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.

• TOC
• Section 1 – Safety
• General Warning
• Section 2 – Vehicle Specifications
• Section 3 – General Information
• General Information
• Model Identification
• Storage
• Preparing the Vehicle for Extended Storage
• Returning the Stored Vehicle to Service
• Section 4 – Body and Trim
• Cleaning the Vehicle
• Seat Cleaning
• Front Body Repair
• Abrasions and Haze
• Light Scratches
• Large Scratches and Abrasions
• Front Body Components
• Instrument Panel Removal
• Instrument Panel Installation
• Dashboard Removal
• Dashboard Installation
• Front Body Removal
• Front Body Installation
• Front Fender Removal
• Front Fender Installation
• Roll-Over Protective Structure (ROPS)
• ROPS Removal
• ROPS Installation
• Seat
• Seat Removal
• Seat Adjustment
• Seat Installation
• Seat Frame Removal
• Seat Frame Installation
• Safety Belts
• Safety Belt Removal
• Safety Belt Installation
• Cargo Bed With Electric Lift
• Testing the Bed Lift Motor
• Bed Lift Motor Removal
• Bed Lift Motor Installation
• Cargo Bed Removal
• Cargo Bed Installation
• Rear Fender
• Rear Fender Removal
• Rear Fender Installation
• Floor Mat
• Floor Mat Removal
• Floor Mat Installation
• Section 5 – Accelerator and Brake Pedal Assemblies
• Accelerator Pedal
• Accelerator Pedal Removal
• Accelerator Pedal Installation
• Accelerator Pedal and RPM Adjustment
• Brake Pedal
• Brake Pedal Removal
• Brake Pedal Installation
• Brake Pedal Adjustment
• Park Brake Pedal
• Park Brake Pedal Removal
• Park Brake Pedal Installation
• Park Brake Cable Installation
• Park Brake Cable Adjustment
• Section 6 – Hydraulic and Park Brake Systems
• Brake System Inspection
• Brake System Troubleshooting
• Brake Pads and Caliper
• Front Brake Pad and Caliper Removal
• Front Brake Pad and Caliper Installation
• Rear Brake Pad and Caliper Removal
• Rear Brake Pad and Caliper Installation
• Brake Disc and Hub
• Front Wheel Disc and Hub Removal
• Front Wheel Disc and Hub Installation
• Rear Wheel Disc Removal
• Rear Wheel Disc Installation
• Hydraulic Line Replacement
• Front Brake Line Removal
• Front Brake Line Installation
• Rear Brake Line Removal
• Rear Brake Line Installation
• Master Cylinder and Reservoir
• Filling the Hydraulic System
• Reservoir Removal
• Reservoir Installation
• Master Cylinder Removal
• Master Cylinder Installation
• Bleeding the Hydraulic Brake System
• Purging the Hydraulic System
• Park Brake System
• Park Brake Adjustment
• Park Brake Cable Adjustment
• Park Brake Wheel Cables
• Front Park Brake Cable Removal
• Front Park Brake Cable Installation
• Section 7 – Steering and Front Suspension
• Steering Wheel
• Steering Wheel Removal
• Steering Wheel Installation
• Steering Column
• Steering Column Removal
• Steering Column Installation
• Rack and Pinion
• Rack and Pinion Removal
• Rack and Pinion Installation
• Rack and Pinion Disassembly
• Rack and Pinion Assembly
• Front Suspension
• Wheel Alignment
• Front Suspension Components
• Steering Upright Removal
• Upper A-Arm Removal
• Upper A-Arm Installation
• Lower A-Arm Removal
• Lower A-Arm Installation
• Front Coil-Over Shock Absorber Removal
• Front Coil-Over Shock Absorber Installation
• Steering Upright Installation
• Section 8 – Wheels and Tires
• General Information
• Wheels
• Wheel Removal
• Wheel Installation
• Tires
• Tire Removal
• Tire Installation
• Section 9 – Rear Suspension
• Rear Coil-Over Shock Absorber
• Swing Arms
• Swing Arm Removal
• Swing Arm Installation
• Section 10 – Periodic Maintenance
• Periodic Service Schedule
• Periodic Lubrication Schedule
• Brake Fluid Reservoir
• Brake Fluid
• Engine Oil
• Oil Pressure – Gasoline Engine
• Engine Oil Level Check
• Engine Oil and Filter Change
• Oil Viscosity
• Gearcase Lubrication
• Lubrication Level Check for Front Differential, Transmission, and Rear Differential
• Lubrication Change for Front Differential, Transmission, and Rear Differential
• Engine Coolant – Diesel Vehicles
• Engine Coolant Level Check
• Fueling Instructions
• Draining Water from Fuel Filter
• Battery
• Section 11a – Troubleshooting and Electrical System: Gasoline Vehicles
• Troubleshooting Guide
• Wiring Diagram
• Test Procedures
• Index of Test Procedures
• Section 11b – Troubleshooting and Electrical System: Diesel Vehicles
• Troubleshooting Guide
• Wiring Diagram
• Test Procedures
• Index of Test Procedures
• Section 12a – Electrical Components: Gasoline Vehicles
• Starter and Starter Solenoid
• Relays
• Neutral Switch
• Carburetor Solenoid
• Voltage Regulator
• Instrument Panel
• Key Switch
• Fuse
• Reverse Warning Buzzer
• Reverse Warning Buzzer Limit Switch
• Low Oil Warning Light
• Fuel Gauge/Hour Meter
• Fuel Level Sending Unit
• Ignition Coil and Charge Coil
• Charge Coil
• Oil Pressure Sensor
• Headlights
• Light Switch
• Wire Harness Diodes
• Bed Lift Switch
• Bed Lift Circuit Breaker
• Battery
• General Information
• Section 12b – Electrical Components: Diesel Vehicles
• Starter and Starter Solenoid
• Relays
• Neutral Switch
• Fuel Solenoid
• 50-Amp Circuit Breaker
• Instrument Panel
• Key Switch
• Fuse
• Reverse Warning Buzzer
• Reverse Warning Buzzer Limit Switch
• Low Oil Warning Light
• Fuel Gauge/Hour Meter
• Electric Fuel Pump
• Fuel Level Sending Unit
• Alternator
• Oil Pressure Sensor
• Headlights
• Light Switch
• Thermostat Switch
• Fan Motor
• Wire Harness Diodes
• Bed Lift Switch
• Bed Lift Circuit Breaker
• Battery
• General Information
• Section 13a – Gasoline Engine, Muffler, Fuel System, and Clutches
• Gasoline Engine
• Engine Removal
• Engine Installation
• Exhaust System
• Muffler Removal
• Intermediate Pipe Removal
• Intermediate Pipe Installation
• Muffler Installation
• Fuel System
• Carburetor
• Main Jet Elevation/Size Chart
• Fuel Filter
• Fuel Pump
• Fuel Level Sending Unit
• Fuel Tank
• Fuel Lines
• Fuel Shut-Off Valve
• Oil Filter Hoses
• Engine Control Linkages
• Accelerator Cable
• Governor Guard
• Governor Cable
• Accelerator Cable Retention Clip Adjustment
• Ground Speed (Transmission) Governor Arm Adjustment
• Engine Governor Arm
• Engine RPM Adjustment
• Choke and Air Intake System
• Air Filter Replacement
• Choke Cable Removal
• Choke Cable Installation
• Air Canister Removal
• Air Canister Installation
• Air Filter Intake Hose Removal
• Air Filter Intake Hose Installation
• Air Filter Outlet Hose Removal
• Air Filter Outlet Hose Installation
• Clutches
• Clutch Troubleshooting
• Drive Belt
• Drive Clutch
• Driven Clutch
• Clutch Cover
• Section 13b – Diesel Engine, Muffler, Fuel System, and Clutches
• Diesel Engine
• Engine Removal
• Engine Installation
• Exhaust System
• Muffler Removal
• Intermediate Pipe Removal
• Manifold Pipe Removal
• Manifold Pipe Installation
• Intermediate Pipe Installation
• Muffler Installation
• Fuel System
• Fuel Line Hose Replacement
• Fuel Filter Replacement
• Draining Water from the Secondary Fuel Filter
• Electric Fuel Pump
• Fuel Level Sending Unit
• Fuel Tank
• Fuel Lines
• Engine Control Linkages
• Accelerator Cable
• Engine RPM Adjustment
• Air Intake System
• Air Filter Replacement
• Air Canister Removal
• Air Canister Installation
• Air Filter Intake Hose Removal
• Air Filter Intake Hose Installation
• Air Filter Outlet Hose Removal
• Air Filter Outlet Hose Installation
• Clutches
• Clutch Troubleshooting
• Drive Belt
• Drive Clutch
• Driven Clutch
• Clutch Cover
• Section 14 – Drivetrain Components
• Half Shafts
• Half Shaft Removal
• Half Shaft Installation
• Front Differential
• Front Differential Removal
• Front Differential Installation
• Front Driveshaft
• Front Driveshaft Removal
• Front Driveshaft Installation
• Rear Receiver Hitch
• Rear Receiver Hitch Removal
• Rear Receiver Hitch Installation
• Rear Axle
• Rear Axle Removal
• Rear Axle Installation
• Rear Driveshaft
• Rear Driveshaft Removal
• Rear Driveshaft Installation
• Transmission
• Troubleshooting
• Transmission Removal
• Transmission Installation
• Forward/Reverse Shifter Cable
• Forward/Reverse Shifter Handle
• Rear Differential and Axles
• Rear Differential Removal
• Rear Axle Shafts and Wheel Bearings
• Rear Differential Installation
• Section 15 – Radiator and Coolant System (Diesel)
• General Information
• Engine Coolant Check
• Engine Coolant Change
• Coolant Reservoir
• Coolant Reservoir Removal
• Coolant Reservoir Installation
• Radiator
• Radiator Removal
• Radiator Installation
• Coolant Pipe Weldment (Steel)
• Coolant Pipe Weldment Removal
• Coolant Pipe Weldment Installation
• Section 16 – Transmission Models 420317 and 420682
• General Information
• Model Identification
• Service Fixture
• Transmission Removal
• Transmission Disassembly
• Input Shaft Disassembly
• Input Shaft Assembly
• Intermediate Shaft Disassembly
• Output Shaft Disassembly
• Shifter Shaft Removal
• Shifter Shaft Installation
• Case Inspection
• Shaft Seal Removal
• Shaft Seal Installation
• Output Shaft Assembly
• Intermediate Shaft Assembly
• Intermediate and Output Shaft Assembly
• Transmission Assembly
• Transmission Installation
• Section 17 – Front Differential Models 6203-01-139-S and 6203-01-189-S
• General Information
• Axle Half Shaft Removal
• Front Differential Removal
• Tools Required For This Section
• Front Differential Coil And Output Cover
• Coil and Output Cover Removal
• Coil and Output Cover Installation
• Front Differential
• Front Differential Disassembly
• Front Differential Assembly
• Front Differential Installation
• Axle Half Shaft Installation
• Section 18 – Rear Differential Models 420366 and 420851
• General Information
• Axle Shafts and Differential Removal
• Rear Differential Disassembly
• Pinion Gear Removal
• Ring Gear Removal
• Clutch Carrier Assembly
• Ring Gear Installation
• Pinion Gear Installation
• Rear Differential Assembly
• Axle Shafts and Differential Installation
• Section 19 – Kubota D722 Diesel Engine Manual
• Section 20 – Honda GX 620 Gasoline Engine Manual
• GX620K1_(GCAD-2000001-FORWARD).pdf
• NAVIGATION QUICKTIPS
• SPECIFICATIONS
• SPECIFICATIONS
• DIMENSIONS AND WEIGHTS
• PERFORMANCE CURVES
• DIMENSIONAL DRAWINGS
• SNORKEL AIR CLEANER EQUIPPED TYPE
• P.T.O. DIMENSIONAL DRAWINGS
• WIRING DIAGRAMS
• SERVICE INFORMATION
• GENERAL SAFETY
• SERIAL NUMBER LOCATION
• SERVICE RULES
• MAINTENANCE STANDARDS
• ENGINE/CARBURETOR
• ELECTRICAL
• VALVES
• CONNECTING ROD/CRANKSHAFT
• CYLINDER/PISTON
• TORQUE VALUES
• SPECIAL TOOLS
• TROUBLESHOOTING
• GENERAL SYMPTOMS AND POSSIBLE CAUSES
• HARD STARTING
• OIL ALERT SYSTEM
• IGNITION SYSTEM
• STARTER MOTOR
• HARNESS ROUTING
• MAINTENANCE
• MAINTENANCE SCHEDULE
• ENGINE OIL
• OIL FILTER
• AIR CLEANER
• SNORKEL TYPE
• VALVE CLEARANCE
• SPARK PLUG
• CARBURETOR
• GOVERNOR
• FUEL FILTER/FUEL LINE
• SPARK ARRESTER
• DISASSEMBLY/REASSEMBLY
• AIR CLEANER
• RECOIL STARTER
• REMOVAL/INSTALLATION
• RECOIL STARTER ASSEMBLY
• FAN COVER
• REMOVAL/INSTALLATION
• INSTALLATION
• CONTROL BOX
• DISASSEMBLY/REASSEMBLY
• INSPECTION
• GOVERNOR ARM/CONTROL ASSEMBLY
• DISASSEMBLY/REASSEMBLY
• INSTALLATION
• FUEL PUMP
• CARBURETOR
• REMOVAL/INSTALLATION
• DISASSEMBLY/REASSEMBLY
• INSPECTION
• ADJUSTMENT
• STARTER MOTOR
• REMOVAL/INSTALLATION
• DISASSEMBLY/REASSEMBLY
• INSPECTION
• INSTALLATION
• COOLING FAN/FLYWHEEL/IGNITION COILS
• DISASSEMBLY/REASSEMBLY
• INSPECTION
• ADJUSTMENT
• CYLINDER HEAD
• REMOVAL/INSTALLATION
• DISASSEMBLY/REASSEMBLY
• INSPECTION
• VALVE GUIDE REPLACEMENT
• VALVE SEAT RECONDITIONING
• INSTALLATION
• CRANKCASE COVER
• REMOVAL/INSTALLATION
• DISASSEMBLY/REASSEMBLY
• INSPECTION
• CRANKSHAFT/CYLINDER BLOCK
• DISASSEMBLY/REASSEMBLY
• INSPECTION
• PISTON
• DISASSEMBLY/REASSEMBLY
• INSPECTION
• PISTON ASSEMBLY/CONNECTING ROD CAP
• VALVE LIFTER ASSEMBLY/CAMSHAFT
• DISASSEMBLY/REASSEMBLY
• INSPECTION
• INSTALLATION
• HIGH MOUNT MUFFLER A/B
• Index
• A
• a-arm, lower
• a-arm, upper
• accelerator
• air canister (diesel vehicles)
• air canister (gasoline vehicles)
• air filter (diesel vehicles)
• air filter (gasoline vehicles)
• alternator (diesel vehicles)
• antifreeze
• axle half shaft
• axle shaft and differential
• axle, rear
• B
• ball joint, lower
• ball joint, upper
• battery (diesel vehicles) 12b-20
• battery (gasoline vehicles) 12a-16
• bed lift circuit breaker (gasoline vehicles)
• bed lift motor
• bed lift motor (gasoline vehicles)
• bed lift switch (gasoline vehicles)
• bed, cargo
• belt, drive
• belt, seat
• body, front
• box bed
• brakes
• C
• cable, accelerator
• cable, forward/reverse
• cable, governor
• cable, park brake
• camber
• carburetor (diesel vehicles)
• carburetor (gasoline vehicles)
• carburetor solenoid (gasoline vehicles)
• cargo bed
• CAUTION
• charge coil (gasoline vehicles) 12a-11
• choke cable (gasoline vehicles)
• circuit breaker (diesel vehicles)
• circuit breaker, bed lift (gasoline vehicles)
• cleaning
• clutch and ring gear
• clutch carrier
• clutch inner cover (diesel vehicles)
• clutch inner cover (gasoline vehicles)
• clutch outer cover (diesel vehicles)
• clutch outer cover (gasoline vehicles)
• clutch, drive
• clutch, driven
• coil and output cover
• coil, charge (gasoline vehicles) 12a-11
• coil, ignition (gasoline vehicles) 12a-11
• column, steering
• coolant reservoir (diesel vehicles)
• coolant, engine (diesel vehicles)
• D
• DANGER
• dashboard
• differential relay (diesel vehicles)
• differential relay (gasoline vehicles)
• differential, front
• differential, rear
• diode, wire harness (diesel vehicles)
• diode, wire harness (gasoline vehicles)
• drive belt (diesel vehicles)
• drive belt (gasoline vehicles)
• drive clutch (diesel vehicles) 13b-28
• drive clutch (gasoline vehicles) 13a-31
• driven clutch (diesel vehicles) 13b-28
• driven clutch (gasoline vehicles) 13a-31
• driveshaft, front
• driveshaft, rear
• E
• engine (diesel vehicles)
• engine (gasoline vehicles)
• engine governor arm
• engine oil
• exhaust system (diesel vehicles)
• exhaust system (gasoline vehicles)
• F
• fan motor (diesel vehicles)
• fan relay (diesel vehicles)
• fender, front
• fender, rear
• floor mat
• fluid, brake 10-6
• forward/reverse cable
• forward/reverse shifter handle
• front body
• front differential
• front drive gearcase coil (diesel vehicles)
• front drive gearcase coil (gasoline vehicles)
• front driveshaft
• fuel filter (gasoline vehicles) 13a-8
• fuel filter, primary (diesel vehicles)
• fuel filter, secondary (diesel vehicles)
• fuel gauge/hour meter (diesel vehicles)
• fuel gauge/hour meter (gasoline vehicles)
• fuel level sending unit (diesel vehicles)
• fuel level sending unit (gasoline vehicles)
• fuel pump (diesel vehicles)
• fuel pump (gasoline vehicles) 13a-8
• fuel shut-off valve (gasoline vehicles) 13a-16
• fuel solenoid (diesel vehicles)
• fuel system (diesel vehicles) 13b-9
• fuel system (gasoline vehicles) 13a-7
• fuel tank (diesel vehicles)
• fuel tank (gasoline vehicles)
• fueling instructions 10-13
• fuse (diesel vehicles)
• fuse (gasoline vehicles)
• G
• gearcase
• gearcase coil
• glow plug circuit (diesel vehicles)
• governor arm, engine (gasoline vehicles)
• governor arm, transmission (gasoline vehicles)
• governor cable (gasoline vehicles)
• governor guard (gasoline vehicles)
• ground cables (diesel vehicles)
• ground cables (gasoline vehicles)
• H
• half shaft
• handle, forward/reverse shifter
• headlight (diesel vehicles)
• headlight (gasoline vehicles)
• high-temperature light circuit (diesel vehicles)
• hitch, receiver
• hydrometer test (diesel vehicles) 11b-9
• hydrometer test (gasoline vehicles) 11a-9
• I
• ignition (gasoline vehicles)
• ignition coil (gasoline vehicles) 12a-11
• input shaft
• input shaft seal
• inspection
• instrument panel (diesel vehicles)
• instrument panel (gasoline vehicles)
• intake hose, air (diesel vehicles)
• intake hose, air (gasoline vehicles)
• intermediate and output shaft
• intermediate shaft
• J
• jetting, carburetor (gasoline vehicles) 13a-7
• K
• key switch (diesel vehicles)
• key switch (gasoline vehicles)
• kill circuit, engine (gasoline vehicles)
• kill wire, engine (gasoline vehicles)
• L
• low oil warning light
• lubrication
• M
• maintenance
• manifold (diesel vehicles)
• muffler
• muffler (diesel vehicles)
• muffler (gasoline vehicles)
• N
• neutral switch (diesel vehicles)
• neutral switch (gasoline vehicles)
• O
• oil filter
• oil warning light, low (diesel vehicles)
• oil warning light, low (gasoline vehicles)
• oil, engine 10-6
• outlet hose, air (diesel vehicles)
• outlet hose, air (gasoline vehicles)
• output shaft
• P
• panel, instrument
• park brake
• pedal, accelerator
• pedal, brake
• periodic lubrication schedule 10-4
• periodic service schedule 10-1
• pinion gear
• pump, fuel (diesel vehicles)
• pump, fuel (gasoline vehicles) 13a-8
• R
• rack and pinion
• radiator (diesel vehicles)
• rear axle
• rear differential
• rear driveshaft
• rear wheel bearing
• receiver hitch
• relay, accessory (diesel vehicles)
• relay, accessory (gasoline vehicles)
• relay, differential (diesel vehicles)
• relay, differential (gasoline vehicles)
• relay, start (diesel vehicles)
• relay, start (gasoline vehicles)
• reservoir, coolant
• reverse buzzer (diesel vehicles)
• reverse buzzer (gasoline vehicles)
• ring gear
• ROPS (roll-over protective structure)
• RPM adjustment (diesel vehicles)
• RPM adjustment (gasoline vehicles)
• S
• safety
• safety belt
• seat
• seat belt
• seat frame
• serial number, vehicle 3-1
• service schedule
• service tools
• shaft seal
• shifter shaft
• shock absorber
• solenoid, fuel (diesel vehicles)
• spark plug (gasoline vehicles)
• specifications
• start relay (diesel vehicles)
• start relay (gasoline vehicles)
• starter control circuit (diesel vehicles)
• starter control circuit (gasoline vehicles)
• steering
• steering column
• steering upright
• steering wheel
• storage
• suspension, front
• suspension, rear
• switch, bed lift (gasoline vehicles)
• switch, neutral (diesel vehicles)
• switch, neutral (gasoline vehicles)
• T
• 12-volt power point (diesel vehicles)
• 12-volt power point (gasoline vehicles)
• test procedures (diesel vehicles)
• test procedures (gasoline vehicles)
• test procedures, index of (diesel vehicles) 11b-8
• test procedures, index of (gasoline vehicles) 11a-8
• thermostat switch (diesel vehicles)
• throttle
• tire
• tools
• torque converter (diesel vehicles) 13b-28
• torque converter (gasoline vehicles) 13a-31
• transmission
• transmission governor arm
• troubleshooting
• V
• v-belt (diesel vehicles)
• voltage regulator (gasoline vehicles)
• W
• WARNING
• wheel
• wheel bearing
• wheel, steering
• wire continuity (diesel vehicles)
• wire continuity (gasoline vehicles)
• wire harness diode (diesel vehicles)
• wire harness diode (gasoline vehicles)
• wiring diagram (diesel vehicles) 11b-6
• wiring diagram (gasoline vehicles) 11a-6