Textron Stampede 900 2017 Repair And Service Manual
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Textron Stampede 900 2017 Repair And Service Manual

4x4 all terrain vehicle
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2018
668061-B

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Galen Gunderson
January 24, 2025

In removing cowl it says to remove rivets. Is there a special tool or a picture on how to remove

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Summary of Contents for Textron Stampede 900 2017

  • Page 1 2018 668061-B...
  • Page 2 Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. The TEXTRON OFF ROAD vehicle has a spark arrester that was The STAMPEDE 900 is an off road vehicle. Familiarize yourself tested and qualified to be in compliance with the USFS standard with all laws and regulations concerning the operation of this vehi- 5100-1.
  • Page 3 Textron Specialized Vehicles, Inc. reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes on units sold previously. The information contained in this manual may be revised periodically by Textron Specialized Vehicles, Inc., and therefore is subject to change without notice.
  • Page 4 GENERAL INFORMATION The use of non-Original Equipment Manufacturer (OEM) approved parts may void the warranty. Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehi- cle warranty. When servicing the engine, all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manu- facture.

  • Page 5: Safety Information

    Textron Specialized Vehicles, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.

  • Page 6: Maintenance

    SAFETY INFORMATION MAINTENANCE ALWAYS: • Replace damaged or missing warning, caution or information labels. • Maintain the vehicle according to the manufacturer’s periodic service schedule. See SCHEDULED MAINTE- NANCE CHART on page 166. • Ensure that repairs are performed by trained and qualified persons. •...

  • Page 7: General Information And Routine Maintenance

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER AND VIN LOCATION Serial Number Label on Steering Column Frame VIN (vehicle frame under seat) MAIN SERIAL NUMBER LABEL Certification Statement...

  • Page 8: Starting The Vehicle With A Discharged Battery

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTING THE VEHICLE WITH A DIS- ROUTINE MAINTENANCE CHARGED BATTERY This vehicle will give years of satisfactory service, if it receives regular maintenance.

  • Page 9: Tires

    Tires must not be moved or rotated from their original position. TEXTRON OFF ROAD does not recommend the use of a pressure washer. High pressure water can damage com- Tire condition must be inspected. Inflation pressures must ponents, chip paint and remove labels.

  • Page 10: Transporting The Vehicle

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRANSPORTING THE VEHICLE days or longer requires some simple steps to prevent var- nish, gum and corrosion in the throttle body and in the To prevent personal injury to occu- engine.

  • Page 11: Repair And Service Manual

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HARDWARE • Grade 5 hardware can be identified by the three marks on the hexagonal head. Periodically inspect the vehicle for loose fasteners.
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 13: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION GENERAL ........................III GENERAL OPERATION....................III MAINTENANCE ....................... IV VENTILATION........................IV GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER AND VIN LOCATION ................ 11 STARTING THE VEHICLE WITH A DISCHARGED BATTERY ........12 SERVICING THE VEHICLE.................... 12 ROUTINE MAINTENANCE.....................
  • Page 14 TABLE OF CONTENTS BODY GENERAL........................21 Painting .......................21 Repairing Scratches ....................21 Complete Panel Repair ..................21 Decal Replacement .....................21 Cowl Removal .....................22 Standard Brush Guard Removal .................24 Premium Brush Guard Removal .................25 Rocker Panel Removal ..................26 Side Panel and Rear Fender Liner Removal ............26 Quarter Panel and Front Fender Liner Removal ..........26 Door Removal .....................27 Door Handle and Latch Assembly Removal ............28...
  • Page 15 TABLE OF CONTENTS ROLLOVER PROTECTION SYSTEM (ROPS) Removing the ROPS as a Complete Unit ............44 INSTALLING ROPS COMPONENTS ................44 A. ROPS Side Tube Installation ................. 44 B. ROPS Extended Cab Tubes Installation ............44 C. Rear Cross-tube Installation ................44 E.
  • Page 16 TABLE OF CONTENTS Brake Pad Replacement ..................66 Rotor Replacement .....................67 BLEEDING AND FLUSHING ................... 68 Bleeding ......................68 Bleeding Sequence .....................68 Flushing the Brake System .................69 BRAKE AND ACCELERATOR PEDALS ................. 69 Brake Pedal Removal And Installation ..............69 Accelerator Pedal Removal ................70 FRONT CV SHAFT, SUSPENSION AND STEERING FRONT SUSPENSION ....................
  • Page 17 TABLE OF CONTENTS STEERING WHEEL ......................89 RIDE HEIGHT ADJUSTMENT ..................89 REAR AXLE AND SUSPENSION REAR SUSPENSION...................... 92 Maintenance ....................... 92 Wheel Bearing Test .................... 92 Hub Removal ..................... 92 Rear Spindle Removal ..................93 CV Shaft Replacement ..................94 CV Joint Boot Replacement ................

  • Page 18: Engine

    TABLE OF CONTENTS Secondary Clutch Installation ................109 Draining the CVT ....................109 PROP-SHAFT GENERAL ......................112 Prop-shaft Maintenance ..................112 Prop-shaft Removal ..................112 ENGINE GENERAL........................116 ENGINE DESCRIPTION....................116 Engine Specifications ..................116 ENGINE BREAK-IN ....................... 116 ENGINE MAINTENANCE ....................116 ENGINE OIL ........................116 Engine Oil Type and Capacity ................116 Checking the Engine Oil Level ................116 CHANGING ENGINE OIL AND FILTER ................
  • Page 19 TABLE OF CONTENTS Coolant Replacement ..................133 Coolant Reservoir Removal ................133 Radiator and Cooling Fan ................133 Radiator Removal .................... 134 Thermostat and Water Pump ................135 FUEL SYSTEM GENERAL ........................138 FUEL ..........................138 FUEL SYSTEM SERVICE .................... 138 Fuel Tank Removal ..................
  • Page 20 TABLE OF CONTENTS Continuity Check ....................161 Testing a Switch for Continuity .................161 Testing the Ignition System ................161 Testing Fuses ....................161 Powertrain Performance ...................162 STARTER FAULT TESTING ..................164 SUSPENSION AND STEERING FAULT TESTING ............164 GENERAL SPECIFICATIONS SCHEDULED MAINTENANCE Initial Service Requirements ................171 Severe Use Conditions ..................171 SCHEDULED MAINTENANCE CHART ................
  • Page 21 TABLE OF CONTENTS Notes: 668061 Repair and Service Manual...
  • Page 22 TABLE OF CONTENTS Notes: Repair and Service Manual 668061...

  • Page 23: Safety

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY NOTICES, CAUTIONS, WARNINGS MODIFICATIONS TO VEHICLE AND DANGERS Do not modify the vehicle in any manner that will change the weight distribution of the vehicle.
  • Page 24 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. must be allowed to rotate or service is being per- ing with clear water. Contact a physician immedi- formed on the brake system. ately.

  • Page 25: Lifting The Vehicle

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIFTING THE VEHICLE Install a jack stand under each side of the vehicle frame just in front of the rear wheels. Tool List Qty.
  • Page 26 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 27: Body

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY GENERAL Shake the aerosol paint a minimum of one minute to mix thoroughly and achieve the best color match. NOTICE: Hardware that is removed must always be Apply paint in light even overlapping strokes.

  • Page 28: Cowl Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cowl Removal Fig. 1 Cowl and Front Fascia Tool List Qty. Remove the plastic rivets (8) and screws (27) that secure the fascia to the cowl (1).
  • Page 29 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Dash Removal Front of Vehicle Fig. 2 Dash and Front Bulkhead Tool List Qty. Remove the rocker panel. See Rocker Panel Removal on page 20.

  • Page 30: Standard Brush Guard Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Standard Brush Guard Removal Front of Vehicle Fig. 3 Standard Brush Guard Tool List Qty. Ratchet ................ 1 Socket, 17mm.............. 1 Wrench, 17mm ............

  • Page 31: Premium Brush Guard Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Premium Brush Guard Removal Front of Vehicle Fig. 4 Premium Brush Guard Tool List Qty. Remove the two bolts (22) that secure the lower shield (12) to the frame.

  • Page 32: Rocker Panel Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rocker Panel Removal Tool List Qty. Screwdriver, Flat Tip ............1 Torx Bit, T30..............1 Ratchet.................1 Remove the rocker panel. See Rocker Panel Removal on page 20.

  • Page 33: Door Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tool List Qty. Ratchet ................1 Socket, 15mm..............1 Cowl Wrench, 15mm ............1 Torque Wrench, ft. lbs..........1 Remove the bolts (15), nuts (16) and hinge plate (8) that secure the door (1) to the upper and lower door hinges (See Fig.

  • Page 34: Door Handle And Latch Assembly Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Door Handle and Latch Assembly Removal Door Front of Vehicle Fig. 9 Door Handle and Latch Assembly Tool List Qty.

  • Page 35: Striker Plate Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Floorboards Item Torque Specification 3, 20, 21 11 - 15 ft. lbs. (15 - 20 Nm) Seat Closeout 11 - 15 ft. lbs. (15 - 20 Nm) 5 - 6 ft.

  • Page 36: Seating

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SEATING Front of Vehicle Seat Frame Fig. 12 Seat Components Repair and Service Manual 668061...

  • Page 37: Seat Bottom Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Bottom Removal The seat bottom (1) is removed by grasping the front edge of the seat bottom and pulling up and out of the vehicle.

  • Page 38: Extended Cab

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EXTENDED CAB Heat Shields Heat Shields Front of Vehicle B-pillar Seat Frame Crossmember Frame Fig. 13 Extended Cab Components Repair and Service Manual 668061...

  • Page 39: Cargo Tray Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cargo Tray Removal Remove the plastic rivets (11) that secure the front closeout panel (8) to the seat frame and B-pillar Tool List Qty.

  • Page 40: Skid Plate Removal

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Skid Plate Removal Front of Vehicle Fig. 15 Skid Plate Tool List Qty. Tighten the hardware to the torque specified below: Ratchet ................
  • Page 41 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...
  • Page 42 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 43: Frame

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRAME Front of Vehicle Fig. 1 Frame Overview 668061 Repair and Service Manual...

  • Page 44: General

    FRAME Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL To remove the door hinges (24) from the bracket (20), remove hinge bolt (23), bushings (22), spacer NOTICE: Hardware that is removed must always be 26) and nut (27).

  • Page 45: Hand Hold Removal

    FRAME Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove bolts (6) that secure the inner legs of the Remove the bolts (8) that secure the front shock support to the frame.
  • Page 46 FRAME Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tool List Qty. Installation is in the reverse order of removal. Tighten hardware to the torque specified below: Ratchet ................ 1 Socket, 17mm..............

  • Page 47: Seat Frame Removal

    FRAME Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Frame Removal Tool List Qty. ITEM NO TORQUE SPECIFICATION Ratchet ................ 1 Socket, 13mm.............. 1 30, 31 30 - 33 ft.lbs.

  • Page 48: Repair And Service Manual

    FRAME Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...
  • Page 49 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ROLLOVER PROTECTION SYSTEM (ROPS) B-Pillar C-Pillar Front of Vehicle A-Pillar Fig. 1 ROPS Components 668061 Repair and Service Manual...

  • Page 50: Rollover Protection System (Rops)

    ROLLOVER PROTECTION SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The ROPS hardware and compo- Remove the cargo tray and cab closeout panel. See nents must be assembled properly the BODY section.
  • Page 51 ROLLOVER PROTECTION SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Slide the ends of the cross-tube (12) in between the wiring harness of the cross-tube. Align the mounting ROPS tube mounting brackets (1 and 4) and align holes of the CHMSL (10) and the mounting bracket.

  • Page 52: Front Cross-Tube Installation

    ROLLOVER PROTECTION SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Once the wiring has been inserted into the extended cab ROPS tube, align the mounting bracket holes of the extended cab cross-tube (7) to the corresponding mounting bracket of the extended cab ROPS tube (4).

  • Page 53: Seatbelt Installation

    ROLLOVER PROTECTION SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. a. Tighten the seat back support (24, 25) to ROPS tubes (2, 1) and the vehicle frame. b.

  • Page 54: Headrest Installation

    ROLLOVER PROTECTION SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Frame Front of Vehicle Fig. 10 Seat Belt Latches Headrest Installation Front of Vehicle Fig. 11 Headrest Attach the headrest (27) to the top of the seat back support by pushing it in against the support and then sliding down to lock into place (Ref.
  • Page 55 ROLLOVER PROTECTION SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...
  • Page 56 ROLLOVER PROTECTION SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...
  • Page 57 TRUCK BED Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRUCK BED Front of Vehicle Bed Stop Bracket Bed Frame Spring Clevis Pin Cotter Pin Frame Bushing Bed Frame Components 668061 Repair and Service Manual...

  • Page 58: Truck Bed

    TRUCK BED Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRUCK BED REMOVAL Tool List Quantity Back Brace ..............2 Ratchet ................ 1 Socket, 10mm.............. 1 The truck bed is heavy and difficult to handle.

  • Page 59: Decal Replacement

    TRUCK BED Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Decal Replacement Tool List Qty. Alcohol..............A/R Clean Cloth..............1 Squeegee ..............1 When replacing decals on the body panels: Prepare the surface by cleaning with alcohol and a clean cloth.
  • Page 60 TRUCK BED Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 61: Weather Protection

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WEATHER PROTECTION GENERAL Finger tighten the hardware to allow for adjustment. Repeat the above step to install the other three The canopy does not provide pro- mounting brackets (4, 6, 7) to the corresponding tection from falling objects.

  • Page 62: Installing Canopy Clamps

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Installing Canopy Clamps Front of Vehicle Fig. 2 Place canopy clamps (3), with the hinged side facing out, onto each side ROPS tube (Ref. Fig. 2). Close the hinges around the ROPS tubes and secure with Torx bolts (11) and washers (12) (Ref.

  • Page 63: Installing The Canopy

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Installing the Canopy Front of Vehicle Fig. 4 Canopy Align the mounting holes on the canopy with the holes in the mounting brackets (4-7) and canopy clamps (3) (Ref.
  • Page 64 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 65: Wheels And Tires

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEELS AND TIRES Lug Nut Dust Cap (Style of wheel and tire may differ from shown.) Valve stem must always be to the outside of the wheel.

  • Page 66: Tire Tread Depth

    Fig. 2 Tire replacement requires a tire mounting machine and Then, tighten lug nuts to torque values in 20ft. lbs. must be done by a qualified tire center or TEXTRON OFF (27 Nm) increments following the same cross ROAD dealer.
  • Page 67 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...
  • Page 68 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 69: Brakes

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKES Brake Caliper Brake Caliper Part of Frame Front of Vehicle Frame and suspension partially shown for clarity Brake Caliper Brake Caliper Fig.

  • Page 70: Maintenance

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE Never apply WD-40 or any petro- leum product to the brake discs. These products are flammable and Daily Brake Performance Test can also reduce the friction between the brake pad and caliper and increase the possibility of an acci- NOTICE: To ensure correct braking performance, all...

  • Page 71: Master Cylinder

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. hone. If corrosion or deposits are detected on the master cylinder, replace it with a new one. Master Cylinder Replacement Fig.

  • Page 72: Brake Pad Replacement

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the cotter pin and clevis pin from the brake pedal. Remove two hex head bolts (4) and nuts (5) that secure the master cylinder and shield (12) to the frame.

  • Page 73: Rotor Replacement

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the two bolts (19) securing the outer caliper half (20) to the inner caliper half (Ref. Fig. 6). Remove the outer caliper half (21).

  • Page 74: Bleeding And Flushing

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bleeding Sequence If the rotor needs replacement, the caliper and pads must be moved to access the rotor. See Brake Pad Replace- ment.

  • Page 75: Flushing The Brake System

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKE AND ACCELERATOR PEDALS Apply moderate (40 - 50 lbs. [18 - 23 kg]), steady pressure on the brake pedal, and open the bleeder valve.

  • Page 76: Accelerator Pedal Removal

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Chassis Frame Front Vehicle Accelerator Pedal Front of Vehicle Figure 11 Accelerator Pedal Figure 10 Brake Pedal Removal Accelerator Pedal Removal Tool List Qty.
  • Page 77 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...
  • Page 78 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...
  • Page 79 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT CV SHAFT, SUSPENSION AND STEERING Front of Vehicle Fig. 1 Front Suspension Components 668061 Repair and Service Manual...

  • Page 80: Front Cv Shaft, Suspension And Steering

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION Remove the brake calipers from the rotor. See Brake Pad Replacement on page 60. NOTICE: Hardware that is removed must always be At the center of the hub, remove the cotter pin (40), installed in its original position unless otherwise...

  • Page 81: Front Spindle Removal

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the hub. See Front Hub Removal on page 68. Remove the nut (2) that secures the spindle to the steering rack ball joint (3) (Ref.
  • Page 82 FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 9 Spindle Nut and Cotter Pin Fig. 7 Ball Joint Separation Fig. 10 Remove Spindle Hardware Remove the cotter pin (31) and castle nut (30) that secure the spindle to the lower control arm (Ref.

  • Page 83: Front Axle

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT AXLE Install new boot clamps (Ref. Fig. 12). CV Shaft Replacement Tool List Qty.

  • Page 84: Lower Control Arm Assembly Replacement

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Spacer Fig. 13 Upper Strut Bolt Fig. 15 Upper Control Arm Spacer Remove the nut (33), spacer (39) and bolt (46) that Remove the strut assembly from the vehicle.

  • Page 85: Upper Control Arm Assembly Replacement

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the front spindle. See Front Spindle Lift and support vehicle. See LIFTING THE VEHI- Removal on page 69.

  • Page 86: Stabilizer Bar Removal

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the stabilizer bar. Installation is the reverse of removal. Tighten the hardware to the torque values specified below: Item Torque Specification...

  • Page 87: Front Differential Oil Replacement

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Check the front differential oil at the Initial Remove the CV shaft. Refer to CV Shaft Replace- Service and then at regular intervals indicated.

  • Page 88: Steering

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STEERING Steering Column Mount Weldment Front of Vehicle Part of Frame Fig. 21 Steering Components (Non-EPAS) Repair and Service Manual 668061...
  • Page 89 FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Column Mount Weldment Front of Vehicle Brake Pedal Mounting Bracket Fig. 22 Steering Component (EPAS) 668061 Repair and Service Manual...

  • Page 90: Steering Wheel Replacement

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Wheel Replacement Tool List Qty. Paint Marker ..............1 Socket, 24mm.............. 1 Ratchet ................ 1 Hammer...............

  • Page 91: Steering Column Removal

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Column Removal Tool List Qty. Paint Pen..............1 Ratchet ................ 1 Hex Bit Socket, 5/16”........... 1 Wrench, 10mm ............

  • Page 92: Electric Power Assist System (Epas) (If Equipped)

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disconnect the two wire harness connections on the EPAS unit (Ref. Fig. 29). Disconnect Fig.

  • Page 93: Steering Rack Replacement

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the nut (28) and bolt (29) securing the steering shaft yoke to the steering rack (Ref. Fig. 32).

  • Page 94: Maintenance

    FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Wheel alignment is required after installa- tion. See Wheel Alignment. Tighten the hardware to the torque values specified below: Item Torque Specification...

  • Page 95: Steering Wheel

    Fig. 35). If there is excessive play, unusual noises, or the steering feels rough, have the steering system inspected by your TEXTRON OFF ROAD dealer. RIDE HEIGHT ADJUSTMENT Fig. 36 Ride Height Adjustment The spring pre-load adjuster can be adjusted on the front...
  • Page 96 FRONT CV SHAFT, SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 97: Rear Axle And Suspension

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE AND SUSPENSION Front of Vehicle Fig. 1 Rear Suspension Components 668061 Repair and Service Manual...

  • Page 98: Rear Suspension

    REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR SUSPENSION At the center of the hub, remove the cotter pin (5), axle nut (4) and washer (17) from the axle. (Ref. Fig. NOTICE: Hardware that is removed must always be 2)(Ref.

  • Page 99: Rear Spindle Removal

    REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tap the hub with a plastic hammer while applying Lift and support vehicle. See LIFTING THE VEHI- outward pressure until the hub slides off the splines CLE on page 13.

  • Page 100: Cv Shaft Replacement

    REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the CV shaft from the differential using a pry bar. Make sure that the hog ring is in place on the CV shaft splines (Ref.

  • Page 101: Rear Strut Assembly Replacement

    REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Strut Assembly Replacement Tool List Qty. Wheel Chocks ............. 4 Floor Jack..............1 Jack Stands..............4 Wrench, 18mm ............

  • Page 102: Upper Control Arm Assembly Replacement

    REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the nuts (20) and bolts (7) that secure each Remove the hub. See Hub Removal on page 86. side of the lower control arm (2) to the vehicle frame Remove the rear spindle.

  • Page 103: Rear Differential

    REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lift and support vehicle. See LIFTING THE VEHI- Replace the fill plug and tighten to 10 ft. lbs. (14 Nm) CLE on page 13.

  • Page 104: Rear Differential Oil Replacement (Lower Chamber)

    REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Differential Oil Replacement (Lower Chamber) Fill Plug - Speed Sensor Drain Plug Fig. 16 Fill Plug at Speed Sensor Remove the speed sensor (Ref.

  • Page 105: Rear Differential Replacement

    REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Differential Replacement Front of Vehicle Stator Cover Rear Differential Engine Fig. 17 Rear Differential Mounting Brackets Tool List Qty.
  • Page 106 REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the CVT clutches, air hoses and belt. See 11. Remove the bolts (10 and 11) and nuts (12) that CONTINUOUSLY VARIABLE TRANSMISSION secure the shifter bracket (22) to the differential (CVT) on page 99.
  • Page 107 REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 21 Disconnect Speed Sensor 14. Disconnect the differential lock wire (Ref. Fig. 21). Fig. 23 Support Engine with Ratchet Strap 16.

  • Page 108: Adjusting The Shift Lever Cable

    REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Item Torque Specification 33 - 37 ft. lbs. (45 - 50 Nm) 33 - 37 ft. lbs. (45 - 50 Nm) 33 - 37 ft.
  • Page 109 REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fig. 28 Shift Cable 668061 Repair and Service Manual...
  • Page 110 REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 111: Continuously Variable Transmission (Cvt)

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONTINUOUSLY VARIABLE TRANSMISSION (CVT) GENERAL Increased Load When a vehicle traveling at governed speed begins to Power is transfered from the engine to the rear axle by climb a grade or is subjected to other increased load con- the Continuously Variable Transmission (CVT).
  • Page 112 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CVT Air Rear Outlet Differential CVT Air Intake Engine Front of Vehicle CVT Backing Plate CVT Belt Secondary Clutch Primary...

  • Page 113: Cvt Belt

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CVT BELT (Ref. Fig. 2). Remove the bed, rear fender liner, side panel and skid plate to access the clutch cover. Tool List Qty.

  • Page 114: Primary Clutch Installation

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Impact Socket, 22mm..........1 Impact Wrench ............1 Thread Locking Adhesive ......... AR Torque Wrench, ft. lbs..........1 NOTICE: To prevent damage to the clutch during removal or installation, be careful not to damage the machined surfaces of the clutch while using a pry...

  • Page 115: Secondary Clutch Removal

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Secondary Clutch Removal Secondary Clutch Installation Tool List Qty. Coat the rear axle input shaft with a light coat of anti- seize compound and slide the clutch onto the shaft.
  • Page 116 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 117: Prop-Shaft

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PROP-SHAFT Front of Vehicle Rear Differential Grease Fitting Grease Fitting Front Differential 668061 Repair and Service Manual...

  • Page 118: General

    PROP-SHAFT Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 Front and Rear Prop-Shaft GENERAL Remove the skid plate. See Skid Plate Removal on page 28. Power from the engine is transferred to the front differen- tial by the use of a prop-shaft system.

  • Page 119: 11. Tighten The Hardware To The Torque Values Specified

    PROP-SHAFT Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disconnect Rear Prop-Shaft Fig. 4 Disconnect Rear Prop-Shaft Remove the front and rear prop-shafts from the vehi- cle. 10. Installation is the reverse of removal. Clean the prop- shaft, gearbox and differential splines with a clean rag.
  • Page 120 PROP-SHAFT Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 121: Engine

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE Part of Frame Front of Vehicle Fig. 1 Engine 668061 Repair and Service Manual...

  • Page 122: General

    ENGINE OIL NOTICE: For detailed engine repair and service pro- NOTICE: The use of an incorrect grade of engine oil cedures, see Textron Motors Repair Manual can damage the engine. Always use the recom- TD409135_RLF and Service Manual TD409135_SHB. mended grade. Do not mix engine oils of different grades or viscosity.

  • Page 123: Changing Engine Oil And Filter

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CHANGING ENGINE OIL AND FILTER Tool List Qty. Dipstick Ratchet ................1 Socket, 13mm..............1 Oil Tank Universal Strap Wrench..........1 Funnel................1 Pliers................1 Oil Drain Pan ...............1 Clean Cloth ..............A/R...

  • Page 124: Replace The Oil Filter

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Starting the engine after the oil is drained Clean the engine sealing surface with a clean cloth can cause serious engine damage. (Ref.

  • Page 125: Spark Plugs

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. performance. See SCHEDULED MAINTENANCE other restrictions in the air intake system. Incorrectly CHART on page 166. adjusted valves, spark plug wires which are in poor condi- tion or poor quality fuel could also contribute to the prob- Air Filter Cartridge lem.

  • Page 126: Engine Compression Test

    The gap must be the cause may be valve damage or a head gasket within the range indicated in the illustration. leak, etc. See Textron Motors Repair Manual • If both spark plugs are within the range, reinstall TD409135_RLF and Service Manual them.

  • Page 127: Engine Removal

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE REMOVAL Stator Cover Rear Differential Engine Part of Frame Front of Vehicle Fig. 14 Engine Mounting Components 668061 Repair and Service Manual...
  • Page 128 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tool List Qty. • Air Intake Hose - See AIR INTAKE on page 121. • Coolant Hoses - See COOLING SYSTEM on Hoist ................

  • Page 129: Exhaust System Removal

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EXHAUST SYSTEM REMOVAL FOR VEHICLES MANUFACTURED Engine BEFORE APRIL 24, 2017 Upper Engine Casting Front of Vehicle Fig. 15 Exhaust System 668061 Repair and Service Manual...
  • Page 130 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tool List Qty. NOTICE: The exhaust manifold nuts (6) must be torqued in three stages in a cross-pattern sequence Spring Hook..............
  • Page 131 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...
  • Page 132 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 133: Air Intake

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. AIR INTAKE Engine Bay Closeout (Part of Extended Cab) Air Inlet Blow-By Air Intake Hose Hoses Hose Clamp Oil Tank Air Filter Housing Engine...

  • Page 134: Engine Air Intake

    ENGINE AIR INTAKE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE AIR INTAKE Replace the seat bottom. NOTICE: Hardware that is removed must always be Cover installed in its original position unless otherwise specified.
  • Page 135 ENGINE AIR INTAKE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...
  • Page 136 ENGINE AIR INTAKE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 137: Cooling System

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. COOLING SYSTEM Part of Frame Constant Bleed Line Engine Coolant Reservoir Engine Engine Part of Frame Fan Assembly Radiator Constant To Radiator Bleed Line Front of Vehicle...

  • Page 138: Cooling System

    COOLING SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. COOLING SYSTEM Start the engine and allow it to idle for 10 seconds. Recheck the level to make sure it is correct. NOTICE: Hardware that is removed must always be installed in its original position unless otherwise NOTICE: If coolant runs low often, or if the coolant...

  • Page 139: Coolant Replacement

    COOLING SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Coolant Replacement enough force to push all the air out of the system. If the engine is allowed to idle, the water pump seal Tool List Qty.

  • Page 140: Radiator Removal

    COOLING SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Do not use a high pressure hose to wash the vehicle. Water from a high pressure hose could damage the radiator cooling fins.

  • Page 141: Thermostat And Water Pump

    COOLING SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 10. Remove the two bolts and nuts that secure the radia- tor to the frame (Ref. Fig. 9). Lift the radiator up and out of the vehicle.
  • Page 142 COOLING SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...
  • Page 143 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FUEL SYSTEM Front of Vehicle Fig. 1 Fuel System Components 668061 Repair and Service Manual...

  • Page 144: Fuel System

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL the fuel/vapor. Never permit smoking or an open flame in an area that contains fuel/vapor. Clean up NOTICE: Hardware that is removed must always be all fuel spills immediately.

  • Page 145: Fuel Pump Assembly

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Always dispose of fuel safely. Disconnect the fuel pump wire located at the top of the fuel tank (See Fig. 3). Fuel Vent Tube Fig.
  • Page 146 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 147: Electrical System

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL SYSTEM MAIN HARNESS NOTICE: Use of fuses with incorrect ratings can damage electrical components. Power Supply Tool List Qty. Circuits and Controls DVOM ................1 The electrical system is a 12 volt negative ground system...

  • Page 148: Voltage Test For Battery

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. starter. Place positive (+) probe on terminal B. a bare wrench with the battery terminals can cause an explosion resulting in severe injury or death The DVOM should indicate approximately 12V.

  • Page 149: Battery Removal

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the battery each month during storage and charge Remove the bolt (5) and nut (6) from the battery tray as needed to maintain full charge.

  • Page 150: Headlight Beam Adjustment

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rotate the bulb and pull it from the light housing. Headlight center line Adjustment Screws Headlight Bulb Top of beam 4 in.

  • Page 151: Information Display Removal

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Information Display Removal Remove th bolts (3) and nuts (2) that secure the ECU to the rear of the engine bay closeout panel Instrument Panel (Ref.
  • Page 152 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle To Main Harness (Rear) To Starter Relay Fig. 8 Engine Electrical Connections Repair and Service Manual 668061...
  • Page 153 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Shock Tower Brace Front of Vehicle Instrument Panel Fig. 9 Dash Electrical Components 668061 Repair and Service Manual...
  • Page 154 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Part of Seat Frame Front of Vehicle Part of Frame Part of Seat Frame Starter Motor Cable Front of Vehicle Battery Fig.

  • Page 155: Voltage Regulator Removal

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Voltage Regulator Removal Tool List Qty. Wrench, Insulated, 1/2” ..........1 Ratchet ................ 1 Socket, 10mm ............. 1 Wrench, 10mm ............

  • Page 156: Wiring Diagrams

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WIRING DIAGRAMS RING2 RING3 RING1 PUSH ON 1 CHASSIS GND (B-) CHASSIS GND (SIG) RING4 CHASSIS GND (B-) ACC GND 5/16”...
  • Page 157 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 668061 Repair and Service Manual...
  • Page 158 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 668061...
  • Page 159 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 668061 Repair and Service Manual...
  • Page 160 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 668061...
  • Page 161 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR PDM J-FUSE A MAIN MAIN BATT RLY (REF ONLY) RING4 HARN BATT (+) FROM SERVICE RLY 5/16” 10AWG CONN9 BATT 12+ ENG HARN...
  • Page 162 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 668061...
  • Page 163 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 668061 Repair and Service Manual...
  • Page 164 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONN 10 FUEL PUMP/SENSOR CONN 16 CONN 11 CHMSL HARN PLUG GREEN BLACK BLACK BLACK WHITE/GREEN SGND BLACK/BLUE BLUE/GREEN BLUE/RED BLUE...
  • Page 165 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...
  • Page 166 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 167: Fault Testing

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT TESTING General To effectively troubleshoot the electrical circuits that include the headlights, brake light and the information display, etc, the technician must be able to use the wiring diagram and a Digital Voltage Ohm Meter (DVOM).

  • Page 168: Powertrain Performance

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Powertrain Performance CONDITION POSSIBLE CAUSE CORRECTION STARTER DOES NOT Weak or bad battery Charge or replace as necessary TURN Terminals are loose or corroded Clean and tighten...
  • Page 169 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONDITION POSSIBLE CAUSE CORRECTION POOR MIDRANGE OR Spark plug fouled Clean or replace HIGH SPEED PERFOR- Dirty air filter Clean or replace MANCE Brake(s) dragging...

  • Page 170: Starter Fault Testing

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER FAULT TESTING CONDITION POSSIBLE CAUSE CORRECTION STARTER IS NOISY Bolts are loose Tighten to correct torque Starter has foreign matter inside Clean starter interior Bearings are faulty Replace...
  • Page 171 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...
  • Page 172 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...
  • Page 173 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL SPECIFICATIONS Item Specification Maximum Weight Capacity (includes 1200 lbs. (544 kg) weight of operator, passenger, cargo, accessories) Seating Capacity 2 person Dry Weight 1650 lbs.

  • Page 174: General Specifications

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Item Specification Cooling Liquid Shift Type Single lever on console Gear Reduction (L) 28.03:1 Gear Reduction (R) 25.49:1 Gear Reduction (H) 12.54:1 Drive Ratio (front)

  • Page 175: General Specifications

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...

  • Page 176: General Specifications

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 177: Scheduled Maintenance

    STAMPEDE 900 so that it remains in safe and reliable condition. See SCHEDULED MAINTENANCE CHART on page 166. Inspect, clean, lubricate, adjust and replace parts as nec- essary. Use original TEXTRON OFF ROAD or equivalent replacement parts. Record the maintenance items performed along with details.

  • Page 178: Scheduled Maintenance Chart

    Perform all services at the maintenance interval reached affect emissions. first. D –Indicates services that must be performed by an S –Indicates operations that need to be performed on authorized TEXTRON OFF ROAD dealer. vehicles subjected to severe use. Interval (perform at interval that comes Item...
  • Page 179 SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Interval (perform at interval that comes Item Remarks first) Hours Calendar Miles (km) Front differential oil 6 Months 1000 Inspect for leaks and contamination;...

  • Page 180: Recommended Lubricants And Fluids

    Universal joint grease or equivalent Control Arms Universal joint grease or equivalent REPLACEMENT OF MAINTENANCE ITEMS These items or their equivalents can be purchased through your dealer, directly from TEXTRON OFF ROAD or any other qualified source. Item Part Number...

  • Page 181: Repair And Service Manual

    SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 668061 Repair and Service Manual...
  • Page 182 SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 668061...

  • Page 183: Fault Codes

    APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. APPENDIX A FAULT CODES DIAGNOSTIC MANUAL Repair and Service Manual...

  • Page 184: Appendix A

    APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual...

  • Page 185: Epas Fault Codes

    APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EPAS FAULT CODES Bridge Code Name Description Notes State This fault monitors the bridge currents to detect A power toggle will recover this fault C1000 Over Current Bridge Off...

  • Page 186: Appendix A

    APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. This fault will set on a failure to transmit or A power toggle will recover this fault C1014 CAN Bus Bridge Off receive a CAN message.

  • Page 187: Can

    APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. This fault will set if a speed is detected above the This fault is only checked for the C1029 Vehicle Speed vehicle speed max calibration for longer than the...

  • Page 188: Appendix A

    APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual...
  • Page 189 DIAGNOSTIC MANUAL 4-Stroke Engine MPE 850 OFF-ROAD This diagnostic manual is valid for the following engine models: – 409135 I2 846 UTV NA-80 TD409135_DHB Rev A Read the introductory chapter before performing the task on the engine. 17.12.2015 Pay particular attention to the safety messages. en_English...
  • Page 191 Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development of its products. All documentation is therefore subject to technical modifications. Reprints and translations, in whole or in part, require written permission from Textron Motors GmbH.
  • Page 192 3.1 Textron Motors diagnostic case ........

  • Page 193: About This Document

    The signal word Information indicates specific features and recommendations. 1.2 Change management Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development of its products. Therefore descriptions in the diagnostic manual can be changed or added. All changes are described in the chapter Overview of revisions.

  • Page 194: Safety

    This diagnostic manual is solely intended for use in a workshop authorized by Textron Motors or the vehicle manufacturer. All work on the engine must be performed by appropriately trained personnel.

  • Page 195: 2.2 Important Safety Messages

    All the components in your engine have been carefully tested and fulfill strict quality and safety requirements. ► Textron Motors offers spare parts to the highest quality. Ensure that equivalent spare parts corresponds with this quality requirements. Add-on parts and modifications Engine modifications may pose a safety risk to persons.
  • Page 196 2 Safety 2.2 Important safety messages Engine exhaust gases contain carbon monoxide (CO). Inhalation of Engine exhaust gases carbon monoxide can deprive the body of oxygen and result in organ damage or death by asphyxiation. ► Never operate the engine in enclosed spaces. Fuel, engine oil and coolant Engine fluids pose a health risk.

  • Page 197: Tools And Accessories

    3 Tools and accessories 3.1 Textron Motors diagnostic case | 3.2 Equipment workshop 3 Tools and accessories 3.1 Textron Motors diagnostic case Textron Motors offers a diagnostic case that contains the following parts. Visit our website www.textronmotors.com for more information. Figure Description...

  • Page 198: Lights In Vehicle

    4 Lights in vehicle 4.1 Oil pressure warning light | 4.2 Temperature warning light 4 Lights in vehicle The following lights are supported by the engine management system. Read the service manual and vehicle manufacturer‘s documentation for more information. – Oil pressure warning light –...

  • Page 199: Malfunction Indicator Light (Mil)

    4 Lights in vehicle 4.3 Malfunction indicator light (MIL) 4.3 Malfunction indicator light (MIL) Description Cause Remedy Illuminated for a few seconds There is no malfunction. – when the ignition is switched Self test of the light. Not illuminated when the The malfunction indicator light ►...

  • Page 200: Troubleshooting With Trouble Codes

    Inf or ma t ion ! Trouble codes can be displayed with the Textron Motors Diagnostic Tool. Connect the notebook to the engine und start Textron Motors Diagnostic Software. (See the vehicle ► manufacturer‘s documentation and Textron Motors Diagnostic Tool manual.)

  • Page 201: 5.2 Description Of Trouble Codes

    5 Troubleshooting with trouble codes 5.2 Description of trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0011 Camshaft Position not Valid Sensor camshaft Invalid signal at the sensor camshaft. ►...
  • Page 202 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0031 HO2S Heater Control Circuit Low Sensor 1 Sensor lambda 1 Short circuit to ground at part or wire harness. ►...
  • Page 203 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0108 Manifold Absolute Pressure Sensor Circuit Sensor intake manifold pressure/temperature High ► Check wiring in the wire harness to Short circuit to plus at part or wire harness.
  • Page 204 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0118 Engine Coolant Temperature Circuit High/ Sensor coolant temperature Open ► Check wiring in the wire harness to Open circuit or short circuit to plus at part or the affected part.
  • Page 205 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0131 O2 Sensor Circuit Low Sensor 1 Sensor lambda 1 Short circuit to ground at part or wire harness. ►...
  • Page 206 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0172 Fuel System Too Rich Sensor lambda 1 Fueling too rich. ► A too high fuel pressure can cause the fault.
  • Page 207 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0219 Engine Overspeed Condition No defect Engine speed > 9000 min [rpm]. NOTICE! Subsequent damage are possible. ► Avoid situations where the speed can exceed the maximum speed.
  • Page 208 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P025C Fuel Pump Module Control Circuit Low Relay fuel pump Short circuit to ground at part or wire harness. ►...
  • Page 209 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0264 Cylinder 2 Injector Circuit Low Injector 2nd cylinder Short circuit to ground at part or wire harness. ►...
  • Page 210 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0315 Crankshaft Position – Camshaft Position Sensor crankshaft Correlation - Gap Position Incorrect ► Check wiring in the wire harness to The sensor crankshaft signal is undetermined.
  • Page 211 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0344 Camshaft Position Signal Timeout Sensor camshaft During operation implausible signals occur at ► Check if the affected part is unusually dirty. the sensor camshaft.
  • Page 212 P0606 Internal Monitoring Error – P060B Internal Control Module A/D Processing ► Contact the vehicle manufacturer or Performance Textron Motors directly. P060C Internal Monitoring_3 Error P0615 Starter Relay Circuit Open Relay starter Open circuit at part or wire harness. ► Check wiring in the wire harness to the affected part.
  • Page 213 Possible consequences ► Possible consequences/remedy P061A Internal Monitoring of Torque Error – ► Contact the vehicle manufacturer or Textron Motors directly. P061B Internal Monitoring - Torque Intervention Throttle body Excessive ► Check wiring in the wire harness to the affected part. (See the vehicle manufacturer‘s documentation.)
  • Page 214 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P063B Auto Configuration Throttle Input - Limp home Throttle body adaptation is out of range ► Check wiring in the wire harness to the affected part.
  • Page 215 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0641 Sensor Reference Voltage 1 Circuit Low 5 V power supply from engine control unit Open circuit at 5 V power supply from engine ►...
  • Page 216 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P0658 Main Relay Supply Voltage Low Battery The battery voltage is too low. ► Check wiring in the wire harness between ECU 64pol-P2 and relay main.
  • Page 217 P1604 ECU Internal Warm Restart Failure – ► Contact the vehicle manufacturer or Textron Motors directly. P2100 Throttle Actuator Control Motor Circuit/Open Throttle body Open circuit at part or wire harness. ► Check wiring in the wire harness to the affected part.
  • Page 218 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P2102 Throttle Actuator Control Motor Circuit Low Throttle body Short circuit to ground at part or wire harness. ►...
  • Page 219 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P2122 Pedal Position Sensor 1 Circuit Low/Open Throttle request unit Open circuit or short circuit to ground at part or ►...
  • Page 220 5 Troubleshooting with trouble codes 5.2 Description of trouble codes Displayed fault Affected part/system Trouble code description Possible consequences ► Possible consequences/remedy P2138 Pedal Position Sensor Plausibility Error Throttle request unit Implausible values of the sensors. ► Check wiring in the wire harness to the affected part.

  • Page 221: Test Procedures At Engine

    6 Test procedures at engine 6.1 Checking voltage regulator 6 Test procedures at engine 6.1 Checking voltage regulator Voltage regulator 200 mm [7.9 in] 3-pole connection at stator generator (yellow wires) 2-pole connection at battery cable (red wires) Connection engine ground inner diameter 8 mm (black wires) 600 mm [23.7 in]...

  • Page 222: 6.2 Checking Generator

    6 Test procedures at engine 6.2 Checking generator 6.2 Checking generator Generator Stator Rotor 3-pole connection at stator generator (yellow wires) Check all electrical contacts for corrosion and proper mechanical connection. ► Make a continuity test with all relevant wires: ►...

  • Page 223: 6.3 Checking Crankshaft Reluctor

    6 Test procedures at engine 6.3 Checking crankshaft reluctor 6.3 Checking crankshaft reluctor – Crankshaft reluctor – Gap (2 missing teeth) – Marking for valve timing Perform a visual inspection of the crankshaft reluctor. ► If mechanical defects are present, for example at the teeth, replace the crankshaft. ►...

  • Page 224: 6.4 Checking Thermostat

    6 Test procedures at engine 6.4 Checking thermostat 6.4 Checking thermostat Inf or ma t ion ! The thermostat is fitted with a wax element. Opening temperature from 82 °C [179 °F] The thermostat is fully open at 88 °C [190 °F] –...

  • Page 225: 6.5 Checking Cam Spike At Rocker Arm

    6 Test procedures at engine 6.5 Checking cam spike at rocker arm 6.5 Checking cam spike at rocker arm – Cam spike at rocker arm Perform a visual inspection of the cam spike at rocker arm. ► If mechanical defects are present, replace the rocker arm. ►...

  • Page 226: 6.6 Checking Oil Pressure

    6 Test procedures at engine 6.6 Checking oil pressure 6.6 Checking oil pressure Inf or ma t ion ! Limited by the oil pressure valve the maximum oil pressure is 5,5 bar. Warm up the engine. (See the ► manufacturer‘s documentation.) Unscrew the switch oil pressure ►...

  • Page 227: 6.6.1 Troubleshooting Guide Too Low Oil Pressure

    6 Test procedures at engine 6.6 Checking oil pressure 6.6.1 Troubleshooting guide too low oil pressure Oil pressure too low Leaks in lubrication system/cylinder head Repair the leaks gasket See the repair manual. Oil pressure valve Replace the oil pressure always opened valve See the repair manual.

  • Page 228: Components Overview

    7 Components overview 7 Components overview – Engine control unit (additional A1-64P A1-32P part) Connector pin assignment: – Switch oil pressure – Sensor intake manifold pressure/temperature Connector pin assignment: DHB MPE850 UTV Rev A | 409135 |...
  • Page 229 7 Components overview – Sensor crankshaft Connector pin assignment: – Sensor camshaft Connector pin assignment: – Sensor coolant temperature Connector pin assignment: The intake manifold is not shown in the figure. DHB MPE850 UTV Rev A | 409135 |...
  • Page 230 7 Components overview – Sensor Lambda 1 (additional part) Connector pin assignment: – Sensor knock Connector pin assignment: – Starter DHB MPE850 UTV Rev A | 409135 |...
  • Page 231 7 Components overview – Generator – Stator – Rotor Connector pin assignment stator: – Relay starter (additional part) Connector pin assignment: DHB MPE850 UTV Rev A | 409135 |...
  • Page 232 7 Components overview – Voltage regulator 200 mm [7.9 in] (additional part) Connector pin assignment: 600 mm [23.7 in] – Ignition coil 1st cylinder – Ignition coil 2nd cylinder Connector pin assignment: “15” “4a” “1” – Injector 1st cylinder – Injector 2nd cylinder Connector pin assignment: DHB MPE850 UTV Rev A | 409135 |...
  • Page 233 7 Components overview – Throttle body Connector pin assignment: DHB MPE850 UTV Rev A | 409135 |...

  • Page 234: Appendix

    Appendix Overview of revisions Appendix Overview of revisions Revision Date Chapter Description Note Rev A 17.12.2015 – 1st edition diagnostic manual – DHB MPE850 UTV Rev A | 409135 |...

  • Page 235: Index

    Appendix Index Index Trouble codes, description 13 Trouble codes, display 12 Cam spike at rocker arm, check 37 Crankshaft reluctor, check 35 Voltage regulator, check 33 Voltage regulator, components overview 44 Diagnostic case, overview 9 Engine control unit, components overview 40 Equipment, workshop 9 Generator, check 34 Generator, components overview 43...
  • Page 237 CONTACT US: TEXTRON SPECIALIZED VEHICLES, INC. 1451 Marvin Griffin Road Augusta, Georgia, USA 30906-3852 www.textronoffroad.com North America: Technical Assistance & Warranty PHONE: 1-800-774-3946 FAX: 1-800-448-8124 Service Parts PHONE: 1-888-438-3946 International: PHONE: 001-706-798-4311 FAX: 001-706-771-4609 Service Parts Manuals and Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts &...

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