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
• 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 COOLING SYSTEM
• Checking Level
• Cleaning
• Removing And Replacing Coolant
• FUEL SYSTEM
• Biodiesel Blend Fuel
• Filling The Fuel Tank
• Fuel Filter
• Removing Air From The Fuel System
• Filling A Portable Fuel Container
• ENGINE LUBRICATION SYSTEM
• Checking And Adding Engine Oil
• Engine Oil Chart
• Removing And Replacing Oil And Filter
• CONTINUOUS VARIABLE TRANSMISSION (CVT)
• CVT Drying
• CVT Filter
• GEARCASE
• Checking Transmission Fluid
• Transmission Fluid
• Adding Transmission Fluid
• Removing And Replacing Transmission Fluid
• Checking Front Gearcase Fluid
• Front Gearcase Fluid
• Adding Front Gearcase Fluid
• Removing And Replacing Front Gearcase Fluid
• Checking Rear Gearcase Fluid
• Rear Gearcase Fluid
• Adding Rear Gearcase Fluid
• Removing And Replacing Rear Gearcase Fluid
• TIRE MAINTENANCE
• Tires
• Tire Tread Depth
• Axle And Wheel Nut Torque
• Wheel Removal And Installation
• Mounting
• Tire Pressure
• SPARK ARRESTER MUFFLER
• Cleaning Procedure
• UTILITY VEHICLE STORAGE AND RETURN TO SERVICE
• Storage
• Return To Service
• STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE
• Procedure
• RELIEVING HYDRAULIC PRESSURE
• Procedure
• HYDRAULIC SYSTEM
• Description
• Checking Fluid
• Hydraulic Fluid
• Removing And Replacing Hydraulic Fluid
• 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)
• 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 And Ducting Components Parts Identification
• CVT (Outer) Cover Removal And Installation
• CVT (Inner) Cover Removal And Installation
• Clutch Offset
• 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
• Assembly
• FINAL DRIVE
• Description
• Front Hub Removal
• Hubstrut Bearing Removal And Installation
• Front Hub Installation
• Front Drive Shaft Removal And Installation
• Outer CV Joint And Boot (Front Drive Shaft) Removal And Installation
• Propshaft Removal And Installation
• Propshaft U-Joint Disassembly
• Propshaft U-Joint Assembly
• Front Gearcase Operation
• Front Gearcase Removal And Installation
• Front Gearcase Parts Identification
• Front Gearcase Disassembly / Inspection
• Front Gearcase Assembly
• 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 (Rear Drive Shaft) Removal And Installation
• Inner Plunging Joint And Boot (Rear Drive Shaft) Removal And Installation
• Rear Propshaft Removal And Installation
• Rear Gearcase Operation
• Rear Gearcase Removal And Installation
• Rear Gearcase Parts Identification
• Rear Gearcase Disassembly
• Rear Gearcase Assembly
• 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
• ATTACHMENT ARM
• Removal And Installation
• FRONT MOUNT
• Removal And Installation
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• 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
• Alternator Voltage Test
• Low Voltage Test
• Removal And Installation
• Alternator Belt Adjustment
• Belt Replacement
• STARTER SYSTEM
• Testing
• Removal And Installation
• STOP SOLENOID
• Description
• LIGHTS
• Headlight Removal And Installation
• Headlight Adjustment
• Tail Light / Brake Light Removal And Installation
• Indicator Lamp Removal And Installation
• Glow Plug Light Removal And Installation
• Oil Pressure Light Removal And Installation
• VEHICLE CONTROL MODULE
• Description
• Removal And Installation
• SPEED SENSORS
• Engine Speed Sensor Removal And Installation
• Vehicle Speed Sensor Removal And Installation
• SWITCH (HEADLIGHT)
• Removal And Installation
• Testing
• SWITCH (BRAKE LIGHT)
• Removal And Installation
• Testing
• SWITCH (PARKING BRAKE)
• Description
• Removal And Installation
• Testing
• SWITCH (AWD / 2WD / TURF)
• Removal And Installation
• Testing
• SWITCH (KEY)
• Removal And Installation
• SWITCH (GEAR SELECTOR)
• Removal And Installation
• SWITCH (JOYSTICK)
• Testing
• Removal And Installation
• SWITCH (FLOAT)
• Testing
• Removal And Installation
• SWITCH (ATTACHMENT ARM LOCK)
• Testing
• Removal And Installation
• TEMPERATURE SENSOR
• Description
• Testing
• Removal And Installation
• DIFFERENTIAL SOLENOID
• Description
• Removal And Installation
• DIFFERENTIAL SOLENOID (REAR RELAY)
• Description
• Removal And Installation
• OIL PRESSURE SENSOR
• Location
• Removal And Installation
• HOURMETER
• Removal And Installation
• BACK-UP ALARM SYSTEM (IF EQUIPPED)
• Description
• Inspecting
• Removal And Installation
• JOYSTICK
• Removal And Installation
• SOLENOID (HYDRAULIC PUMP)
• Testing
• Removal And Installation
• ENGINE SERVICE
• ENGINE INFORMATION
• Description
• Specifications
• Torque Values
• Troubleshooting
• Engine Removal And Installation
• 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 Disassembly And Assembly
• Thermostat Housing Removal And Installation
• LUBRICATION SYSTEM
• Oil Pan Removal And Installation
• Oil Pump Disassembly And Assembly
• Oil Pump Inspection
• Engine Oil Pressure – Testing
• FUEL SYSTEM
• Stop Solenoid
• Removal And Installation
• High-Pressure Fuel Injection Lines Removal And Installation
• Fuel Return Line Removal And Installation
• Fuel Injection Pump Removal
• Fuel Injection Pump Installation
• Injection Pump – Timing
• Fuel Injector Removal And Installation
• Fuel Injector Disassembly
• Fuel Injector Assembly
• Fuel Injector Nozzle Pressure – Checking
• Nozzle Spraying Condition
• CYLINDER HEAD
• Intake And Exhaust Valves
• Valve Clearance Adjustment
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head – Servicing
• Valve Guide – Checking
• Reconditioning The Valve And Valve Seat
• Valve Spring
• Valve Tappets
• Rocker Arm And Shaft – Checking
• Push Rod Alignment – Checking
• CRANKSHAFT AND PISTONS
• Piston And Connecting Rod Removal And Installation
• Piston And Connecting Rod – Servicing
• Cylinder Bore – Checking
• Crankshaft And Bearings Removal
• Crankshaft And Bearings Installation
• Crankshaft And Bearings – Servicing
• Honing And Boring
• CAMSHAFT AND TIMING GEARS
• Timing Gearcase Cover Removal And Installation
• Timing Gears Backlash – Checking
• Timing Gears Removal
• Timing Gears Installation
• Idler Gear And Camshaft Removal And Installation
• Camshaft – Servicing
• Idler Gear And Shaft – Servicing
• HYDRAULIC SYSTEM
• CYLINDER (LIFT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (TILT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• HYDRAULIC POWER UNIT
• Main Relief Valve Testing
• Removal And Installation
• HYDRAULIC CONTROL VALVE
• Removal And Installation
• Disassembly And Assembly
• AUXILIARY CONTROL VALVE (IF EQUIPPED)
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC RESERVOIR
• Removal And Installation
• FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
• Removal And Installation
• SPECIFICATIONS
• (3450) 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: 3450 – 1
• Revision No: 3450 – 2
• Revision No: 3450 – 3