JOHN DEERE Trail Buck Utility ATV 500 650 650EX and 650EXT-TM2160 Technical Service Repair Manual-PDF

JOHN DEERE Trail Buck Utility ATV 500, 650, 650EX and 650EXT - TM2160 TECHNICAL SERVICE REPAIR MANUAL - PDF DOWNLOAD !! This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: Table of Contents Specifications Component Location System Schematic Theory of Operation Troubleshooting Chart Diagnostics Tests & Adjustments Repair Note: Depending on the particular section or system being covered, not all of the above groups may be used. Each section will be identified with a symbol rather than a number. The groups and pages within a section will be consecutively numbered. COVERS THE FOLLOWING TOPICS: Lubricants 2-9 B Battery Charging 4-20 Load Test 4-21 Specifications 4-3 Test 4-20 Belt Tension Adjust, Mower Drive 8-7 Brake Switch Adjustment 4-24 Brake Switch/Blade Drive Switch Test 4-24 C Component Location 38 Inch Mower Deck 8-4 42 Inch Mower Deck 8-5 46 Inch Mower Deck 8-6 Dash Panel 9-3 Fuel Tank 9-3 Hydrostatic Drive Traction System 6-8 Hydrostatic Power Train Transaxle 6-7 Transaxle External 6-6 Mower Lift Linkage 8-3 Pedal Linkage Assembly 6-8 Shift Linkage 6-9 Steering 7-3 Cranking & Fuel Shutoff Solenoid Circuit Operation 4-9 Diagnosis 4-10 D Dash Panel Removal and Installation 9-5 Diagnostics Charging Circuit 4-17 Cranking & Fuel Shutoff Solenoid 4-10 Gear Power Train 5-13 Headlight Circuit 4-18 Hydrostatic Power Train 6-18, 6-20 E Electrical AC Voltage Output Test 4-22 Battery Charging 4-20 Load Test 4-21 Test 4-20 Charging & Headlight Circuit Operation 4-16 Charging Circuit Diagnosis 4-17 Component Location 4-7 DC Amperage Output Test 4-21 Diagnostic Information 4-4 Diagnostics 4-9 General Information 4-4 General Specifications 2-2 Ground Circuit Test 4-26 Reading Schematics 4-4 Schematic 4-5 Seat Switch Test 4-23 Specifications 4-3 Theory of Operation 4-4 Troubleshooting 4-8 Wire Color Chart 4-4 Wire Harness 4-6 Engine General Specifications 2-2 Installation 3-5 Oil 2-8 Other Materials 3-3 Removal 3-4 Repair 3-4 Service Equipment & Tools 3-3 Specifications 3-3 F Front Axle Installation 9-5 Removal 9-5 Repair 9-5 Front Wheels Removal & Installation 9-4 Fuel Tank Removal and Installation 9-5 G Gasoline Specifications 2-8 Storage 2-8 INDEX INDEX - 2 4/1/98 Gear Power Train Brake Adjustment 5-16 Component Location 5-12 Test 5-15 Clutch Actuating Spring 5-16 Component Location 5-8 Diagnostics 5-13 Drive Belt Inspection 5-19 Installation 5-20 Specifications 5-3 Drive System Adjustment 5-15 Ground Speeds Specifications 5-4 Input Shaft Gear & Pinion Inspect 5-25 Gear/Pinion Gear Installation 5-26 Input Shaft Gear Disassembly 5-25 Intermediate & Drive Shaft Disassembly 5-29 Intermediate Shaft Repair 5-29 Other Materials 5-4 Rear Axle Loading Specification 5-3 Service Parts Kits 5-4 Sheave & Shift Arm Removal 5-23 Shift Linkage Adjustment 5-17 Component Location 5-9 Removal & Installation 5-22 Specifications 5-3 Theory of Operation 5-10 Torque Specifications 5-4 Traction Drive Belt Removal 5-18 System Component Location 5-9 System Removal 5-20 Transaxle Brake Installation 5-33 Brake Removal 5-24 Case Halves Assembly 5-32 Case Separation 5-24 Component Location 5-6 Differential/Axle Shaft Assembly 5-30 Disassembly 5-30 Inspection 5-30 Dimensions 5-3 Disassembly 5-23 Drive Sheave/Shift Arm Install 5-34 Gear Ratios Specifications 5-4 Gear Tooth Specifications 5-3 Idler Assembly Installation 5-32 Idler Gear Disassembly 5-28 Idler Gear Inspection 5-28 Intermediate/Drive Shaft Inspection 5-29 Installation 5-31 Lubrication Specification 5-3 Operation 5-11 Shift Detent Removal 5-24 Shifter Detent Installation 5-33 Shifter Disassembly 5-27 Transaxle Assembly 5-30 Troubleshooting 5-5 General Specifications Battery 4-3 Chassis 2-5 Fuel/Air system 2-2 Mower Deck Drive Belt 2-3 Spark Plug 4-3 Steering 2-5 Tires 2-5 Traction Drive Belt 2-3 Wheel & Tire 2-5 Grease 2-9 H Hydrostatic Power Train Brake Spring Adjustment 6-24 Brake/Neutral Return Pedal Component Location & Operation 6-12 Pedal Travel 6-13 Theory of Operation 6-12 Component Location Pedal Linkage Assembly 6-8 Shift Linkage 6-9 Transaxle 6-7 Transaxle External 6-6 Diagnosis 6-20 Diagnosis, General 6-18 Drive Belt Specifications 6-3 Linkage Removal/Installation 6-28 Other Materials 6-5 Repair Specifications 6-4 Traction Drive Belt Inspection 6-26 Traction Drive Belt Installation 6-26 Traction Drive Belt Removal 6-26 Shift Linkage Adjustment 6-23 Shift Linkage Spring Adjustment 6-24 Specifications 6-3 Torque 6-4 Tests & Adjustments INDEX 4/1/98 INDEX - 3 Traction Drive System 6-22 Theory of Operation 6-10 Traction Drive Belt Adjustment 6-22 Traction Drive Component Location 6-8 Traction Drive System Drive Belt Tensioning System Removal/Inspection/Installation 6-27 Transaxle Assembly 6-40 Disassembly 6-33 Installation 6-32 Removal and Installation 6-30 Removal External Components 6-31 Transport Valve (Free-Wheel) Operation 6-13 Troubleshooting 6-15 Hydrostatic Transaxle Assembly 6-40 Axle Loading Specification 6-3 Brake Components Wear Tolerance 6-4 Brake Torque Rating Specification 6-3 Disassembly 6-33 Drive Sheave And Fan Installation 6-32 Removal 6-31 Drive Sheave And Fan Removal 6-33 Fan/Drive Sheave Installation 6-42 Gear Ratios Specifications 6-3 Ground Speed Specifications 6-3 Housing Case Halves Separation 6-33 Installation 6-32 Lubrication Specifications 6-3 Motor/Drive Shaft Disassemble/Inspect 6-36 Motor/Drive Shaft Installation 6-40 Output Torque Rating Specifications 6-3 Pump Input Shaft Assembly Removal and Installation 6-38 Removal and Installation 6-30 Removal External Components 6-31 Reservoir Cover Removal 6-42 Reservoir Fill Procedure 6-42 Transaxle Components Wear Tolerance 6-4 I Ignition Circuit Operation 4-12 Circuit Test Points 4-14 Specifications 4-3 Ignition Switch Removal & Installation 4-27 Test 4-25 L Lubricant Storage 2-9 M Mower Deck 38 Inch 8-4 42 Inch 8-5 46 Inch 8-6 Gage Wheel Adjustment 8-15 Installation 8-12 Leveling (Front-To-Rear) 8-9 Leveling (Side-To-Side) 8-8 Removal 8-10 Mower Drive Belt Replacement 8-11 Mower Lift Linkage 8-3 Mower Spindle Assembly Repair 8-14 O Oil Filters 2-9 R Readjusting Suspension for Mower Cut Height 8-10 Rear Wheels Removal And Installation 9-4 S Serial Number Engine 2-10 Gear Transaxle 2-10 Tractor Identification Number 2-10 Spark Plug Specifications 4-3 Specifications 2-2 Spindle Brake Adjustment 8-7 Starter Amp Draw Test 4-23 Solenoid Test 4-22 Specifications 4-3 Stator Specifications 4-3 Steering Backlash Adjustment 7-5 Column Bushings Replacement 7-5 INDEX INDEX - 4 4/1/98 Component Location 7-3 Repair 7-4 Service Equipment & Tools 7-4 Steering Gear Removal 7-4 Synthetic Lubricants 2-9 T Tests and Adjustments Hydrostatic Power Train 6-22 Mower Drive Belt Tension 8-7 Spindle Brake 8-7 Torque Values Metric 2-7 Unified Inch 2-6 Traction Drive System Drive Belt Inspection 6-26 Drive Belt Installation 6-26 Drive Belt Operation 6-10 Drive Belt Removal 6-26 Drive Belt Tensioning System Removal/Inspection/Installation 6-27 Tests And Adjustments 6-22 Transaxle and Shift Linkage System Operation 6-10 Transport Valve (Free-Wheel) Operation 6-13 W Wheels Repair This is the same type of manual used by professional Mechanics and Technicians containing step by step instructions & highly detailed exploded diagrams & pictures to show you how to complete every job correctly. Q. Can I print out a page? A. Yes you can print out a single page or the entire manual, its your choice. Q. Can I use this Manual on more than one computer? A. Yes, this Manual can be used on as many computers as required. Q. Is this a trial or a limited version? A. No, this is the FULL Manual without any limitations or trial periods and can be used for life. Q, Will this Manual expire in 12 months or will I have to pay a renewal fee? A. NO, Absolutely not! You can continue to use this Manual for life without the need to renew or pay any extra. Q. Will this PDF Manual work on Windows & MAC computers? A. Yes, it is fully compatible with all Windows & All MAC Computers. File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader & WinZip JUST GO FOR IT!! MASSIVE MASSIVE MANUAL - 100s OF PAGES AND NEATLY INDEXED AND ORGANISED!! THIS IS THE BEST VERSION OF THE MANUAL THAT THERE IS!! AGAIN, LET ME REPEAT, COMPLETE MANUAL WITH 100s OF PAGES!! PRINTABLE, ZOOMABLE, NEATLY INDEXED, CATEGORISED & WELL ORGANISED AND MORE IMPORTANTLY THIS IS THE SAME EXACT OEM MANUAL USED BY YOUR DEALERS!!! WHAT ELSE YOU WANT?? JUST GO FOR IT!! ___________________________________________________________________________________ POINTS TO NOTE: ============== 1) ► AFTER PURCHASING THE MANUAL, IF YOU FEEL IT IS NOT AS DESCRIBED, FULL REFUND WILL BE GRANTED. THATS OUR PROMISE!! DOES THAT SOUND GOOD FOR YOU? 2) ► WANT SAMPLE PAGES FROM THE MANUAL? CONTACT ME BY COPY PASTING THE LINK IN YOUR BROWSER: OR WRITE TO ME AT ( CHANTMANTRA@GMAIL,com ) SAMPLE PAGES WILL BE SENT WITHIN 2-24 HOURS TIME. 3) ► LOOKING FOR A DEEP DISCOUNT OR SOME OTHER MANUAL? AGAIN JUST WRITE TO US! ( CHANTMANTRA@GMAIL,com ) WE HAVE MILLIONS OF MANUALS STILL UNLISTED! WE WILL GIVE YOU A NICE DISCOUNT!! THANKS FOR VISITING OUR PAGE! HAVE A GREAT DAY AHEAD!! :) :)