
Remove the oil pressure switch (Item 1) [Figure 50-60-

10] from the rocker arm cover.

Using the proper adapter, install the compression gauge
into the rocker arm cover.
Start the engine. At operating temperature, the oil

pressure must be at or above 100Kpa (1.0 bar) (14.5 psi).

FUEL SYSTEM Operation
Service Notes The fuel system is designed to provide peak engine

performance with optimum fuel efficiency and lowest
Never attempt to service any fuel system component possible emissions. The injector unit functions are
while the engine is running or ignition switch is “ON”. mechanically controlled and governed. The fuel injector
unit is not serviceable. It must be serviced by an
Cleanliness is essential and must be maintained at all authorized dealer.
times when service or working on the fuel system. Dirt,
even in small quantities, can cause significant problems. An in line electric fuel pump is used to move fuel from the
tank through the fuel line and in line fuel filter/water
Do not use compressed air if the system is open. Cover separator. The fuel pump maintains a system operating
any parts removed and wrap any open joints with plastic pressure of 1 - 5 psi. Any excess fuel returns to the tank
if they will remain open for any length of time. New parts via the return line attached to the injection system.
should be removed from their protective packaging just
prior to installation. At the engine, fuel is fed to the fuel injector unit, which
combines the fuel pump and injector functions in a single
Clean any connection before opening to prevent dirt from unit. The camshaft operates lobes that activate the
entering the system. injector units. A precise amount of fuel is injected into the
pre combustion chambers when the cam lobe pushes the
Although every precaution has been taken to prevent rocker arm into the injector unit.
water intrusion failures, avoid high pressure spray contact
with system components. Initial Priming / Starting Procedure

Do not allow the battery terminals to touch opposing NOTE: The injection system must be purged of all air
terminals. When connecting battery cables attach the prior to the initial start-up, and / or any time
positive (+) cable to positive (+) battery first, followed by the fuel system has been disassembled.
negative (-) cable to negative (-) battery terminal.
If the fuel system is completely out of fuel or has been
Never start the engine when the cables are loose or disassembled and repaired:
poorly connected to the battery terminals.
• Cycle the key switch from “OFF” to “ON” 6 times,
Never disconnect the battery when the engine is running. waiting approximately 3 seconds at each “ON” cycle
to allow the fuel pump to cycle and shut down.
Do not charge the battery with the key switch in the “ON”
position. • Once step 1 is completed, turn the key switch to
“START” until the engine starts or 5 seconds has
Always disconnect negative (-) battery cable lead before passed.
charging battery.
• If the engine failed to start, repeat steps 1 for 2 more
cycles and attempt to start the engine.
• If the engine fails to start, a problem may still exist,

and should be diagnosed.

FUEL SYSTEM (CONT’D) Fuel Tank Removal
Fuel Line Removal / Installation Remove the driver and passenger seat base and storage
bins.
Disconnect the negative (-) battery cable from the battery.

WARNING Remove the main floor.
AVOID INJURY OR DEATH NOTE: Siphon as much fuel from the tank as possible
Diesel fuel or hydraulic fluid under pressure can before attempting to remove it from the
penetrate skin or eyes, causing serious injury or vehicle.
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do Figure 50-70-2
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Thoroughly clean the hose connection area and place a

shop towel around the fuel line to catch any excess fuel.
Figure 50-70-1
1

3
2
P120330
While holding a shop towel over the fuel line connectors,

remove the fuel line (Item 1) [Figure 50-70-2] from the
fuel sender.
1
fuel lines or pump fitting. Properly drain fuel
into a suitable container.
P120330
Remove the fuel tank return line (Item 2) [Figure 50-70-

Squeeze the clamp tabs (Item 1) [Figure 50-70-1] 2].
together and slide the clamp down the fuel line.
Disconnect the fuel sender harness (Item 3) [Figure 50-
Gently twist and pull the fuel line to remove it from the 70-2].
pump outlet.
When installing the fuel hose, verify the hose and fuel
return inlet are clean and free of debris.
Slide the hose fully onto the fuel tank outlet. Squeeze the
clamp tabs and slide the clamp onto the hose connection
area.

FUEL SYSTEM (CONT’D) Fuel Tank Installation
Fuel Tank Removal (Cont’d) Figure 50-70-5
Figure 50-70-3
1
P120354
P120353
Position the fuel tank under the operator’s seat.
Remove the fuel tank bracket bolts (Item 1) [Figure 50- Install the three tie straps (Item 1) [Figure 50-70-5]
70-3] retaining the fuel tank to the chassis. securing the wire harness to the fuel tank.

Swing the tank brackets clear of the fuel tank for removal. Figure 50-70-6
Figure 50-70-4
1 P120354
P120458
Remove the tie straps (Item 1) [Figure 50-70-4] retaining

the main wire harness to the fuel tank. Install the fuel tank bracket bolts (Item 1) [Figure 50-70-
6]. Tighten the bolts to 11 N•m (8 ft-lb) torque.
Slide the fuel tank towards the front of the vehicle and
remove.

FUEL SYSTEM (CONT’D) Fuel Pump
Fuel Tank Installation (Cont’d) Operation
Figure 50-70-7 Figure 50-70-8
4
1 5 1
P120330
P120245
Connect the fuel pump electrical harness (Item 1)
[Figure 50-70-7].

The electric fuel pump (Item 1) [Figure 50-70-8] is used
Install the fuel line (Item 2) and clamp (Item 3) [Figure to supply fuel from the tank to the fuel injection system.
50-70-7]. The main in-line components for fuel pump include the
fuel pump, fuel / water separator, and fuel shutoff valve.
Install the return line (Item 4) and clamp (Item 5) [Figure
50-70-7]. Fuel Pump Test
NOTE: The fuel transfer pump is non-serviceable and

must be replaced if determined to be faulty. If
a fuel delivery problem is suspected, make
certain the fuel pump is be activated by key
“ON”, all electrical connectors are properly
connected, the fuses are good and a minimum
of 12.0 Vdc is being supplied.
Cover the fuel line connection with a shop towel and

disconnect the fuel line from the fuel pump where it
connects to the engine.
Install a commercially available low pressure test gauge

on the fuel line between the fuel pump and the fuel filter /
water separator assembly.
Turn the key switch to activate the pump and check the
system pressure on the gauge. If system pressure of 1 -
5 psi is observed, the ignition switch and fuel pump are
working properly. Turn the key switch off and relieve the
system pressure.
NOTE: If the pressure is to low, check in-tank fuel

filter. If in-tank fuel filter is OK, replace the
pump assembly.

FUEL SYSTEM (CONT’D) Removal And Installation
Fuel Pump (Cont’d) Figure 50-70-9
Fuel Pump Test (Cont’d)
If the pump did not activate, disconnect the plug from the
fuel pump. Connect a DC voltmeter across terminals in
the plug on the vehicle harness side. Turn the key switch 2
to “ON” and observe voltage to ensure a minimum of 12
Vdc is present.
NOTE: If the voltage was below 12 Vdc, test battery,

ignition switch, relay(s), wiring harness and
ECM.
1 1
If the reading is around 12 Vdc, turn the key switch “OFF” 3
an connect an ohmmeter between the power terminal
and the pump and to frame ground to check continuity
P120245
within the fuel pump.
NOTE: If there was no continuity, replace the fuel Disconnect the harness at the fuel pump.
pump.
Disconnect the fuel lines (Item 1) [Figure 50-70-9].

If voltage at the plug is within the specific range, and
there is continuity across the pump terminals, reconnect Remove the bolt (Item 2) [Figure 50-70-9] from the
the plug to the pump. Turn the key switch to “ON” and bracket.
listen for the pump to activate.
Remove the fuel pump (Item 3) [Figure 50-70-9].
NOTE: If the pump starts, verify you have the correct
amount of fuel pressure.
NOTE: If the pump starts but still does not operate,

check the fuel tank assembly for line blockage
or no fuel. Replace the pump if no blockage is
found.

FUEL SYSTEM (CONT’D) Removal And Installation
Fuel Sender If the fuel gauge sender is broken, replace the sender
and pickup as an assembly.
Fuel Sender Test
Move the vehicle to a well ventilated area. Put the
If the fuel gauge reading on the instrument cluster is not transmission in PARK and key switch OFF.
working, or if the display reading differs in large
comparison to the fuel in the tank, perform a resistance Remove the drivers seat and storage bin.
test on the fuel sender.
Disconnect the negative (-) battery cable.
Figure 50-70-10
Clean the top of the fuel tank of dirt and debris.
Discharge static electricity by touching a ground source

such as the engine or frame.
Figure 50-70-11
1
1

P120355
2
Allow the sender float to sit in the empty position (Item

1) [Figure 50-70-10]. Measure and record the
resistance.
P120330
Slowly move the sender float to the full position (Item 2)
[Figure 50-70-10]. Measure and record the resistance.
Loosen the clamp and remove the fuel supply line (Item
Fuel Sender Empty: <15 ± 2 Ohms 1) [Figure 50-70-11] from the sender.
Fuel Sender Full: 95 ± 2 Ohms
fuel lines or sender fitting. Properly drain fuel
If the readings are out of specification, or if the reading is
into a suitable container.
erratic or LCD display “sticks”, check the following before
replacing the fuel pick-up assembly:
the sender.
• Loose float
• Float making contact with the tank
• Bent float rod
If none of these conditions exist, the fuel sender

assembly is faulty. Replace the fuel pick-up assembly.

FUEL SYSTEM (CONT’D) Figure 50-70-13
Fuel Sender (Cont’d)
Figure 50-70-12 1
P118758
Figure 50-70-14
1
2
P118767

Install the fuel sender service tool (Item 1) and remove
the nut (Item 2) [Figure 50-70-12]. Discard the nut.
NOTE: Apply downward force on the fuel sender 1

flange while removing the fuel sender nut.
P118759
Carefully lift the fuel pump (Item 1) [Figure 50-70-13] out

of the fuel tank. As the fuel pump assembly is being
removed, be aware of float arm and pump pre-filter (Item
1) [Figure 50-70-14]. Hold the float arm to the pump
body as you lift and tilt the pump to ensure that the float
arm is not bent when removed from the tank,
Transfer the old fuel pump to a suitable container capable

of safely holding the fuel. The fuel pump will retain some
fuel.
Inspect the inside of the fuel tank for debris (may require
flashlight and mirror). If debris like mud or sand is
present, fuel tank should be flushed and cleaned out
prior to installation of new fuel pump assembly.
NOTE: It is recommended to remove the fuel tank

from the vehicle and rinse it with a small
amount of clean fuel. Do not use water or any
other chemicals to remove debris.

FUEL SYSTEM (CONT’D) Connect a fuel supply line to the supply fitting (Item 3)
[Figure 50-70-15] on the tool. Begin supplying fuel to the
Injector Timing injector. Fuel should begin to flow from the drain hose.
Figure 50-70-16
WARNING 2

Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
1
Perform an injection timing adjustment procedure any P120332
time a unit injector is replaced or when it was removed

without a pin to lock the timing. Rotate the drive pulley (Item 1) [Figure 50-70-16]
Remove the rocker arm cover. (See Rocker Arm Cover towards TDC (PMS) mark until fuel stops leaking out of
the drain hose. The timing mark for the applicable

Removal on Page 50-80-7.)
cylinder should line up with the timing mark for 11°
Remove the fuel rail. (See Fuel Rail Removal on Page BTDC, which is the mark closest on the left to the TDC
50-80-8.) (PMS) mark.
Put the cylinder to be tested on the compression stroke. NOTE: The timing mark for cylinder 1 on the drive
The intake and exhaust valves will be closed during the pulley is a larger stamped dot than the rest of
compression stroke. the marks.
Remove the non-return check valve. Figure 50-70-17
Figure 50-70-15
1
2
1
P120333
P120368
If injection timing is not 11 ° BTDC, loosen the jam nut
Install the injection timing tool (Item 1) [Figure 50-70-15] (Item 1) and adjust the screw (Item 2) [Figure 50-70-17]
onto the unit injector. Move the unit injector control lever on the unit injector follower as needed. Rotating the
that attaches to the fuel control rod to the wide open screw 1/2 turn will change the injection advance by 5°
position so that the tool can seat properly on the unit (Clockwise advances, counterclockwise retards). Repeat
injector. until timing is 11° BTDC.
Place a drain cup under the drain hose (Item 2) [Figure

50-70-15] installed on the return line.

ENGINE DISASSEMBLY AND INSPECTION Intake Manifold Removal
Crankcase Vacuum Regulator Valve Removal Figure 50-80-2
The vacuum relief valve is an engine safety device. Its

function is that of limiting the vacuum whenever it tends
to increase. Without this, should the air filter be clogged,
the oil contained in the cover may be sucked back into
the intake manifold causing the condition for engine
runaway. The vacuum relief valve fails closed.
Figure 50-80-1 1
P118979
1
Remove the bolts (Item 1) and intake duct (Item 2)

[Figure 50-80-2].
2
Discard the gasket.

P118960
Figure 50-80-3
Loosen the clamps (Item 1) and remove the valve (Item

2) [Figure 50-80-1].
Inspect the valve for any oil in the hose to the intake
manifold.
P118980
Remove the manifold bolts (Item 1) [Figure 50-80-3].
Lift the intake manifold and remove the throttle cable.
Inspect the manifold for cracks and breaks. Discard the

gasket.

ENGINE DISASSEMBLY AND INSPECTION (CONT’D) Figure 50-80-6
Exhaust Manifold Removal
Figure 50-80-4
P118970
1 Remove the center bolt (Item 1) [Figure 50-80-6] first to

2 keep the dowel pin from being damaged.
P118972
NOTE: The center bolts is reverse threaded. Turn

Remove the bolts (Item 1) and exhaust manifold (Item 2) clockwise to remove from the pulley.
[Figure 50-80-4].

Figure 50-80-7
Inspect the manifold for breaks and cracks. Discard the
gasket.
Drive Pulley Removal
Remove the starter. (See Removal And Installation on

Page 40-40-2.)
1 1
Figure 50-80-5
P118969
Remove the outer bolts (Item 1) and pulley (Item 2)

[Figure 50-80-7].
P118971
Install the crankshaft locking tool (Item 1) [Figure 50-80-

5] to prevent the crankshaft from turning during removal.

ENGINE DISASSEMBLY AND INSPECTION (CONT’D)
Flywheel Removal
Figure 50-80-8
2
1
P118973
Remove the bolts (Item 1) and the flywheel (Item 2)

[Figure 50-80-8].

Figure 50-80-9
P118974
Inspect the ring gear (Item 1) [Figure 50-80-9] for wear

and damage.

Timing Belt Removal
Figure 50-80-10
P120006
1
2
Remove and discard the timing belt (Item 1) [Figure 50-

80-12].

P120004
Remove the bolts (Item 1) and the timing belt cover (Item
2) [Figure 50-80-10].
Inspect the rubber sealing gasket condition around the

peripheral of the cover and replace if necessary.
Figure 50-80-11
P120005
Loosen the nut (Item 1) [Figure 50-80-11] holding the

timer belt idler pulley. This should relieve tension on the
timing belt.

Timing Pulleys Removal

1
Figure 50-80-13
P120275
1
Remove the center fasteners holding the camshaft timing

P120007 pulley (Item 1) [Figure 50-80-15] onto the camshaft.
Remove the nut (Item 1) and the idler gear pulley (Item 2)
[Figure 50-80-13].

Figure 50-80-14
P120010
Remove the crankshaft timing pulley (Item 1) [Figure 50-

80-14].
NOTE: The crankshaft timing pulley is keyed to the

crankshaft. Keep the key with the pulley for
installation.

ENGINE DISASSEMBLY AND INSPECTION (CONT’D) Speed Governor Removal
Water Pump Removal Figure 50-80-18
The water pump assembly is non serviceable. If any part

(including the pulley) is found faulty, replace the entire
assembly.
Figure 50-80-16
P120001
1 1
Remove the bolts (Item 1) [Figure 50-80-18] securing
the governor to the engine.
Figure 50-80-19
P120017

6
5
4
Remove the bolts (Item 1) [Figure 50-80-16] securing 2 3
the alternator mounting bracket to the engine.
1
Figure 50-80-17
P120002
1
1
Note the order of components during disassembly for
ease of assembly [Figure 50-80-19].
NUMBER DESDCRIPTION
P120018
1 Oil Seal
2 Support
Remove the bolts (Item 1) [Figure 50-80-17] securing 3 Bearing
the water pump to the engine.
4 Retainer
5 Screw
6 Flyweight Assembly

Rocker Arm Cover Removal
The engine control components are all under the rocker

arm cover on the cylinder head.
Figure 50-80-20
1
P120000
Inspect the cover lubrication duct space (Item 1) [Figure

50-80-22] for any debris or damage.
P118998

Remove the bolts (Item 1) [Figure 50-80-20] securing
the rocker arm cover to the cylinder head.
Figure 50-80-21
P118999
Discard the cover gasket (Item 1) [Figure 50-80-21].

ENGINE DISASSEMBLY AND INSPECTION (CONT’D) Unit Injector Removal
Fuel Rail Removal The fuel system is a mechanical type injection system
that uses cam lobes to activate the rocker arm assembly.
Figure 50-80-23 The rocker arm than activates the unit injector. The
injector control rod links all of the unit injectors to the
engine governor which controls fuel volume.
NOTE: When removing more that one of the injectors,

mark each one to the cylinder it goes with for
1
proper installation.
Figure 50-80-25
P118975
Remove the bolts (Item 1) [Figure 50-80-23] holding the

fuel rail to the injectors.

Figure 50-80-24 2
3
P118977
2
Remove the bolts (Item 1) and return spring (Item 2)

[Figure 50-80-25] holding the control rod to the unit
injectors.
Disconnect the control rod (Item 3) [Figure 50-80-25]

from the governor and remove.
NOTE: Remove only the fasteners that hold the

1
control rod to unit injectors. The other
P118976
fasteners on the fuel control rod affect
cylinder to cylinder fuel balancing and should
not be adjusted.
Inspect the non-return check valves (Item 1) and O-rings
(Item 2) [Figure 50-80-24] on the inlet and return orifices
on the injectors.

ENGINE DISASSEMBLY AND INSPECTION (CONT’D) Rocker Arm Assembly Removal
Unit Injector Removal (Cont’d) NOTE: The rocker arm assembly may be removed
without removal of the unit injectors.
Figure 50-80-26
Figure 50-80-28
P120273
1 P118996
Rotate the crankshaft until the cam lobe forces the cam
follower to the highest position on the unit injector. Insert Remove the nuts (Item 1) [Figure 50-80-28] attaching

a hardened pin into the hole (Item 1) [Figure 50-80-26] the rocker arm assembly to the cylinder head and remove
on the top of the unit injector to lock the injection timing the rocker arm assembly.
on the pump. Then, rotate the crankshaft until the cam
lobe is no longer pushing the cam follower up to release Figure 50-80-29
tension on the unit injector. Mark the push rod between
the cam follower and unit injector to the injector and
remove it.
Figure 50-80-27
1
2
P118997
Inspect the cam followers (Item 1) [Figure 50-80-29] for

1 any uneven wear or damage.
P120274
Remove the bolts (Item 1) holding the unit injector to the

cylinder head and remove the unit injector (Item 2)
[Figure 50-80-27].

Camshaft Removal
Figure 50-80-30
P118954
Remove the bolts (Item 1) holding the camshaft end

cover (Item 2) [Figure 50-80-30] to the cylinder head.

Inspect the O-ring on the camshaft cover for damage or
wear.
Figure 50-80-31
1
P118955
Gently pull out the camshaft (Item 1) [Figure 50-80-31]

through the cylinder head. Slight rotations may be
required to avoid binding the camshaft lobes against the
camshaft bearing surface bores.
Inspect the lobes for uneven wear or damage.

Camshaft Inspection
Figure 50-80-32
P118953
Use a commonly available outside micrometer, measure

P118952 camshaft journal diameter. [Figure 50-80-33].
Camshaft Journal Diameter 36,975 - 37,000 mm

Use a commonly available inside micrometer, measure (1.456 - 1.457 in)
camshaft housing diameters [Figure 50-80-32].

Subtract the camshaft housing diameter minus the
Camshaft Housing Diameter 37,035 - 37,060 mm camshaft journal diameter. Replace the camshaft if any
(1.458 - 1.459 in) clearance is out of specification.
Camshaft Journal To Housing 0,170 mm

Clearance (Max) (0.0067 in)
The camshaft will wear on the cam lobe where the

follower rides. Measure the lobe height in two spots, one
where the follower rides and one where it does not.
Replace the camshaft if the cam is above the wear limit
specified.
Camshaft Lobe Wear Limit 0,10 mm (0.039 in)

ENGINE DISASSEMBLY AND INSPECTION (CONT’D) Valve Removal
Cylinder Head Removal Figure 50-80-36
NOTE: The cylinder head may be removed as an

assembly. However, the rocker arm assembly
1
must be removed to access some of the
cylinder head bolts.
Figure 50-80-34
P120014
Install the valve removal adapter (Item 1) [Figure 50-80-

36] over the valve spring.
1
Figure 50-80-37

P120295
Remove the bolt (Item 1) [Figure 50-80-34] and the 1

cooler bypass hose.
Figure 50-80-35
P120015
1 Using a clamp, compress the valve spring with the

removal adapter and remove the valve spring retainers
(Item 1) [Figure 50-80-37].
Release the clamp slowly and remove the spring

assembly components.
P118968
Remove the valve from the cylinder head.
Remove the cylinder head bolts (Item 1) [Figure 50-80-
35].
Inspect the cylinder head for deformation. If beyond

specification, replace the cylinder head.
Cylinder Head Flatness 0,1mm

(0.0039 in)

Valve And Spring Inspection
Figure 50-80-38
P120313
Measure the intake and exhaust valve head angles

P120276 [Figure 50-80-40].
Intake Valve Head Angle 60°

Measure the free height of the spring [Figure 50-80-38].
Exhaust Valve Head Angle 45°

Valve Spring Free Height 46 mm
(Nominal) (1.81 in)
Valve Spring Free Height 43,5 mm Figure 50-80-41
(Minimum) (1.71 in)
Figure 50-80-39
1
1 3
2 4
P120016
P120312 Measure the intake and exhaust valve seat housing

inside diameter, valve seat outside diameter and valve
seat angle [Figure 50-80-41].
Inspect the valves for damage or excessive carbon
buildup [Figure 50-80-39]. Intake Valve Seat 35,220 - 35,245 mm
1 Housing Inside Diameter (1.387 - 1.388 in)
Using an outside micrometer (Item 1) [Figure 50-80-39]
measure the intake and exhaust valve head diameters. Intake Valve Seat 35,306 - 35,315 mm
2
Outside Diameter (1.389 - 1.390in)
Intake Valve Head 34,40 mm 3 Exhaust Valve Seat 31,220 - 31,241 mm
Diameter (1.354 in) Housing Inside Diameter (1.229 - 1.230in)
Exhaust Valve Head 30,20 mm 4 Exhaust Valve Seat 31,308 - 31,.316 mm
Diameter (1.189 in) Outside Diameter (1.232 - 1.233 in)

ENGINE DISASSEMBLY AND INSPECTION (CONT’D) Subtract the valve guide diameter minus the valve stem
diameter to get the valve guide clearance.
Valve And Spring Inspection (Cont’d)
Valve Guide Clearance 0,1 mm
Figure 50-80-42
(0.0039 in)
Figure 50-80-44
P120011
Using an outside micrometer (Item 1) [Figure 50-80-42]

measure the valve stem diameters. The intake and
1
exhaust valves have the same valve stem dimensions. P120013

Valve Stem Diameter 6,96 - 6,99 mm
(0.274 - 0.275 in) Measure the valve recess and seat sealing width [Figure
50-80-44].
Figure 50-80-43
Valve Recess (Nominal) 0,7 - 1,0 mm
1
(0.028 - 0.039 in)
Valve Recess (Limit) 1,3mm
(0.051in)
Valve Seat Sealing Width 0,063 mm
2
(Nominal) (1.6 in)
Valve Seat Sealing Width 2,0 mm
(Limit) (0.079 in)
The valve and cylinder head measurements are supplied

in finished form and cannot be machined. If they are out
of specification, replace the component.
P120012
Using a commercially available ball gauge and outside

micrometer, measure the valve guide diameters. The
intake and exhaust valve guides have the same
dimensions. [Figure 50-80-43].
Valve Guide Diameter 7,005 - 7,020 mm

(0.276 - 0.276 in)

Pre-Combustion Chamber Removal
Figure 50-80-45
1
P118995
Screw the Pre-Combustion Chamber Extractor onto the

P118993 pre-combustion chamber. Sharply slide the hammer part
of the tool up the shaft until contact is made with the end
of the tool (Item 1) [Figure 50-80-47].
Remove the glow plug (Item 1) [Figure 50-80-45].

Figure 50-80-46
P118994
The pre-combustion chamber is fixed to the cylinder head

by a ring nut. Use the Pre-Combustion Chamber Ring
Nut Tool to loosen and remove the ring nut (Item 1)
[Figure 50-80-46].

Piston And Connecting Rod Removal
Figure 50-80-48
2 1
2
1
2 P118992
Remove the stop clips from the piston pin and the piston
P118990 pin (Item 1) [Figure 50-80-50].
Clean all components of carbon build up.

Remove the bolts (Item 1) [Figure 50-80-48] that hold
the connecting rod end caps to the connecting rod.

Remove the end caps (Item 2) [Figure 50-80-48].
Figure 50-80-49
P118991
Pull the piston and connecting rod (Item 1) [Figure 50-

80-49] from the top of the engine.

Piston And Piston Ring Inspection
On the top of the piston should be either the letter A, B or

C. Those letters designate which size class the piston
falls into. Measure the piston diameter 9 mm (0.354 in)
from the base of the skirt. Compare the measurement to
the specifications. If out of the class specification, replace
with a new piston and set of piston rings.
CLASS PISTON DIAMETER

A 74,930 - 74,940 mm
(2.9500 - 2.9504 in)
B 74,940 - 74,950 mm P118989
(2.9504 - 2.9508 in)
C 74,950 - 74,940 mm
Measure the clearance between the piston ring and the
(2.9500 - 2.960 in)
edge of the piston groove [Figure 50-80-52]. Replace if
out of specification.
Figure 50-80-51
PISTON RING GROOVE CLEARANCE

PISTON
GROOVE CLEARANCE
RING
TOP 0,090 - 0,125 mm
(0.0035- 0.0049 in)
MIDDLE 0,050 - 0,085 mm
(0.0020 - 0.0033 in)
BOTTOM 0,040 - 0,075 mm
(0.0016 - 0.0029 in)
P118988
Place the piston rings squarely into the unworn part of

the lower cylinder and measure the end gap using a
feeler gauge [Figure 50-80-51]. Replace if out of
specification.
PISTON RING END GAP
PISTON
END GAP LIMIT VALUE
RING
TOP 0,250 - 0,450 mm 1,0 mm
(0.0098 - 0.0177 in) (0.039 in)
MIDDLE 0,250 - 0,450 mm 1,0 mm
(0.0098 - 0.0177 in) (0.039 in)
BOTTOM 0,250 - 0,450 mm 1,0 mm
(0.0098 - 0.0177 in) (0.039 in)

Connecting Rod Inspection
Figure 50-80-53
B D
E
A
P118987
C
Weight the connecting rods and piston assemblies before
installation in order to avoid unbalance [Figure 50-80-
P118956 54].
Connecting Rod Weight 10 g

Measure the dimensions listed in the below [Figure 50- Difference (Max) (0.022 lb)
80-53].
Piston Assembly Weight 14 g

Difference (Max) (0.031 lb)
CONNECTING ROD
DIMENSION
DIMENSION SPECIFICATION
A: Center to Center 126,48 - 126,52 mm
Distance (4.979- 4.981 in)
B: Piston Pin Bore 20,015 - 20,025 mm
Diameter (0.7880 - 0.7884 in)
C: Crankshaft Bearing 40,021 - 40,050 mm
Bore Diameter (1.5756 - 1.5768 in)
D: Piston Pin Diameter 19,996 - 20,000 mm
(0.7872 - 0.7874 in)
E: Piston Pin Length 54,000 - 55,100 mm
2.1260 - 2.1693 in)
B-D: Piston Pin 0,060 mm
Clearance (Max) (0.0024 in)

Cylinder Inspection
Inspect each cylinder for wear, scratches or damage.
NOTE: Do NOT hone the cylinder or attempt to repair

a damaged cylinder by honing.
Inspect the hone marks to make sure they are not glazed
over and have a 45 - 55° angle with each other.
Insert a dial bore gauge to measure the diameter

throughout the cylinder to check for taper and out of
round.
Figure 50-80-55

P118967
Take two measurements perpendicular from each other

at the top, bottom and middle of the cylinder [Figure 50-
80-55].
Compare the measurements to the class cylinder

diameter specification in the table based on piston class.
CYLINDER
DIAMETER SIZE
CLASS
PISTON TO
CYLINDER
CLASS CYLINDER
DIAMETER
CLEARANCE
A 74,990 - 75,000 mm 0,050 - 0,070 mm
(2.9524 - 2.9527 in) (0.0020 - 20.0028 in)
B 75,000 - 75,0xz0 mm 0,050 - 0,070 mm
(2.9524 - 2.9527 in) (0.0020 - 20.0028 in)
C 74,990 - 75,000 mm 0,050 - 0,070 mm
(2.9531- 2.9535 in) (0.0020 - 20.0028 in)

Crankshaft Removal
Figure 50-80-56
1 2 2
1
P118966
Remove and discard the lateral gaskets (Item 1) [Figure

P118964 50-80-58] on either side of the front and rear main
bearing caps.
The central main bearing caps are not marked to match Inspect the bearings for any excessive wear or damage.
the crankshaft main bearings. They must be marked Replace if necessary.

during removal for proper installation order.
Mark the main bearing caps (Item 1) [Figure 50-80-56].
Remove the bolts (Item 2) [Figure 50-80-56] and cap.
Figure 50-80-57
1 1
P118965
Remove the bolts (Item 1) [Figure 50-80-57] from the

front and rear main bearing caps.
Remove the caps.

Crankshaft Inspection
1
Figure 50-80-59
2
P118959
Measure the main (Item 1) and connecting rod (Item 2)

[Figure 50-80-60] & [Figure 50-80-61] journal
P118957 diameters. Measure the ID of the journal bearings. Check
that the clearances are within specification.
Either before removal or after installation, use a feeler
gauge to measure the axial clearance between the
CRANKSHAFT
crankshaft flywheel side shoulder and the main bearing
MEASUREMENTS
half rings [Figure 50-80-59].

DIMENSION SPECIFICATION LIMIT VALUE
Crankshaft Axial Clearance 0,130 - 0,313 mm
Main Journal 50,981 - 51,000 mm 50,900 mm
(0.0051 - 0.0123 in)
Diameter (2.0071 - 2.0079 in) (2.0039 in)
Figure 50-80-60 Connecting Rod 39,394 - 40,000 mm 39,900 mm

Journal (1.5509 - 1.5750 in) (1.5709 in)
Diameter
Bearing ID (2.0088 - 2.0102 in) (2.0117 in)
1 1 1 1 1
Connecting Rod 40,021 - 40,050 mm 40,00 mm
Journal Bearing 1.5759 - 1.5768 in) (1.5787 in)
ID
Clearance (0.0009 - 0.0031 in) (0.0079 in)
Connecting Rod 0,021 - 0,066 mm 0,130 mm
2 2 Clearance (0.0008 - 0.0026 in) (0.0044 in)
2 2 P118958


ENGINE ASSEMBLY Figure 50-90-3
Crankshaft Installation
Figure 50-90-1
1
3 3
P118962
2 Place a Main Bearing Cap Later Gasket Installation Plate

P118964 (Item 1) [Figure 50-90-3] on either side of the front and
rear main bearing cap slot on the block.
Install the crankshaft (Item 1) [Figure 50-90-1]. Install the front and rear bearing caps. Be sure the lateral
gaskets have some material still protruding from both

Install the center main bearing caps (Item 2) [Figure 50- ends. Install the bolts and slowly remove the gasket
90-1] with the marking on the caps matching and on the installation plates.
same side as the marks on the block.
Figure 50-90-4
Install the bolts (Item 3) [Figure 50-90-1] and tighten to
60 N•m (44 ft-lb) torque.
Figure 50-90-2
1 1
P118990
Tighten the bolts (Item 1) [Figure 50-90-4] to 60 N•m (44

P118961 ft-lb) torque.
Apply Loctite® 518 to lateral gasket slot (Item 1) [Figure

50-90-2] and then install new lateral rubber gaskets that
go on the front and rear main bearing caps. Place the
lateral gaskets in the slots on either side of the front and
rear main bearing caps with a smaller length (1 - 2 mm)
protruding above the top than the bottom of the cap. The
gasket will get pushed up during installation to extend out
of the top and bottom.

ENGINE ASSEMBLY (CONT'D) Piston And Connecting Rod Installation
Crankshaft Installation (Cont’d) Figure 50-90-6
Figure 50-90-5
1 1
P118992
P118963
Place the connecting rod into the piston. Install the piston
pin (Item 1) [Figure 50-90-6].
Place a drop of grease on the protruding lateral gasket
from the surface of the engine block that will mate with Install the stop rings on either side of the piston pins.

the oil pan (Item 1) [Figure 50-90-5] to keep the lateral
gaskets from sticking to the oil pan during future removal. Figure 50-90-7
P120297
Using a piston ring compressor, compress the piston

rings and install the piston into the applicable cylinder.
Make sure the piston is orientated with the combustion
chamber cutout towards the intake side of the engine
[Figure 50-90-7].

ENGINE ASSEMBLY (CONT'D) Oil Pan Installation
Piston And Connecting Rod Installation (Cont’d) Clean all gasket material from the oil pan and engine
block mating surfaces.
Figure 50-90-8
Install a new O-ring on the oil pickup tube.
Install a new fiber gasket on the oil pan mating surface

before installing to the engine block to prevent the O-ring
from coming unseated during installation.
1
Figure 50-90-9
P118990
1 2
Install the connecting rod end cap with the notches in the
end cap on the same side as the connecting rod. Install

the bolts (Item 1) [Figure 50-90-8] and tighten to 40 N•m
(30 ft-lb) torque.
P118982
Position the oil pan (Item 1) and install the bolts (Item 2)
[Figure 50-90-9].
Figure 50-90-10
P118981
Position the CVT cover and install the bolts (Item 1)

[Figure 50-90-10].

ENGINE ASSEMBLY (CONT'D) Valve Installation
Pre-Combustion Chamber Installation Figure 50-90-12
Figure 50-90-11
P
P120316
P118994
Install the intake and exhaust valves into the appropriate
valve guides (Item 1) [Figure 50-90-12].
Install the pre-combustion chamber (Item 1) [Figure 50-
90-11] and ring into the engine so that the side glow plug Figure 50-90-13

hole of the pro-combustion chamber aligns with the
cylinder head glow plug hole. Insert the glow plug
alignment tool into the glow plug hole to verify alignment.
Torquing the pre-combustion chamber is a two step 1

process.
Tighten the pre-combustion chamber ring to 100 N•m (74

ft-lb) torque.
Tighten the pre-combustion chamber ring to 180 N•m

(133 ft-lb) torque.
Install the glow plugs and tighten to 20 N•m (14 ft-lb)

torque. P120315
Lubricate the valve stem seal ring (Item 1) [Figure 50-90-

13] and install over the valve stem using the valve stem
seal installer to prevent deformation of the sealing ring.

ENGINE ASSEMBLY (CONT'D) Cylinder Head Installation
Valve Installation (Cont’d) Figure 50-90-15
Figure 50-90-14
P120291
P120316
There are three different head gaskets with different
thicknesses to compensate for cylinder height. The
Install the valve spring (Item 1), valve spring retainer different thicknesses are indicated by notches (Item 1)
(Item 2) valve keeper (Item 3) [Figure 50-90-14]. [Figure 50-90-15] on the tab of the gasket. Measure all

the piston heights above the cylinder at TDC. Use the
piston with the greatest protrusion to determine gasket
thickness from the table.
HEAD GASKET
THICKNESS
GASKET PISTON TARGET PISTON

NOTCH PROTRUSION CLEARANCE
1 0,82 - 0,91 mm 0,54 - 0,63 mm
(0.032 - 0.036 in) (0.021 - 0.025 in)
2 0,90 - 1,10 mm 0,54 - 0,63 mm
(0.35 - 0.40 in) (0.021 - 0.025 in)
3 1,02 - 1,10 mm 0,55 - 0,63 mm
(0.04 - 0.43 in) (0.022 - 0.025 in)
Place the correct head gasket onto the engine block and
match the gasket to the cylinder head outline.
NOTE: The head gasket DOES NOT exactly match the

engine block coolant openings for restriction
purposes.

ENGINE ASSEMBLY (CONT'D) Camshaft Installation
Cylinder Head Installation (Cont’d) Figure 50-90-18
Figure 50-90-16
1
1
P120290
P118968
Install the camshaft (Item 1) [Figure 50-90-18] through
the cylinder head. Slight rotations may be required to
Place the cylinder head on the new gasket and install
avoid binding the camshaft lobes against the camshaft
NEW head bolts (Item 1) [Figure 50-90-16].
bearing surface bores.

Figure 50-90-17
Figure 50-90-19
2
5 4 1 8
6 2 3 7
P120292
1 P118954
Tighten the head bolts in three steps in the sequence
shown [Figure 50-90-17].
Position the camshaft cover (Item 1) and install the bolts
• First Step: 50 N•m (37 ft-lb) Torque (Item 2) [Figure 50-90-19].
• Second Step: 90° CW Tighten the bolts to 10 N•m (7 ft-lb) torque.
• Third Step: 90° CW

ENGINE ASSEMBLY (CONT'D) Valve / Rocker Arm Clearance
Rocker Arm Assembly Installation Bring each cylinder piston to TDC on the compression
stroke.
Lay the rocker arm assembly on a table to line up the
components. Figure 50-90-22
Figure 50-90-20
1 1
1
P120294
P118997
Using a feeler gauge, inspect the clearance between the

rocker arm rollers and the cam lobes (Item 1) [Figure 50-
Rotate the rocker arms (Item 1) [Figure 50-90-20] so that 90-22].
the cam followers are all facing up in a straight line.
Valve / Rocker Arm Clearance 0,15 mm
Figure 50-90-21
(0.0059 in)
Figure 50-90-23
2
0,15 mm
0,2 mm 1 (0.0059 in)
(0.0079 in)
P120298
Grab all of the assembly parts and hold them together NA9854
tightly so the rocker arms do not rotate. [Figure 50-90-
21].
If adjust is required, bring the appropriate cylinder to TDC
NOTE: If it is difficult to hold the rocker arm assembly on the compression stroke. For convenience, the
together without rocker arms rotating, use a clearance may be checked at either point indicated
temporary holding device like a rubber band [Figure 50-90-23].
or straight edge across the rocker arms.
To adjust, loosen the nut (Item 1) and turn the screw
Line up the holes in the rocker arm mounts to the studs in (Item 2) [Figure 50-90-23] in the desired direction.
the cylinder head. Roll the rocker arm assembly onto the Tighten the nut when the proper clearance is obtained.
studs and down into position.

ENGINE ASSEMBLY (CONT'D) Figure 50-90-25
Speed Governor Installation
NOTE: With the speed governor installed there

should be NO camshaft axial clearance.
Figure 50-90-24
2 1 1
3
5 4
P120001
Position the governor and install the bolts (Item 1)

[Figure 50-90-25]. Tighten the bolts to 10 N•m (7 ft-lb)
torque.
P120002
Install the governor components in the opposite order of

removal. [Figure 50-90-24].
REFERENCE # DESCRIPTION
1 Flyweight Assembly
2 Screw
3 Retainer
4 Bearing
5 Support
6 Oil Seal
When inserting the flyweight assembly on the camshaft,

do it so that the flyweights enter opened so they can
receive the spool and close over it.
Inspect the condition of the sealing rings of the cover.

Unit Injector Installation

3
If the unit injector was not replaced, the rocker arm was
not tampered with and the unit injectors are installed in
the original cylinders, re-timing of the unit injector is not
required.
Figure 50-90-26
1
4
2
P118977
2 Install the injector control rod (Item 1) and attach the

return spring (Item 2) [Figure 50-90-28].
Install the bolts (Item 3) [Figure 50-90-28] and tighten to

3 1,1 N•m (9.7 in-lb) torque.
1

P120321
Every time the unity injector is removed, the spark

arrestor (Item 1), copper gasket (Item 2), oil O-ring (Item
3), and fuel O-rings (Item 4) [Figure 50-90-26] must be
replaced. Insert the spark arrestor in the injector housing
in the cylinder head with the concave surface facing up.
Figure 50-90-27
P118978
Install the unit injector (Item 1) [Figure 50-90-27].
NOTE: Make sure the non-return check valve is fully

seated into the unit injector. Any gap can
cause fuel to leak into the cylinder head.
Install the bolts (Item 2) [Figure 50-90-27]. Tighten the


ENGINE ASSEMBLY (CONT'D) Rocker Arm Cover Installation
Fuel Rail Installation Figure 50-90-30
Figure 50-90-29
1
2
2
2
P120300
11
P118975
Install a new rocker arm cover gasket (Item 1) [Figure
P118975 50-90-30] onto the cylinder head.
Install new O-rings on the unit injectors. Figure 50-90-31
Position the fuel rail (Item 1) onto the unit injectors and

1
install the bolts (Item 2) [Figure 50-90-29].
1
Verify that the non return check valves and O-rings from
the injectors are fully seated in the fuel rail.
Tighten the bolts to 4 N•m (3 ft-lb).
P120301
Apply a bead of silicon sealant over the fuel rail from

either side of the fuel rail where the gasket meets the fuel
rail (Item 1) [Figure 50-90-31].

ENGINE ASSEMBLY (CONT'D) Oil Pump Installation
Rocker Arm Cover Installation (Cont’d) Figure 50-90-33
Figure 50-90-32
1 2
P120247
P118998
Position the backplate (Item 1) and install the bolts (Item
2) [Figure 50-90-33]. Tighten the bolts to 10 N•m (7 ft-lb)
Position the rocker arm cover (Item 1) and install the bolts torque.
(Item 2) [Figure 50-90-32]. Tighten the bolts to 9 N•m

(6.6 ft-lb) torque. Place a new oil pump gasket on the engine.
Install a key in the crankshaft.
Figure 50-90-34
3
1
2
3
P118984
Rotate the crankshaft until the crankshaft timing pulley

keyway (Item 1) [Figure 50-90-34] is in the 12 o’clock
position. When the crankshaft timing pulley keyway is in
position, the oil pump drive keyway will be at 3 o’clock
position, allowing the oil pump assembly to be installed.
Position the oil pump (Item 2) and install the bolts (Item 3)
[Figure 50-90-34]. Tighten the bolts to 25 N•m (18 ft-lb)
torque.

ENGINE ASSEMBLY (CONT'D) Timing Pulleys Installation
Water Pump Installation Figure 50-90-37
Figure 50-90-35
1
P120275
P120018
Line up the camshaft pulley key (Item 1) [Figure 50-90-
37] and install the camshaft pulley.
Position the water pump (Item 1) and install the bolts
(Item 2) [Figure 50-90-35]. Tighten the bolts to 25 N•m Install the center bolt and tighten to 80 N•m (59 ft-lb)

(18 ft-lb) torque. torque.
Figure 50-90-36 Figure 50-90-38
1
1
2
2
P120017 P120309
Position the alternator bracket (Item 1) and install the Install the crankshaft timing pulley key (Item 1) and timing
bolts (Item 2) [Figure 50-90-36]. Tighten the bolts to 25 gear (Item 2) [Figure 50-90-38].

ENGINE ASSEMBLY (CONT'D) Timing Belt Installation
Timing Pulleys Installation (Cont’d) Figure 50-90-40
Figure 50-90-39
2
2
P120302
P120007
Line the camshaft timing mark (Item 1) up with the
reference notch (Item 2) [Figure 50-90-40] on the
Install the tensioning pulley (Item 1) [Figure 50-90-39] cylinder head.
onto the tensioning lever.

Figure 50-90-41
Install the center nut (Item 2) [Figure 50-90-39] finger
tight.
2
P120010
Line up the reference mark (Item 1) on the crankshaft

timing pulley with the reference mark (Item 2) [Figure 50-
90-41] on the oil pump housing. When aligned, the
number one piston (flywheel side) is at TDC.

CRANKSHAFT AND PISTONS (CONT'D) Figure 50-90-44
Timing Belt Installation (Cont’d)
Figure 50-90-42
P120006
Hold the timing belt, camshaft timing pulley and

P120303 crankshaft timing pulley in place. Run the timing belt
taught over the water pump pulley and end up with slack
belt at the timing belt idler pulley. [Figure 50-90-44].
Place the timing belt on the camshaft pulley with the
arrows on the belt facing the direction of rotation [Figure Figure 50-90-45

50-90-42].
Figure 50-90-43 1
P120305
P120304 Install the timing belt tightening tool (Item 1) [Figure 50-
90-45] over the timing belt idler pulley adjustment ear.
Hold the timing belt and camshaft timing pulley in place

while running the timing belt down to the crankshaft
pulley. If the pulleys are properly aligned, the belt teeth
should fit perfectly into the pulley notches [Figure 50-90-
43].

Timing Belt Installation (Cont’d)
Figure 50-90-46
1 1
2 2
P120004
Position the timing belt cover (Item 1) and install the bolts
P120306 (Item 2) [Figure 50-90-47]. Tighten the bolts to 10 N•m
(7 ft-lb) torque.
Install a torque wrench onto the preload tool (Item 1)

[Figure 50-90-46] 90° to the axis line that runs from the

timing belt idler pulley center to the camshaft timing
pulley center. Torque and hold the tightening tool to 20
With a second torque wrench, torque the timing belt idler

pulley center nut (Item 2) [Figure 50-90-46] to 40 N•m
(30 ft-lb) torque.
NOTE: Make sure the timing belt idler pulley nut is

seated properly in the center of the pulley and
not ridding on the pulley lip.
Rotate the crankshaft a few times to check tension

alignment and smooth operation of the timing belt.
Return the timing pulleys to timing marks for proper drive
pulley installation. The timing belt should have 12,7 mm
(0.5 in) of deflection in the middle between the camshaft
and crankshaft timing pulleys.

ENGINE ASSEMBLY (CONT'D) Drive Pulley Installation
Flywheel Installation Figure 50-90-49
Figure 50-90-48
2
2
P118971
1
P118973
With the starter removed, install the crankshaft locking
toll (Item 1) [Figure 50-90-49].
Position the flywheel (Item 1) and install the bolts (Item 2)
[Figure 50-90-48]. Tighten the bolts to 80 N•m (59 ft-lb) Figure 50-90-50

torque.
3 3
P118969
Align the hole in the drive pulley (Item 1) with the

crankshaft dowel pin and Install the drive pulley (Item 2)
[Figure 50-90-50] onto the crankshaft.


ENGINE ASSEMBLY (CONT'D) Starter Installation
Drive Pulley Installation (Cont’d) Figure 50-90-52
Figure 50-90-51
1
P120003
P118970
Remove the crankshaft locking tool if installed.
Apply anti-seize compound to the center drive pulley bolt Position the starter motor in the adapter plate and install
(Item 1) [Figure 50-90-51] and install. Tighten the bolt to the bolts (Item 1) [Figure 50-90-52]. Tighten the bolts to

360 N•m (266 ft-lb) torque. 40 N•m (30 ft-lb) torque.
NOTE: The center bolt is reverse threaded. Turn

counterclockwise to install the bolt in the
crankshaft.

ENGINE ASSEMBLY (CONT'D) Intake Manifold Installation
Exhaust Manifold Installation Figure 50-90-54
Figure 50-90-53
2 P120322
1
P118972
Install a new intake manifold gasket onto the manifold.
Install a new manifold gasket onto the manifold. Apply Loctite® 242 to the three bolts (Item 1) [Figure 50-
90-54] and install.

Position the manifold (Item 1) and install the nuts (Item 2)
[Figure 50-90-53]. Tighten the nuts to 25 N•m (18 ft-lb) Figure 50-90-55
torque.
1
1
P118980


ENGINE ASSEMBLY (CONT'D) Crankcase Vacuum Regulator Valve Installation
Intake Manifold Installation (Cont’d) Figure 50-90-57
Figure 50-90-56 4
3
1
2
2
P118960
P118979
Install the hose (Item 1) on the intake manifold and
tighten the clamp (Item 2) [Figure 50-90-57].
Position the intake manifold duct elbow (Item 1) and
install the bolts (Item 2) [Figure 50-90-56]. Tighten the Install the hose (Item 3) to the rocker arm cover and

bolts to 22 N•m (16 ft-lb) torque. tighten the clamp (Item 4) [Figure 50-90-57].
Do not over tighten the clamps.


SPECIFICATIONS
3400 UTILITY VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Dimensions (B3FK16999 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Dimensions (B3FK17001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
(3400XL) Dimensions (B3FM16999 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
(3400XL) Dimensions (B3FM17001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Fluid And Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
TECHNICAL SERVICE GUIDE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Transmission / Clutch / Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-2
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-5
HVAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-8
Certain specification(s) are based on engineering calculations and are not actual measurements. Specification(s)
are provided for comparison purposes only and are subject to change without notice. Specification(s) for your
individual Bobcat equipment will vary based on normal variations in design, manufacturing, operating conditions,
and other factors.
454 of 481 SPEC-01 3400, 3400XL Service Manual

455 of 481 SPEC-02 3400, 3400XL Service Manual

3400 UTILITY VEHICLE SPECIFICATIONS
Dimensions (B3FK16999 & Below)
• Dimensions are given for utility vehicle equipped with standard tires.
• Where applicable, specification conform to SAE, ANSI or ISO standards and are subject to change without notice.
1352 mm
(53.2 in) 1321 mm
1606 mm (52.0 in)
(63.2 in)
297 mm
(11.7 in)

1847 mm
(72.7 in)
2129 mm
(83.8 in)
242 mm
(9.5 in) 3078 mm
TO BOTTOM OF (121.2 in)
3104 mm
RECEIVER HITCH
(122.2 in)
254 mm Ground Clearance

(10.0 in) at Front Differential
45°
1542 mm
(60.7 in)
846 mm
(33.3 in)
279 mm
(11.0 in)
Turning Radius - Turf Mode = 2311 mm (91 in) Box Inside Dimensions:
Turning Radius - Two Wheel Drive Mode = 2817 mm (111 in) 1371 x 927 x 292 mm
Turning Radius - Four Wheel Drive (4x4) = 2817 mm (111 in) (54.0 x 36.5 x 11.5 in)
456 of 481 SPEC-10-1 3400, 3400XL Service Manual

3400 UTILITY VEHICLE SPECIFICATIONS (CONT’D)
Dimensions (B3FK17001 & Above)
1352 mm
(53.2 in) 1321 mm
(52.0 in)
1618 mm
(63.8 in)
323 mm
(12.7 in)

1875 mm
(73.7 in)
2129 mm
292 mm (83.8 in)
(11.5 in) 3078 mm
RECEIVER HITCH 3104 mm
(122.2 in)
267 mm Ground Clearance

(10.5 in) at Front Differential
45°
1585 mm
(62.4 in)
851 mm
(33.5 in)
330 mm
(13.0 in)
Turning Radius - Two Wheel Drive Mode = 2817 mm (111 in) 1104 x 1372 x 292 mm
Turning Radius - Four Wheel Drive (4x4) = 2817 mm (111 in) (43.5 x 54 x 11.5 in)

(3400XL) Dimensions (B3FM16999 & Below)
1351 mm
(53.2 in) 1321 mm
(52.0 in)
1605 mm
(63.2 in)
297 mm

(11.7 in)
1847 mm
(72.7 in)
2941 mm
(115.8 in) 254 mm
241 mm
(9.5 in) (10.0 in)
3861 mm
RECEIVER HITCH
45°
1542 mm
(60.7 in)
846 mm
(33.3 in)
279 mm
(11.0 in)
Turning Radius - Two Wheel Drive = 4140 mm (153 in) 1371 x 927 x 292 mm
Turning Radius - Four Wheel Drive (4x4) = 4140 mm (153 in) (54.0 x 36.5 x 11.5 in)

(3400XL) Dimensions (B3FM17001 & Above)
1351 mm
(53.2 in) 1321 mm
(52.0 in)
1618 mm
(63.7 in)

1872 mm
(73.7 in)
2941 mm
292 mm (115.8 in) 267 mm
323 mm (10.5 in)
(11.5 in) (12.7 in)
TO BOTTOM OF 3861 mm
RECEIVER HITCH (152.0 in)
45°
1585 mm
(62.4 in)
851 mm
(33.5 in)
330 mm
(13.0 in)
Turning Radius - Two Wheel Drive = 4140 mm (153 in) 1104 x 1372 x 292 mm
Turning Radius - Four Wheel Drive (4x4) = 4140 mm (153 in) (43.5 x 54 x 11.5 in)

(3400) UTILITY VEHICLE SPECIFICATIONS (CONT’D)
Performance
Load Capacity 3400 3400XL
Cargo Box Load (Maximum) 566 kg (1250 lb) 566 kg (1250 lb)
Vehicle Rated Capacity (B3FK16999 & Below, 
B3FM16999 & Below) 861 kg (1900 lb) 975 kg (2150 lb)
(Includes: cargo box load, 
weight of occupant(s), and the weights of any
accessories - including cab kits)
Vehicle Rated Capacity (B3FK17001 & above, 
B3FM17001 & Above)  861 kg (1900 lb) 952 kg (2100 lb)
(Includes: cargo box load, 
weight of occupant(s), and the weights of any
accessories - including cab kits)
Total Rated Capacity (Includes:
the Vehicle Rated Capacity and the tow weight) 1136 kg (2506 lb) 1005kg (2215 lb)
Trailer Hitch Tongue Weight (Max) (B3FK16999 & 68 kg (150 lb) 68 kg (150 lb)
Below, B3FM16999 & Below)
Trailer Hitch Tongue Weight (Max) (B3FK17001 & 90,7 kg (200 lb) 90,7 kg (200 lb)
Above, B3FM17001 & Above)

Tow Capacity (Includes the Weight of Trailer) 907 kg (2000 lb) 907 kg (2000 lb)
Hitch Type Standard 2 in. Receiver
Operating Weight (With full fluids, full fuel, and a 75 kg.

(165 lb) operator) (B3FK16999 & Below, B3FM16999 & 787 kg (1736 lb) 923 kg (2034 lb)
Below)
Operating Weight (With full fluids, full fuel, and a 75 kg.
(165 lb) operator) (B3FK17001 & Above, B3FM17001 & 807 kg (1780 lb) 925 kg (2040 lb)
Above)
Shipping Weight (B3FK16999 & Below, B3FM16999 & 678 kg (1496 lb) 814 kg (1794 lb)
Below)
Shipping Weight (B3FK17001 & 701 kg (1545 lb) 819 kg (1805 lb)
Above, B3FM17001 & Above)
Operating Slope Limit 15° Maximum
Travel Speed Low Gear High Gear

Forward Reverse Forward Reverse
Factory Set Speed 0 - 25 km/h 0 - 25 km/h 0 - 56 km/h 0 - 25 km/h
(0 - 16 mph) (0 - 16 mph) (0 - 35 mph) (0 - 16 mph)
Controls
Vehicle Steering Steering Wheel With Tilt Column and Electronic Power Steering
Engine Foot pedal electronic engine speed control; key-type starter switch.
Brake Pedal Foot pedal activates four wheel disc brakes.

Engine
Make / Model Kohler liquid cooled diesel Tier 4

Fuel / Cooling Diesel Fuel / Liquid
Horsepower (SAE Net) 17,9 kW (24 hp) @ 3600 rpm
Torque (SAE Net) 49,9 N•m (36.8 ft-lb) @ 2200 rpm
Type Of Cycle 4 - Stroke
Air Induction Naturally Aspirated
Low Idle RPM 1250 ± 50 rpm
High Idle RPM 3600
Number of Cylinders 3
Displacement 1,028 L (62.7 in3)
Bore / Stroke 75,0 / 77,6 mm (2.95 / 3.06 in)
Lubrication Full pressure with full flow filter
Crankcase Ventilation Closed Breather
Air Pre-Cleaner Cleanable screen
Air Cleaner Replaceable dry paper cartridge
Engine Coolant Ethylene Glycol / Water Mixture

Electrical
Alternator 110 amp @ 3600 rpm

Battery 12 volt, 575 CCA
Starter 12 volt
Instrumentation Warning lights (Red): Low Engine Oil Pressure,
High Engine Temperature, Seat Belt.
Indicator Lights (Orange): Glow Plug, Check engine.
Indicator Lights (Blue): High Beam.
LCD Display: Fuel Level, Hourmeter, Trip Meter, Odometer, Tachometer,
Battery Voltage, Engine Coolant Temperature, Ambient Air Temperature,
Service Interval, Check Engine / Service Codes
Head Light Low beam 2 x 27W / High Beam 2 x 27W
Tail Light / Brake Light LED (Entire Assembly Is One Unit)

Drive System
Gearbox Ratio - Low Gear Front 7.62:1 / Rear 22.79:1

Gearbox Ratio - High Gear Front 3.10:1 / Rear 9.26:1
Gearbox Ratio - Reverse Front 6.83:1 / Rear 20.41:1
Final Drive ratio - Front 3.818:1
Suspension - Front Dual Control Arm, 152,4 mm (6.0 in) Travel
Suspension - Rear De-Dion, 127 mm (5.0 in) Travel
Suspension - Front And Rear 5 Position Spring Preload Adjust
Adjustment
Rear Differential Type Electronically Lockable, Open Differential
Rear Differential Selection Electrical Lock / Unlock Switch
Steering Rack and Pinion With Electronic Power Steering
Brakes - Front and Rear 4 Wheel Hydraulic Disc
Clutch Engagement rpm 1650 +/- 50 rpm
Fluid And Capacities

Capacity Capacity Fluid
3400 Standard 3400XL (See SERVICE SCHEDULE on Page 10-50-1.)
Engine Cooling System 5,1 L (5.4 qt) 6,1 L (6.4 qt) ETHYLENE GLYCOL ANTI-FREEZE
Fuel Tank 38 L (10 U.S. gal) DIESEL FUEL (See FUEL SYSTEM on Page 10-
80-1.)
Engine Lubrication & Filter
B3FK11001 - B3FK12299 & 2,4 L (2.5 qt) BOBCAT PREMIUM ENGINE OIL
B3FM11001 - B3FM12299
B3FK12300 & Above & 2,8 L (3.0 qt) BOBCAT PREMIUM ENGINE OIL
B3FM12300 & Above
B3FK17001 & Above & 2,4 L (2.5 qt) BOBCAT PREMIUM ENGINE OIL
B3FM17001 & Above
Main Gearcase
(Transmission) Lubricating Oil 946 mL (32 oz) SYNTHETIC GEARCASE FLUID
Differential - Front 200 - 225 mL (6.7 - 7.6 oz) FRONT DIFFERENTIAL FLUID
(B3FK16999 & Below,
B3FM16999 & Below)
Differential - Front 250 mL (8.5 oz) FRONT DIFFERENTIAL FLUID
(B3FK17001 & Above,
B3FM17001 & Above)

Tires
Factory Supplied Tires (AT489) Tire Size Wheel Size Tire Pressure (3400 STD) Tire Pressure (3400XL)
Front (B3FK16999 & Below, 25 x 10 - 12 12 x 6 69 kPa (0,69 bar) (10 psi) 97 kPa (0,97 bar) (14 psi)
B3FM16999 & Below)
Rear (B3FK16999 & Below, 25 x 11 - 12 12 x 8 83 kPa (0,83 bar) (12 psi) 110 kPa (1,10 bar) (16 psi)
B3FM16999 & Below)
Front (B3FK17001 & Above, 26 x 9 - 12 12 x 6 48 kPa (0,48 bar) (7 psi) 48 kPa (0,48 bar) (7 psi)
B3FM17001 & Above)
Rear (B3FK17001 & Above, 26 x 11 - 12 12 x 8 110 kPa (1,10 bar) (16 psi) 138 kPa (1,38 bar) (20 psi)
B3FM17001 & Above)
NUT TYPE LOCATION TORQUE

Front and Rear 81 N•m
Tapered Nut
(60 ft-lb)
NOTE: The wheel nuts must be checked and torqued after the first eight hours of operation of a new machine and
after the first eight hours of operation when wheel(s) have been removed for service.

TECHNICAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Oil Pressure at Low Idle 100 kPa (1,00 bar) (14.5 psi)
Engine Oil Pressure at High Idle 400 - 450 kPa (4,00 - 4,48 bar) (58 - 60 psi)
Location of Number 1 Cylinder Closest to water pump
Crankshaft Rotation (Facing Clockwise
Crankshaft Pulley)
NOTE: For additional engine specifications, (See Specifications on Page 50-10-2.)
Engine Torques
Unit Injector 20 N•m (15 ft-lb)

Glow Plugs 20 N•m (14 ft-lb)
Fuel Rail 4 N•m (3 ft-lb)
Valve Cover Bolts 9 N•m (6.6 ft-lb)
Head Bolts Initial torque 50 N•m (37 ft-lb) + 90° clockwise & 90° clockwise
NOTE: For additional engine torques, (See Torque Values on Page 50-10-6.)

Cooling System
Coolant Hot Lamp (On Solid) 1.45 k Ω 2%

Cooling Fan On 2.80 k Ω 2%
Cooling Fan Off 3.40 k Ω 2%
Room Temperature 29.9 k Ω 2%
Radiator Cap Relief Pressure 13 psi
NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 50-50-1.)


TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat Company that have zinc phosphate coating are specified by the letter H following the part number.
Thread
SAE grade 5 SAE grade 8
size
N•m 0.250 9,0 - 10,2 12,4 - 13,6
(in-lb) (80 - 90) (110 - 120)
0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
N•m 0.375 34 - 38 47 - 54
(ft-lb) (25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)
0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)

0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2200) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4900)
1.875 4270 - 4750 5830 - 6500
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)
Torque For General Metric Bolts
THREAD PROPERTY CLASS

NOM. DIA 8.8 10.9 12.9
- N•m ft-lb N•m ft-lb N•m ft-lb
M4 3,5 - 2,5 2.5 - 2.0 4,2 - 3,8 3.1 - 2.8 5,3 - 4,7 3.9 - 3.5
M5 6,5 - 5,5 5.0 - 4.0 8,4 - 7,6 6.2 - 5.6 9,5 - 8,5 7.0 - 6.2
M6 10,5 - 9,5 7.5 - 7.0 13,7 - 12,3 10.1 - 9.1 15,8 - 14,2 11.6 - 10.4
M7 17 - 15 12.5 - 11.0 22 - 20 16.2 - 14.7 26,3 - 23,7 19.5 - 17.5
M8 26 - 24 19 - 18 32,6 - 29,4 24.0 - 21.7 39 - 35 28.5 - 25.5
M10 47 - 43 35 - 32 63 - 57 46.5 - 42.0 79 - 71 58.5 - 52.5
M12 85 - 75 60 - 55 115 - 105 85 - 78 137 - 123 110 - 91
M14 140 - 125 100 - 90 180 - 160 133 - 118 210 - 190 155 - 140
M16 210 - 190 155 - 140 285 - 255 210 - 188 330 - 300 245 - 225
M18 290 - 260 215 - 190 385 - 345 285 - 255 460 - 420 340 - 310
M20 410 - 370 300 - 275 550 - 490 405 - 360 650 - 590 490 - 440
M22 550 - 500 400 - 370 740 - 760 545 - 560 880 - 800 650 - 590
M24 700 - 640 520 - 470 950 - 850 700 - 625 1120 - 1000 830 - 730
M27 1030 - 930 760 - 680 1370 - 1230 1000 - 900 1630 - 1470 1200 - 1100

M30 1400 - 1260 1030 - 930 1900 - 1700 1400 - 1250 2200 - 2000 1600 - 1500
M33 1900 - 1720 1400 - 1270 2500 - 2300 1850 - 1700 3100 - 2700 2300 - 2000
M36 2450 - 2200 1800 - 1620 3200 - 2900 2400 - 2200 3900 - 3500 3900 - 2600
NOTE: Use the torque value for the part having the lesser property class when a fastener and nut are used
together but have a different property class.

CONVERSIONS
Decimal And Millimeter Equivalent Chart

CONVERSIONS (CONT’D)
U.S. To Metric Conversion Chart

SERVICE TOOLS REQUIRED
The following is a list of service tools required for servicing utility vehicles.
Hydraulic Tools
TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1074 O-Ring Seal Hook 3450, 3600,
3650
MEL1075 Adjustable Gland Nut Includes MEL1075-1 and MEL1075-2

Wrench
MEL1075-1 Standard Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders.
MEL1075-2 Offset Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders.

MEL1396-1 Universal Seal MEL1396 includes: MEL1396-1 and
Expander MEL1396-2
MEL1396-2 Piston Ring

Compressor
MEL1033 Rod Seal Installation

Tool
MEL1418 Cylinder Hone =

2.00 in
OEM6275 Cylinder Hone =
2.75 - 3.00 in
3.00 - 3.50 in
3.50 - 4.00 in
MEL1729 Hydraulic Test Kit 3600, 3650 This test kit includes various adapters,
couplers and wrenches that are used
when testing hydraulic functions.
See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST UV-0318

SERVICE TOOLS REQUIRED (CONT’D)
Transmission / Clutch / Drive Tools
TOOL PART MODELS

NUMBER USED ON
2871282 Seal Driver 3200, 3400 Used on Transmission (Gear case)
Rear Output Shaft Seal.
PA-50231 Snorkel Removal 3400, 3600, Used on Transmission (Gear case)

Tool 3650 Disassembly.
2870654 Clutch Alignment 3200, 3400 Used to align the drive and driven
Tool clutch for correct belt positioning.
2870560 Drive Clutch Puller 3400 No Image Available

PA-48595 Drive Clutch Puller 3200, 3400,
3450
2871358 Clutch Holding 3200, 3400, Used to hold the stationary sheave

Fixture 3450 when removing the spider on drive
clutch.
2871358-A Clutch Holding No Image Available

Fixture
2871358-B Clutch Holding 3400, 3450 Used to hold the stationary sheave
Fixture when removing the spider on drive
clutch. 2871358-B adds three M12 x
1.75 x 15mm cap screws for use with
the Yanmar Diesel drive clutch.
2870341 Clutch Spider 3200, 3400, For removing and re-torquing clutch
Removal Tool 3450 spider. Fits all aluminum drive clutch
spiders.
2870910 Clutch Roll Pin Tool 3200, 3400 This tool has been updated so it can
be used with all aluminum drive
clutches to service drive rollers and
their bushings.
2870910-A Clutch Roll Pin Tool 3200, 3400, This tool has been updated so it can
3450 be used with all aluminum drive
clutches to service drive rollers and
their bushings.
ST UV-0318

Transmission / Clutch / Drive Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
2870386 Piston Pin Puller 3200, 3400,
3450
2870506 Piston Pin Puller 3200, 3400, For removing clutch drive.
3450
2871226 Clutch Bushing Used to remove and replace clutch

Replacement Tool bushings. Requires Pin Puller
2870386 for use (sold separately).
This kit is used with EBS Bushing
Replacement Kit 2201379 (sold
separately) for ORV clutches with
EBS-style bushings.

5020632 Main Puller Adapter Service part for parent tool 2871025.
Includes replacement Main Puller
Adapter.
8700220 Clutch Compression 3400, 3450 Used to compress the drive or driven
Tool clutch during assembly and
disassembly. NOTE: PU-50518
replaces 8700220-A. Some quantities
of 8700220-A are still available while
supplies last.
PS-45909 Compression 3400, 3450 Used with 8700220 to compress the
Extension clutch. NOTE: This extension is not
required for use with the new
8700220-A Clutch Compression Tool.
MEL1644 Axle Boot Clamp Tool 3200, 3400,
3450
2870871 Ball Joint Removal / 3200, 3400, For removal and installation of lower
Installation Tool 3450 ball joints on models with pressed-in
ball joints on the front strut casting.
8700226 Boot Clamp Pliers 3400, 3450,

(Earless Type) 3600, 3650
ST UV-0318

Transmission / Clutch / Drive Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
2870338 Spider Nut Tool 3000 Series For removing and installing spider jam
Utility nut on P-85 clutches.
Vehicles
2871043-A Heavy Duty Flywheel Used To Remove The Flywheel.

Puller-6-Bolt

ST UV-0318

Engine Tools
TOOL PART MODELS

NUMBER USED ON
MEL1721 Digital Wrench Smart 3400G, These are the computer cable need to No Image Available
Link Module Kit 3400D, 3450, connect the laptop to the UV.
3600, 3650
2872105 Water Pump Seal 3200, 3400G For gas engines. Needed to position
Puller piston pin puller correctly onto piston.
Requires use of 2870386 Piston Pin
Puller.
2872106 Replacement T 3200, 3400G

Handle for 2872105
8712100DX Tachometer 3200 Either Tachometer is OK to use.

8712500 Tachometer No Image Available
PA-44689 Valve / Clutch 3200, 3400G Used for adjusting engine intake/
Adjuster Tool exhaust valves.
2871460 Premium Grease Used for engine reassembly. No Image Available
2871293-B Socket For Nut Used on cam chain drive sprocket

retaining nut.
2871283 Crankshaft / Water Prevents damage to crankshaft and

Pump Installation main bearings during installation.
Tool Kit Includes: 5020796, 5130910,
5131134, 5131136, 5131137 and
5131138.
5131135 Water Pump Included with 2871283 Crankshaft /

Installation Tool Water Pump Installation Tool Kit.
2870569 Crankshaft Truing For holding crankshaft while checking

Stand runout for all Polaris engines.
ST UV-0318

Engine Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
MEL10630 Engine Compression 3400D, 3450, Includes: MEL1352, MEL1433,
Test Kit 3600, 3650 MEL1489, MEL1546, MEL1551,
MEL1594, MEL1594,
MEL10630-1 - MEL10630-11 and
MEL10630-14
MEL1352 Compression Used in glow plug port for testing

Adapter compression - Included with
MEL10630.
RCL30 Snap-On™ Ring 3200, 3400 Clutch Control holds tension band in
Compressor position as piston is inserted into
cylinder. (Order from Snap-On™
tools)
2201519-A TPS Tester 3400 Tests the throttle position sensor.

PU-47466 TPS Tester Wire 3400 Throttle position sensor tester wire
Harness harness. Used with TPS tester.
547927 TPS Tester Regulator 3400 *Make sure 9v battery is new per
instruction manual.
PU-50326 PFA Tool 3400, 3600, Used to assist removal of fuel pump
3650 PFA nut.
PV-48656 Fuel Pressure Gauge 3400 Used in-line with fuel pump and fuel
Adapter line to check pressure.
PU-51601 Crankshaft Locking 3400, Installs in place of the starter to hold

Tool 3400XL, the crankshaft stationary while
3600, 3650 removing the drive pulley.
Model Year
2015 Utility
Vehicles
PU-51602 Timing Belt Fits a feature on the timing belt
Tightening Tool tensioner to set tension with a
standard hex socket.
ST UV-0318

Engine Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
PU51603 Fuel Injector Timing 3400, Installs on a fuel injector and indicates
Tool 3400XL, spill to set injector timing.
3600, 3650
Model Year
2015 Utility
Vehicles
PA-49316 Flywheel Puller Tool Used for removal/installation of water
pump drive gear on rotor and
removing rotor from crankshaft.
PU-50896 Water Pump Used on engine with water pump

Mechanical Seal/Oil repair.
Seal Installation Kit

PU-51220 Flywheel Holding Used to hold flywheel during removal
Tool and installation.
2872085 Drive Clutch Puller Used for removing the drive clutch
Tool from the engine shaft.
ST UV-0318

HVAC Tools
TOOL PART MODELS

NUMBER USED ON
MEL1581 HVAC Recover, 3600, 3650
Recycling,
Recharging Machine
MEL1735 Deluxe HVAC

Recover, Recycling,
Recharging Machine
MEL1736 Standard HVAC

Recover, Recycling,
Recharging Machine
MEL1592 HVAC Refrigerant

Identification Tool
MEL1595 AC Compressor 3600, 3650

Pulley Puller
ST UV-0318

ALPHABETICAL INDEX
3400 UTILITY VEHICLE SPECIFICATIONS FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
A-ARMS . . . . . . . . . . . . . . . . . . . . . . . 30-100-1 FUEL SENDER . . . . . . . . . . . . . . . . .40-150-1
AIR CLEANER SERVICE . . . . . . . . . . . 10-60-1 FUEL SOLENOID . . . . . . . . . . . . . . . . .40-50-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . 50-40-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .10-80-1
BACK-UP ALARM SYSTEM . . . . . . . 40-120-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .50-70-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 FUEL TANK . . . . . . . . . . . . . . . . . . . . .30-80-1
BRAKE (FRONT) . . . . . . . . . . . . . . . . . 20-11-1 GEARCASE . . . . . . . . . . . . . . . . . . . .10-110-1
BRAKE (REAR) . . . . . . . . . . . . . . . . . . 20-12-1 GLOW PLUGS . . . . . . . . . . . . . . . . . . .40-100-1
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1 INSTRUMENT CLUSTER . . . . . . . . .40-140-1
BUMPER COVER . . . . . . . . . . . . . . . . 30-40-1 LIFTING AND BLOCKING THE UTILITY
CARGO BOX . . . . . . . . . . . . . . . . . . . 30-130-1 VEHICLE . . . . . . . . . . . . . . . . . . . . . . .10-10-1
CHARGING SYSTEM . . . . . . . . . . . . . 40-30-1 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . .40-60-1
CONTINUOUS VARIABLE TRANSMISSION LUBRICATING THE UTILITY VEHICLE
(CVT) (DRIVE CLUTCH) . . . . . . . . . . . 20-41-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-170-1
CONTINUOUS VARIABLE TRANSMISSION LUBRICATION SYSTEM . . . . . . . . . . .50-60-1
(CVT) (DRIVEN CLUTCH) . . . . . . . . . . 20-42-1 MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1

CONTINUOUS VARIABLE TRANSMISSION MUFFLER . . . . . . . . . . . . . . . . . . . . . . .50-30-1
(CVT) . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
OPERATOR SEAT . . . . . . . . . . . . . . . .30-20-1
CONTINUOUS VARIABLE TRANSMISSION
(CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 REAR SUSPENSION LINK AND AXLE
BRACE . . . . . . . . . . . . . . . . . . . . . . . . .30-50-1
CONVERSIONS . . . . . . . . . . . . . . . SPEC-40-1
ROLL OVER PROTECTIVE STRUCTURE
DASH . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1 (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14 ROLLOVER PROTECTIVE STRUCTURE
DIAGNOSTIC TESTING . . . . . . . . . . 40-160-1 (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . .10-20-1
DIFFERENTIAL SOLENOID (REAR RELAY) SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-111-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . .10-160-1
DIFFERENTIAL SOLENOID . . . . . . . 40-110-1 SERIAL NUMBER LOCATIONS . . . . . . . . 1-13
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . 20-30-1 SERVICE SCHEDULE . . . . . . . . . . . . .10-50-1
ELECTRICAL SYSTEM INFORMATION SERVICE TOOLS REQUIRED . . . .SPEC-50-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
SHOCKS . . . . . . . . . . . . . . . . . . . . . . .30-90-1
ELECTRONIC CONTROL MODULE (ECU)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1 SPARK ARRESTER MUFFLER . . . . .10-130-1
ELECTRONIC POWER STEERING (EPS) STARTER SYSTEM . . . . . . . . . . . . . . .40-40-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1 STEERING BOX . . . . . . . . . . . . . . . . . .30-70-1
ENGINE ASSEMBLY . . . . . . . . . . . . . . 50-90-1 STEERING COLUMN . . . . . . . . . . . . . .30-60-1
ENGINE COOLING SYSTEM . . . . . . . 10-70-1 STOPPING THE ENGINE AND LEAVING THE
ENGINE COOLING SYSTEM . . . . . . . 50-50-1 UTILITY VEHICLE . . . . . . . . . . . . . . .10-150-1
ENGINE DISASSEMBLY AND INSPECTION SWITCH (AWD / 2WD / TURF) . . . . . .40-92-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1 SWITCH (BRAKE LIGHT) . . . . . . . . . .40-91-1
ENGINE INFORMATION . . . . . . . . . . . 50-10-1 SWITCH (GEAR SELECTOR) . . . . . . .40-94-1
ENGINE LUBRICATION SYSTEM . . . . 10-90-1 SWITCH (HEADLIGHT) . . . . . . . . . . . .40-90-1
FENDER . . . . . . . . . . . . . . . . . . . . . . . 30-140-1 SWITCH (KEY) . . . . . . . . . . . . . . . . . . .40-93-1
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . 20-50-1 TAILGATE . . . . . . . . . . . . . . . . . . . . . .30-120-1
478 of 481 INDEX-01 3400, 3400XL Service Manual

TECHNICAL SERVICE GUIDE
SPECIFICATIONS . . . . . . . . . . . . . SPEC-20-1
TEMPERATURE SENSOR . . . . . . . .40-130-1
THROTTLE SYSTEM . . . . . . . . . . . . . .50-20-1
TIE ROD . . . . . . . . . . . . . . . . . . . . . . .30-110-1
TIRE MAINTENANCE . . . . . . . . . . . .10-120-1
TORQUE SPECIFICATIONS FOR BOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TOWING THE UTILITY VEHICLE . . . .10-40-1
TRANSMISSION . . . . . . . . . . . . . . . . .20-20-1
TRANSPORTING THE UTILITY VEHICLE ON
A TRAILER . . . . . . . . . . . . . . . . . . . . . .10-30-1
UTILITY VEHICLE IDENTIFICATION (3400)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
UTILITY VEHICLE IDENTIFICATION (3400XL)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
UTILITY VEHICLE STORAGE AND RETURN
TO SERVICE . . . . . . . . . . . . . . . . . . .10-140-1
VEHICLE SPEED SENSOR . . . . . . . . .40-80-1
479 of 481 INDEX-02 3400, 3400XL Service Manual

480 of 481
Bobcat®, the Bobcat logo and the colors of the Bobcat machine are registered trademarks of
Bobcat Company in the United States and various other countries.
481 of 481

Manual de Servicio 3400XL

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Manual de Servicio 3400XL

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Service Manual

Dealer Copy -- Not for Resale

Safety Alert Symbol: This symbol with a warning statement, CORRECT

CORRECT WRONG WRONG

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

NA5183 NA13238 B-6589

3 of 481 1-1 3400, 3400XL Service Manual

4 of 481 1-2 3400, 3400XL Service Manual

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 481 1-3 3400, 3400XL Service Manual

6 of 481 1-4 3400, 3400XL Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Dealer Copy -- Not for Resale

UTILITY VEHICLE IDENTIFICATION (3400XL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7 of 481 1-5 3400, 3400XL Service Manual

8 of 481 1-6 3400, 3400XL Service Manual

2. Check that ROPS mounting 10. Check all machine fluid

3. The operator and passenger 11. Inspect for fluid, oil or

Dealer Copy -- Not for Resale

5. Foot pedals must return to 13. Check the condition of the

7. The parking brake must 15. Check the electrical charging

8. RapidLink must function 16. Check tires for wear and

9 of 481 1-7 3400, 3400XL Service Manual

18. Check for any field 21. Check function or condition of

19. Operate the vehicle and 22. Recommend to the owner

Dealer Copy -- Not for Resale

10 of 481 1-8 3400, 3400XL Service Manual

• The Delivery Report is used to assure that complete

WARNING service procedures. It is a part of the vehicle and can

IMPORTANT • An Operator’s Handbook fastened to the operator

Dealer Copy -- Not for Resale

• The Service Manual and Parts Manual are available

• The Utility Vehicle Safety Video is available from your

The signal word WARNING on the utility vehicle and

11 of 481 1-9 3400, 3400XL Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

12 of 481 1-10 3400, 3400XL Service Manual

Dealer Copy -- Not for Resale

Have good ventilation when grinding or welding painted

13 of 481 1-11 3400, 3400XL Service Manual

Know where fire extinguishers and first aid kits are

Dealer Copy -- Not for Resale

14 of 481 1-12 3400, 3400XL Service Manual

Utility Vehicle Serial Number

The engine serial number is located on top of the engine

Dealer Copy -- Not for Resale

The utility vehicle serial number plate is located on the

Module 1 - Model / Engine

Explanation of utility vehicle Serial Number [Figure 2]:

1. The four digit Model / Engine Combination Module

2. The five digit Production Sequence Number identifies