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.

• MAINTENANCE SAFETY
• CONTENTS
• FOREWORD
• FOREWORD
• SAFETY INSTRUCTIONS
• FIRE PREVENTION
• Maintenance
• Operation
• Electrical
• Fueling
• Starting
• Spark Arrestor Exhaust System
• Welding And Grinding
• Fire Extinguishers
• SERIAL NUMBER LOCATIONS
• Utility Vehicle Serial Number
• Engine Serial Number
• DELIVERY REPORT
• UTILITY VEHICLE IDENTIFICATION (3200)
• SAFETY & MAINTENANCE
• LIFTING AND BLOCKING THE UTILITY VEHICLE
• Procedure
• ROLLOVER PROTECTIVE STRUCTURE (ROPS)
• Description
• TRANSPORTING THE UTILITY VEHICLE ON A TRAILER
• Loading And Unloading
• Fastening
• TOWING THE UTILITY VEHICLE
• Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Pre-Filter Element
• Replacing Filter Element
• Engine Breather Filter
• ENGINE COOLING SYSTEM
• Checking Level
• Cleaning
• Removing And Replacing Coolant
• FUEL SYSTEM
• Fuel Specifications
• Replacing The Fuel Filter
• Filling The Fuel Tank
• Filling A Portable Fuel Container
• ENGINE LUBRICATION SYSTEM
• Checking And Adding Engine Oil
• Engine Oil
• Removing And Replacing Oil And Filter
• Oil Pump Priming Procedure
• CONTINUOUS VARIABLE TRANSMISSION (CVT)
• CVT Drying
• CVT Filter
• GEARCASE
• Checking Transmission Fluid
• Transmission Fluid
• Adding Transmission Fluid
• Removing And Replacing Transmission Fluid
• TIRE MAINTENANCE
• Tires
• Tire Tread Depth
• Axle And Wheel Nut Torque
• Wheel Removal And Installation
• Mounting
• Tire Pressure
• SPARK ARRESTOR MUFFLER
• Cleaning Procedure
• UTILITY VEHICLE STORAGE AND RETURN TO SERVICE
• Storage
• Return To Service
• STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE
• Procedure
• DRIVE SYSTEM
• BRAKE
• General Specifications
• Torque Specifications
• System Service Notes
• Noise Troubleshooting
• System Troubleshooting
• Hydraulic Brake System Operation
• System Parts Identification
• Master Cylinder Removal And Installation
• Foot Brake Pedal Removal And Installation
• Bleeding / Fluid Removal And Installation
• Brake Inspection
• Brake Pad Inspection
• Burnishing
• BRAKE (FRONT)
• Pad Removal
• Pad Installation
• Caliper Removal
• Caliper Parts Identification
• Caliper Disassembly
• Caliper Inspection
• Caliper Assembly
• Caliper Installation
• Disc Inspection
• Disc Removal And Installation
• BRAKE (REAR)
• Pad Removal
• Pad Installation
• Caliper Removal
• Caliper Parts Identification
• Caliper Disassembly
• Caliper Inspection
• Caliper Assembly
• Caliper Installation
• Disc Inspection
• Disc Removal And Installation
• BRAKE (PARK)
• Inspection And Maintenance
• Parts Identification
• Lever Removal And Installation
• Cable Tension Inspection
• Cable Adjustment
• Caliper Removal
• Caliper Parts Identification
• Caliper Disassembly
• Caliper Inspection
• Pad Installation
• Caliper Assembly
• Disc Inspection
• Disc Removal And Installation
• Caliper Installation
• GEARCASE (TRANSMISSION)
• General Operation
• System Troubleshooting
• Shift Lever Removal And Installation
• Shift Cable Inspecting
• Shift Cable Adjustment
• Removal And Installation
• Parts Identification
• Disassembly
• Gear Cluster Disassembly
• Assembly
• DRIVE BELT
• Removal
• Installation
• Belt Inspection
• CONTINUOUS VARIABLE TRANSMISSION (CVT)
• CVT System Overview
• Drive Clutch Operation
• Driven Clutch Operation
• CVT Break-In (Drive Belt / Clutches)
• Maintenance And Inspection
• Overheating Troubleshooting
• System Troubleshooting
• CVT Sealing, Guard And Ducting Components Parts Identification
• CVT (Outer) Cover Removal And Installation
• CVT (Inner) Cover Removal And Installation
• Clutch Alignment
• Clutch Offset
• Clutch Center Distance
• CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH)
• Removal And Installation
• Spring Specifications
• Shift Weights
• Parts Identification
• Inspection
• Button To Tower Clearance Inspection
• Disassembly
• Moveable Sheave Bushing Removal And Installation
• Clutch Cover Bushing Removal And Installation
• Assembly
• CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH)
• Removal And Installation
• Parts Identification
• Disassembly
• Bushing Removal
• Bushing Installation
• Assembly
• FINAL DRIVE
• Description
• Front Hub And Spindle Removal
• Front Hub And Spindle Installation
• Rear Bearing Carrier Inspection
• Rear Bearing Carrier Removal
• Rear Bearing Carrier Disassembly And Assembly
• Rear Bearing Carrier Installation
• Rear Drive Shaft Removal And Installation
• Outer CV Joint And Boot Removal And Installation
• Inner Plunging Joint And Boot Removal And Installation
• MAINFRAME
• ROLL OVER PROTECTIVE STRUCTURE (ROPS)
• Removal And Installation
• OPERATOR SEAT
• Seat Back Removal And Installation
• Seat Base Removal And Installation
• Seat Belt Removal And Installation
• DASH
• Front Access Cover Removal And Installation
• Left Dash Removal And Installation
• Right Dash Removal And Installation
• Center Dash Removal And Installation
• BUMPER COVER
• Removal And Installation
• STRUT
• Strut Cartridge Removal And Installation
• STEERING COLUMN
• Removal And Installation
• STEERING BOX
• Removal And Installation
• FUEL TANK
• Removal And Installation
• SHOCKS
• Removal And Installation
• Shock Spring Removal And Installation
• CONTROL ARMS
• Removal And Installation (Rear Lower Arm)
• Removal And Installation (Upper Arm)
• Removal And Installation (Front Arm)
• Inspection
• Ball Joint Removal And Installation
• TIE ROD
• Description
• Removal And Installation
• Toe Adjustment Procedure
• TAILGATE
• Removal And Installation
• Latch Removal And Installation
• CARGO BOX
• Removal And Installation
• FENDER
• Removal And Installation (Front)
• Removal And Installation (Rear)
• Flare Removal And Installation
• REAR STABILIZER BAR / LINKAGE
• Removal And Installation
• Inspection
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATIC
• ELECTRICAL SYSTEM INFORMATION
• Glossary Of Electrical Symbols
• Description
• Troubleshooting
• Fuse And Relay Location – Cab Panel
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• CHARGING SYSTEM
• Current Draw – Key OFF
• Break Even Test
• Stator Testing
• Stator Plate Assembly Removal
• Stator Plate Assembly Installation
• Testing Flow Chart
• STARTER SYSTEM
• Testing
• Removal And Installation
• Parts Identification
• Starting Testing Flow Chart
• REGULATOR / RECTIFIER
• Location
• Removal And Installation
• Testing
• LIGHTS
• Headlight Removal And Installation
• Headlight Adjustment
• Tail Light / Brake Light Removal And Installation
• Indicator Lamp Removal And Installation
• VEHICLE CONTROL MODULE
• Description
• Removal And Installation
• DC / CDI IGNITION SYSTEM
• Description
• CDI Module Removal And Installation
• Testing
• Ignition System Troubleshooting
• Ignition System Testing Flow Chart
• HEADLIGHT SWITCH
• Removal And Installation
• Testing
• BRAKE LIGHT SWITCH
• Removal And Installation
• Testing
• PARKING BRAKE SWITCH
• Description
• Removal And Installation
• Testing
• SWITCH (2WD / TURF)
• Removal And Installation
• Testing
• IGNITION SWITCH
• Removal And Installation
• GEAR SELECTOR SWITCH
• Removal And Installation
• TEMPERATURE SENSOR
• Removal And Installation
• Testing
• DIFFERENTIAL SOLENOID
• Description
• Removal And Installation
• DIFFERENTIAL SOLENOID (REAR RELAY)
• Description
• Removal And Installation
• AIR SOLENOID
• Description
• Removal And Installation
• HOURMETER
• Removal And Installation
• BACK-UP ALARM SYSTEM (IF EQUIPPED)
• Description
• Inspecting
• Removal And Installation
• ENGINE SERVICE
• ENGINE INFORMATION
• Description
• Specifications (Engine Model EH460PLE040)
• Torque Values
• Troubleshooting
• Accessible Engine Components
• Engine Removal And Installation
• Engine Installation Notes
• Engine Mount Replacement
• Compression – Checking
• THROTTLE SYSTEM
• Throttle Pedal Removal And Installation
• Throttle Cable Removal And Installation
• Throttle Freeplay
• Inspection And Maintenance
• Throttle Freeplay Adjustment
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Housing Removal And Installation
• ENGINE COOLING SYSTEM
• Cooling System Pressure Test
• Radiator Cap Pressure Test
• Radiator Removal And Installation
• Cooling Fan Removal And Installation
• Shroud Removal And Installation
• Water Pump Housing Cover Removal And Installation
• Water Pump Disassembly And Assembly
• Water Pump Mechanical Seal Removal (Engine Installed)
• Thermostat Housing Removal And Installation
• Thermostat Removal And Installation
• LUBRICATION SYSTEM
• Oil Tank Removal And Installation
• Engine Oil Pressure – Testing
• Oil Flow Diagram
• Oil Flow Chart
• FUEL SYSTEM (CARBURETOR)
• Fuel Pump Removal And Installation
• Carburetor Jetting
• Jetting Guidelines
• Carburetor Parts Identification
• System Function – Mikuni CV Carb
• Vent Systems – Mikuni CV Carb
• Operation – Mikuni CV Carb
• Pilot System (Idle And Slow Speed)
• Starter System (Choke Or Enrichment)
• Float System
• Main System
• Pilot Screw
• Pilot Screw Adjustment
• Idle Speed Adjustment
• Choke Cable Adjustment
• Choke Cable Removal And Installation
• Removal And Installation
• Disassembly
• Cleaning
• Inspection
• Float Height Adjustment
• Fuel Level
• Assembly
• ENGINE DISASSEMBLY AND ASSEMBLY
• Cam Chain Tensioner / Rocker Arm / Camshaft Removal
• Cam Chain Tensioner Inspection
• Rocker Shaft / Rocker Arm Assembly Removal
• Rocker Arm / Shaft Inspection
• Rocker Shaft / Rocker Arm Assembly Installation
• Valve Clearance Adjustment (Intake And Exhaust)
• Camshaft Removal
• Automatic Compression Release Removal / Inspection
• Automatic Compression Release Installation
• Camshaft Inspection
• Cam Chain / Camshaft Installation
• Camshaft Timing
• Engine Parts Illustration
• Cylinder Head Removal
• Cylinder Head Warpage
• Cylinder Head Disassembly
• Valve Inspection
• Combustion Chamber
• Valve Seat Reconditioning
• Cylinder Head Assembly
• Valve Sealing Test
• Cylinder Head Installation
• Cylinder Removal
• Cylinder Inspection
• Cylinder Hone Selection / Honing Procedure
• Cleaning The Cylinder After Honing
• Cylinder Installation
• Piston Removal
• Piston – To – Cylinder Clearance
• Piston / Rod Inspection
• Piston Ring Installed Gap
• Piston Ring Installation
• Piston Installation
• Crankcase Disassembly
• Starter Drive Removal And Installation
• Flywheel Removal And Installation
• Stator Removal / Inspection
• Stator Installation
• Cam Chain / Tensioner Blade
• Cam Chain Drive Sprocket Removal And Installation
• One Way Valve Removal And Installation
• Crankcase Separation
• Crankcase Inspection
• Crankcase Assembly
• Oil Pump Removal / Inspection
• Oil Pump Assembly
• Counter Balancer Shaft Removal / Inspection
• Crankshaft Removal / Inspection
• Crankshaft Straightening
• Crankcase Bearing Inspection
• Oil Seal / Mechanical Seal Removal (Engine Disassembled)
• Pump Shaft Oil Seal Installation
• Water Pump Mechanical Seal Installation
• Bearing Installation
• End Play Inspection / Adjustment
• Crankshaft End Play Adjustment
• Counter Balancer Shaft End Play Adjustment
• Oil Pump Shaft End Play Adjustment
• Crankshaft / Counter Balance / Oil Pump Installation
• Oil Pump Priming Procedure
• SPECIFICATIONS
• (3200) UTILITY VEHICLE SPECIFICATIONS
• Utility Vehicle Dimensions
• Performance
• Controls
• Engine
• Electrical
• Drive System
• Fluid And Capacities
• Tires
• TORQUE SPECIFICATIONS FOR BOLTS
• Torque For General SAE Bolts
• Torque For General Metric Bolts
• CONVERSIONS
• Decimal And Millimeter Equivalent Chart
• U.S. To Metric Conversion Chart
• ALPHABETICAL INDEX
• SERVICE MANUAL REVISION
• Revision No: 3200 – 1