A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• Contents
• Section1– Safety
• General Warning
• Section2– Vehicle Specifications
• Section3– General Information
• General Information
• Serial Number Identification
• Storage
• Preparing the Vehicle for Extended Storage
• To Return Vehicle to Service
• Section4– Body and Trim
• Cleaning the Vehicle
• Front Body Repair
• Abrasions and Haze
• Light Scratches
• Large Scratches and Abrasions
• Front Body Components
• Dashboard Removal
• Dashboard Installation
• Front Body Removal
• Front Fender Removal
• Front Fender Installation
• Front Body Installation
• Seat
• Seat Adjustment
• Front Seat Support
• Front Seat Support Removal
• Front Seat Support Installation
• Rear Seat Support
• Rear Seat Support Removal
• Rear Seat Support Installation
• Cargo Bed
• Cargo Bed Removal
• Cargo Bed Installation
• Bed Stop Bumper Adjustment
• Rear Fender
• Rear Fender Removal
• Rear Fender Installation
• Tailskirt
• Tailskirt Removal
• Tailskirt Installation
• Receiver Hitch
• Receiver Hitch Removal
• Receiver Hitch Installation
• Floor Mat
• Floor Mat Removal
• Floor Mat Installation
• Section5– Accelerator and Brake Pedal Assemblies
• Brake Pedal
• Brake Pedal Removal
• Brake Pedal Installation
• Brake Pedal Adjustment
• Accelerator Pedal
• Accelerator Pedal Removal
• Accelerator Pedal Installation
• Accelerator Pedal Adjustment
• Section6– MC012C-AS00 Transaxle: Hydraulic and Park Brake Systems
• Brake System Inspection
• Brake System Troubleshooting
• Brake Drum Removal
• Front Wheel Brake Drum Removal
• Rear Wheel Brake Drum Removal
• Brake Shoe Removal
• Front Brake Shoe Removal
• Rear Brake Shoe Removal
• Brake Cluster Inspection and Cleaning
• Brake Shoe Installation
• Front Brake Shoe Installation
• Rear Brake Shoe Installation
• Brake Drum Installation
• Front Wheel Brake Drum Installation
• Rear Wheel Brake Drum Installation
• Brake Cluster Assembly Replacement
• Front Brake Cluster Assembly Removal
• Front Brake Cluster Assembly Installation
• Rear Brake Cluster Assembly Removal
• Rear Brake Cluster Assembly Installation
• Wheel Cylinder Replacement
• Front Wheel Cylinder Removal
• Front Wheel Cylinder Installation
• Rear Wheel Cylinder Removal
• Rear Wheel Cylinder Installation
• Brake Shoe Adjuster Replacement
• Front Brake Shoe Adjuster Removal
• Front Brake Shoe Adjuster Installation
• Rear Brake Shoe Adjuster Removal
• Rear Brake Shoe Adjuster Installation
• Hydraulic Line and Hose Replacement
• Front Brake Line Removal
• Front Brake Line Installation
• Front Brake Hose Assembly Removal
• Front Brake Hose Assembly Installation
• Rear Brake Line Removal
• Rear Brake Line Installation
• Rear Brake Hose Removal
• Rear Brake Hose Installation
• Master Cylinder And Bell Crank Replacement
• Bell Crank Removal
• Bell Crank Installation
• Master Cylinder Removal
• Master Cylinder Installation
• Bleeding the Hydraulic Brake System
• Purging the Hydraulic System
• Filling the Hydraulic System
• Park Brake System
• Park Brake Cable Removal
• Park Brake Cable Installation
• Park Brake Handle Removal
• Park Brake Handle Installation
• Park Brake Adjustment
• Section7– Steering and Front Suspension
• Steering Wheel
• Steering Wheel Removal
• Steering Wheel Installation
• Steering Column
• Steering Column Removal
• Steering Column Disassembly
• Steering Column Assembly
• Steering Column Installation
• Rack and Pinion
• Rack and Pinion Removal
• Rack and Pinion Disassembly
• Rack and Pinion Assembly
• Rack and Pinion Installation
• Front Suspension
• Lubrication
• Wheel Alignment
• Front Suspension Components
• Kingpin and Steering Spindle Removal
• Kingpin and Steering Spindle Installation
• A-Arm Removal
• A-Arm Installation
• Shock Absorber Removal
• Shock Absorber Installation
• Front Wheel Bearings and Hubs
• Front Wheel Free Play Inspection
• Front Wheel Bearings and Hub Removal
• Front Wheel Bearings and Hub Installation
• Section8– Wheels and Tires
• General Information
• Section9– Rear Suspension
• Shock Absorbers
• Shock Absorber Removal and Inspection
• Shock Absorber Installation
• Multi-Leaf Springs
• Multi-Leaf Spring Removal
• Multi-Leaf Spring Installation
• Snubber
• Snubber Removal
• Snubber Installation
• Section10– Periodic Maintenance
• Periodic Service Schedule
• Periodic Lubrication Schedule
• Master Cylinder
• Brake Fluid
• Engine Oil
• Engine Oil Level Check
• Engine Oil and Filter Change
• Oil Viscosity
• Fueling Instructions
• Battery
• Section11– Troubleshooting and Electrical System: FE400 Engine
• Troubleshooting Guide
• Electrical System
• Wiring Diagram
• Electrical Circuits
• Starter Circuit
• Generator Circuit
• Engine Ignition Circuit
• Engine Kill Circuit
• Reverse Buzzer Circuit
• Low Oil Warning Circuit
• Lockout Cam Circuit
• Fuel Gauge and Sending Unit Circuit
• Hour Meter Circuit
• Lighting Circuit
• Circuit Testing
• Testing the Starter Circuit and Generator Circuit
• Testing the Engine Ignition Circuit
• Testing the Engine Kill Circuit
• Testing the Reverse Buzzer Circuit
• Testing the Low Oil Warning Circuit
• Testing the Lockout Cam Circuit
• Testing the Fuel Gauge and Sending Unit Circuit
• Testing the Lighting Circuit
• Test Procedures
• Index of Test Procedures
• Section12– Electrical Components: FE400 Engine
• Starter/Generator
• Voltage Regulator
• Diode
• Key Switch
• Solenoid
• Fuse
• Lockout Cam Limit Switch
• Lockout Cam
• Reverse Warning Buzzer
• Reverse Buzzer Limit Switch
• Low Oil Warning Light
• Fuel Gauge/Hour Meter
• Fuel Level Sending Unit
• RPM Limiter
• Ignition Coil
• Oil Level Sensor
• Headlights
• Headlight Diode
• Light Switch
• Testing the Light Switch
• Battery
• General Information
• Ground Straps
• Section13– FE400 Engine
• General Information
• Before Servicing
• Lubrication System
• Spark Plug
• Cylinder
• Breather Valve (Reed Valve)
• Valve Clearance Check and Adjustment
• Crankcase
• Engine Removal
• Crankcase Cover Removal
• Oil Level Sensor
• Ignition Coil and Flywheel
• Crankcase Cover Installation
• Flywheel Installation
• Engine Installation
• Torque Specifications
• Adjustment and Settings
• Section14– Fuel System
• General Information
• Carburetor
• Main Jet Elevation/Size Chart
• Changing the Main Jet
• Engine Control Linkage
• General Information
• Accelerator Rod
• Governor Cable
• Accelerator Cable
• Closed Throttle or Idle Adjustment
• Engine RPM Adjustment
• Choke and Air Intake System
• Choke Cable Removal
• Choke Cable Installation
• Air Box Removal
• Air Box Installation
• Intake Duct Repair
• Intake Duct Removal
• Intake Duct Installation
• Air Filter
• Fuel Filters
• Fuel Filter Removal
• Fuel Filter Installation
• Fuel Pump
• General Information
• Fuel Pump Removal
• Fuel Pump Disassembly
• Fuel Pump Cleaning and Inspection
• Fuel Pump Assembly
• Fuel Pump Installation
• Fuel Tank
• Fuel Tank Removal
• Fuel Tank Storage or Disposal
• Fuel Tank Installation
• Fuel Lines
• Fuel Shut-Off Valve
• Section15– Exhaust System
• Muffler
• Muffler Removal
• Muffler Installation
• Section16– MC012C-AS00 Unitized Transaxle with Differential Lock
• General Information
• Lubrication
• Axle Shaft
• Axle Shaft, Bearing, and Oil Seal Removal
• Axle Bearing Removal
• Axle Shaft, Bearing, and Oil Seal Installation
• Unitized Transaxle Removal
• Unitized Transaxle Installation
• Forward/Reverse Shifter Cable
• Forward/Reverse Shifter Cable Removal
• Forward/Reverse Shifter Cable Installation
• Forward/Reverse Shifter Cable Adjustment
• Differential Lock System
• Differential Lock System Inspection
• Differential Lock Cable Removal
• Differential Lock Cable Installation
• Section17– Torque Converter
• General Information
• Troubleshooting
• Drive Belt
• Drive Belt Removal
• Drive Belt Installation
• Drive Clutch
• Drive Clutch Removal
• Drive Clutch Cleaning and Inspection
• Drive Clutch Disassembly
• Inspection of Drive Clutch Parts
• Drive Clutch Assembly
• Drive Clutch Installation
• Driven Clutch
• Driven Clutch Removal
• Driven Clutch Disassembly
• Driven Clutch Inspection
• Driven Clutch Assembly
• Driven Clutch Installation
• Section18– Reconditioning the FE400 Engine
• General Information
• Special Engine Service Tools Available
• Recommended Replacement Parts For Engine Teardown
• Before Servicing
• Mechanical Systems
• Cylinder Components
• Cylinder Head
• General Information
• Cylinder Shroud Removal
• Rocker Arm and Push Rod Removal
• Cylinder Head Removal
• Valve Removal
• Breather Valve (Reed Valve)
• Cylinder Head Cleaning and Inspection
• Valve Guides
• Valve Seats
• Valves
• Rocker Arm and Rocker Shaft inspection
• Push Rod Inspection
• Cylinder Head Installation
• Valve Clearance Check and Adjustment
• Breather Valve (Reed Valve)
• Installation of Remaining Engine Components
• Crankcase Components
• Crankcase Cover Removal
• Camshaft and Hydraulic Lifters
• Piston and Connecting Rod
• Cylinder Block
• Ignition Coil and Flywheel
• Oil Pump
• Oil Pressure Relief Valve
• Crankshaft and Counterbalance
• Counterbalance Weight
• Oil Screen
• Ball Bearing
• Oil Seals
• Crankshaft Axial Play Adjustment
• Crankcase Cover Installation
• Engine Assembly
• Engine Installation
• Service Specifications
• Specifications for Resizing Cylinder Bore
• Torque Specifications
• Adjustment and Settings
• Section19– Reconditioning the MC012C- AS00 Unitized Transaxle with Differential Lock
• General Information
• Transaxle Model and Identification
• Lubrication
• Axle Shaft
• Unitized Transaxle Removal
• Unitized Transaxle Disassembly
• Component Disassembly
• Differential Gear Lock Housing Disassembly
• Governor Gear Disassembly
• Differential Gear Case Disassembly
• Shifter Fork Disassembly
• Synchronizer Gear Disassembly
• Intermediate Gear Disassembly
• Idler Shaft Disassembly
• Unitized Transaxle Component Inspection
• Component Assembly
• Idler Shaft Assembly
• Intermediate Gear Assembly
• Synchronizer Gear Assembly
• Shifter Fork Assembly
• Differential Gear Case Assembly
• Governor Gear Assembly
• Differential Gear Lock Housing Assembly
• Unitized Transaxle Assembly
• Unitized Transaxle Installation
• A
• accelerator
• air box
• air filter 141
• armature
• axle
• B
• ball bearing
• battery 1228
• bed, cargo
• belt, drive
• body, front
• brakes
• breather valve (reed valve) 189
• C
• camshaft
• camshaft and hydraulic lifter
• carburetor
• cargo bed
• CAUTION
• choke 141
• cleaning
• clutch (torque converter) troubleshooting 173
• clutch, drive
• clutch, driven
• column, steering
• commutator
• connecting rod
• counterbalance
• counterbalance guide shaft
• counterbalance weight
• crankcase 1820
• crankshaft
• cylinder block 1826
• cylinder head 184
• cylinder shroud
• D
• DANGER
• dashboard
• differential gear case
• differential lock
• differential lock housing
• diode
• diode, headlight
• drive belt
• drive clutch
• driven clutch
• E
• electrical system
• engine
• engine oil 104
• exhaust system 141
• F
• fender, front
• fender, rear
• field coil
• fluid, brake 104
• flywheel
• forward/reverse
• front body
• fuel filter 141
• fuel gauge
• fuel gauge sending unit circuit
• fuel gauge/hour meter
• fuel level sending unit 1222
• fuel lines 141
• fuel pump 141, 1417
• fuel shut-off valve 1428
• fuel tank
• fueling instructions 107
• fuse
• G
• generator circuit
• governor cable
• governor gear
• governor system 163, 193
• ground straps
• H
• headlight bulb
• headlight diode
• headlight switch
• headlights
• hour meter
• hydraulic lifter
• hydrometer test 1121
• I
• idler shaft
• ignition
• ignition coil
• inspection
• intake duct
• intermediate gear
• K
• key switch
• kill circuit, engine
• kill wire, engine
• L
• leaf springs, multi 91
• lighting circuit
• link rod
• lockout cam
• lockout cam circuit
• low oil warning circuit
• low oil warning light
• lubrication
• M
• maintenance
• master cylinder
• muffler
• N
• neutral lockout 163
• O
• oil level sensor
• oil light
• oil pressure relief valve
• oil pump
• oil screen
• oil seal
• oil viscosity 107
• oil, engine 104
• P
• park brake
• pedal, accelerator
• pedal, brake
• periodic lubrication schedule 102
• periodic service schedule 101
• piston
• piston and connecting rod
• piston pin
• piston ring
• push rod
• R
• rack and pinion
• receiver hitch
• reed valve
• reverse buzzer
• reverse buzzer circuit
• rocker arm
• rocker arm and push rod
• rocker shaft
• RPM adjustment 1410
• RPM limiter
• S
• safety
• seat
• serial number, vehicle 31
• service schedule
• shifter fork
• shock absorber
• snubber
• solenoid
• spark plug 131, 141
• specifications
• starter/generator
• starter/generator circuit
• steering
• steering column
• steering wheel
• storage
• suspension, front
• suspension, rear
• synchronizer gear
• T
• test procedure
• test procedures, index of 1119
• testing
• tire
• torque converter
• torque specifications 1848
• trailer hitch
• transaxle
• troubleshooting
• U
• unitized transaxle 191
• V
• valve (cylinder)
• valve guide
• valve seat
• valves (engine)
• voltage limiter
• voltage regulator
• W
• WARNING
• wheel
• wheel cylinder
• wire continuity testing 1129
• wiring diagram 115