John Deere 500, 650, 650EX, 650EXT ATV Technical Manual TM2160 PDF

JOHN DEERE

WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION

2160 January

2004

Trail Buck Utility ATV 500, 650, 650EX and 650EXT TM2160 JANUARY 2004

TECHNICAL MANUAL

North American Version Litho in U.S.A.

For the full PDF version of this manual, Please click on the above download PDF button.

INTRODUCTION Manual Description Introduction

T h i s t e c h n i c a l m a n u a l i s w r i t t e n f o Safety r an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program.

T h e m a n u a l i s o r g a n i z e d s o t h a t a l lTechnical t h e i n f Data ormation on a particular system is kept together. The order of grouping as follows: •Table

of

Contents

•Specifications

and

•Identification

Numbers

•Tools

and

Information

Location

•Schematics

and

•Theory

of

•Operation •

Harnesses

Drive Train

Operation and

Diagnostics

Diagnostics

•Tests

and

•

Repair

•

Other

Engine Electrical

Materials

•Component

is

Steering

Adjustments

Suspension

NOTE: Depending on the particular section or system being covered, not all of the above groups may be used.

Brakes

The bleed tabs for the pages of each section will align the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section Body / Frame through the last section.

with

We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us.

All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT© 2004 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT©

Introduction

SAFETY Handle Fluids Safely - Avoid Fires

Safety

Recognize Safety Information

Be Prepared For Emergencies

MIF

This is the safety-alert symbol.

When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended

Understand p r e c a u t i oSignal n s a Words nd safe servicing MIF p r a c t i c e s .

A s i g n a l w o r d - D A N G E R , W A R N I N G •, Wo hr eCn A yUoTuI OwNo r- k i sa r o u n d f u e l , d o u s e d w i t h t h e s a f e t y - a l e r t s y m b o l .nD t i of ir ek s ntehaer h e a t e r s oA t Ns G mEo Rk ei doer n w most serious hazards. or other fire hazards.

DANGER or WARNING safety signs a d mnaeba lre f l u i d s a w a y • Sr te o lr oe c fal taem specific hazards. General precautions are listed on r o cma l fl isr ea tht ae znat ri d s . tDo o n o t C A U T I O N s a f e t y s i g n s . C A U T I O N a l sf o on i n c i n e r a t e o r p u n t ue rr es . safety messages in this manual. p r e s s u r i z e d c o n t a ci n •Make sure machine is clean of

Replace Safety Signs

trash, grease, and debris.

•Do not store oily rags; they can ignite and burn s p oCare n t a In n eHandling o u s l y . and Servicing Batteries Use •Be prepared if a fire starts.

•Keep a first aid kit and fire extinguisher handy.

•Keep emergency numbers for doctors, ambulance MIF

sd ee rpvai rc tem , hospital, and fire t e l e p h o neen. t n e a r y o u r

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Safety - 1

MIF

SAFETY

such as earmuffs or earplugs to pr objectionable or uncomfortable lo •Keep sparks, lighted matches, and open flame away f r o m t h e t o p o f b a t t e r y . B a t t e r y Ogpaesr ac tai nn ge xepql uo idpem. e n t s a f e l y r e q u i r operator. Do not wear radio or mu •Never check battery charge by o pp l ae cr iant g o eb .j e c t i n ag m m ea tcahl i n across the posts. Use a volt-meter or hydrometer.

•Do not charge a frozen battery; it may explode. Warm

Prevent Battery Explosions

battery

to

16°C

Service Machines Safely

(60°F).

Prevent Acid Burns •Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid acid burns by: 1.Filling

batteries

2.Wearing

eye

in

a

well-ventilated

MIF

rubber gloves.

Tie long hair behind your head. Do 3 . A v o i d i n g b r e a t h i n g f u m e s w h e sn c e . r necklace a lr ef ,c tl ro oo l syet ec li os t a hd i nd ge ,d o m a c h i n e t o o l s o r m o v i n g parts. If 4.Avoiding spilling or dripping electrolyte. caught, severe injury could result 5.Use proper jump start procedure.

Remove rings and other jewelry to If you spill acid on yourself: and entanglement in moving parts 1.Flush your skin with water.

2.Apply

baking

3.Flush

your

protection

area.

soda

eyes

or

with

and

lime

to

hUse e l pProper n e uTools tralize

the

acid.

water

f o r U 1s0e -t o1 o 5 lm s ianpupt reosp. r i a t e t o t h e w o r k . p r o c e d u r es can create safety haza 4.Get medical attention immediately. only to loosen threaded parts and and tightening hardware, use the If acid is swallowed: NOT use U.S. measurement tools o 1 . D r i n k l a r g e a m o u n t s o f w a t e r oArv o mi idl kb. o d i l y i n j u r y c a u s e d b y s l i p i cne epgagr st ,s om 2 . T h e n d r i n k m i l k o f m a g n e s i a , bs ee ar vt e r eveetgi n e tg a Jb ol eh n D e e r e oil.

3.Get medical attention immediately.

Park Machine Safely

Wear Protective Clothing

MIF

Before working on the machine: MIF

1. Lower all equipment to the ground.

Wear close fitting clothing and safety equipment 2.Stop the engine and remove the key. appropriate to the job.

3. Disconnect the battery ground strap.

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device 4.Hang

Safety

-

2

SAFETY Support Machine Properly and Use Proper Lifting Equipment

Work In Ventilated Area

MIF

Engine exhaust fumes can cause s necessary to run an engine in an e o n a l i f t e d m a ct h a st t a fcuhm meesn ft r, o m t h e a r e a w h ien e x oh ra u t h e m a c h i n e o re xa tt et n a cs ihomn e. n t .

MIF

If you must work securely support

D o n o t s u p p o r t t h e m a c h i n e o n cI fi nydoeur db ol o nc ok ts , h h l l oa w ea s ,u s t p i p e ao ve n te ixl h o r p r o p s t h a t m a y c r u m b l e u n d ed r ocoor ns t ia nn ud o g ue s t l oo au dt .s i Dd oe n ao i rt i n t o t h e work under a machine that is supported solely by a jack.

Follow recommended procedures in this manual.

Warning: California Proposition 65 Warning Lifting heavy components incorrectly can cause severe l ionm e me en ng di n i n j u r y o r m a c h i n e d a m a g e . F o l l o Gwa sr o ec ee d exhaust from this c h e m i c a l s k n o w procedure for removal and installation of compn o nteon tt sh ei nS tt ah tee o f C b i r t h d e f e c t s , o r other reproductiv manual.

Diesel engine exhaust and some of known to the State of California t Work In Clean Area defects, and other reproductive ha Before starting a job: 1.Clean

work

area

and

Remove Paint Before Welding or Heating

machine.

Avoid potentially toxic fumes and can be generated when paint is he 2.Make sure you have all soldering, or using a torch. Do all necessary tools to do your ventilated area. Dispose of paint a Remove paint before welding or he job.

3.Have the right parts grind paint, avoid breathing the d on hand. respirator. If you use solvent or p Using High Pressure Washers stripper with soap and water befo 4.Read all instructions D i r e c t i n g p r e s s u r i z e d w a t e r a t es l oe l cv ter no tn iocr / ep l ae i cnttr isct ar li p p e r c o n t a i n e thoroughly; do not attempt c o m p o n e n t s o r c o n n e c t o r s , b e a rm i nagt se, r ihayl d fr raoum l i ca rseeaa. l sA, l lf ou w elfumes to shor tcuts. i np u at e o r ce o w i n j e c t i o n p u m p s o r o t h e r s e n s i t im ve r ts s baenf d mepl od ni n eg n t os r h e a t i n g may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle.

Service Tires Safely

Illuminate Work Area Safely

MIF

E ex q pu l oa st ievl ey sbeupt a sr a ft ei ol yn . oUf s e a a tire and rim Illuminate your work area ad e ir ni og u isn is ni dj ue r y r nddeear t ht h . e p o r t a b l e s a f e t y l i g h t f o r w o rs k o ro u m a c h i n e . M a k e s u r e t h e b u l bD oi s n eont c al o d pbt y t ao w e nct a a g et . i r e u n l e s s t ts ee m mi or u The hot filament of an accidentally broken bulb can ignite equipment and experience to perform spilled fuel or oil.

Always maintain the correct tire press

tires above the recommended pressure a wheel and tire assembly. The heat ca in air pressure resulting in a tire expl Safety

-

3

SAFETY

Direct exposure to hazardous chem injury. Potentially hazardous chem Deere equipment include such item coolants, paints, and adhesives.

structurally

weaken

or

deform

A Material Safety Data Sheet (MSD details on chemical products: phys safety procedures, and emergency Check the MSDS before you start a hazardous chemical. That way you the risks are and how to do the jo procedures and recommended equi the wheel.

When inflating tires, use a clip-on chuck and extension h o s e l o n g e n o u g h t o a l l o w y o u t Dispose o s t a nofdWaste t o oProperly ne side and N O T i n f r o n t o f o r o v e r t h e t i r e Iam s sp er m f eg t yo fc a o pb el y r l. y U ds ies pa o ss ai n w ga es t e c a n if available. environment and ecology. Potentia C h e c k w h e e l s f o r l o w p r e s s u r e , cwui tt sh , Jbouhbnb lDe es e, r de a e mqaugi ep dm e n t i n c l u d coolant, brake fluid, filters, and b r i m s o r m i s s i n g l u g b o l t s a n d n uc tosn. t a i n e r s w h e n d r a i n i n g f l u i d s . D beverage containers that may misl drinking from them. Do not pour w Service Cooling System Safely down a drain, or into any water so proper way to recycle or dispose o environmental or recycling center dealer.

Live With Safety

MIF

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut

off

remove

machine. filler

cap

Only when

Handle Chemical Products Safely

cool

enough tS ol o two l uy c lho owsi et h r et o h af ni rd ss t. n b c aa p stop to relieve pressure before removing

MIF

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems.

Install all guards and shields.

completely.

MIF

Safety

-

4

SPECIFICATIONS TABLE OF CONTENTS Table of Contents Specifications

Fastener Torques..............................................7 Metric Fastener Torque Values......................7 Inch Fastener Torque General Information..........................................9 Values........................ .8 Gasoline .................................. .......................9 G a s roal g ine S ........... . . t. o . . . . . . .e. .. .. .. .. .. .. .. .. .. .. .. 9 4 - Cycle Gasoline Engine Coolant Specifications...................................13 Oil......................10 B r e a k - eI n E n g i n e O i l 4 G -a Cs yo cl il n e . . Buck.............................15 ......10 Specifications - Trail Hydrostatic Transmission

and

Hydraulic Oil.11 Gear Case Oil............................. ..................12 Gear Transmission Grease........................ ..12 A l t e r n a t i tvse. . . . . . . . . . . . . . . . . .

L . . u. .b. .r . i . c. .a. n ......12 Synthetic Lubricants.................. ...................13 L u b rr ai c ant S . . t. o . . . . . g. .e. .. .. .. .. .. .. .. .. 1. .3. . . . . . . . . . . .

Mixing of Lubricants.................. ...................13 Oil Filters........................ ..............................13 Gasoline

Engine

C o o l a n t . . . . . . . . . . . . . S. .p. e. .c . i .f .i .c. a t i o n s T a b l e o f C o n t e n t s - 5 .......13

SPECIFICATIONS FASTENER TORQUES Fastener Torques Metric Fastener Torque Values 4.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

10

5 5

10

10

12.9 12

10

10

5

Property Class and Nut Marking s

12.9

8.8

12

Property Class and Head Marking s

12

MIF

Class

4.8Class

Lubricated SIZE

N•m

M6

4.8

M8

12

aDry

lb-ft

3.5

8.8

6

or

9.8Class

aLubricated

N•m

4.5

9

lb-ft

6.5

8.5

15

11

22

16

8.5 20

12.9

aDry

aLubricated

lb-ft

N•m

lb-ft

17

15

N•m

11

28

10.9Class

13

32

9.5

24

40

30

11.5

37

19

47

N•m

lb-ft

N•

14.5

35

17

29

21

43

32

55

40

63

M12

40

29

50

37

75

55

95

70

110

80

M14

63

47

80

60

120

150

110

175

M16

100

73

M18

135

100

175

M20

190

140

240

180

375

275

475

350

530

400

675

500

625

460

800

M 2 2

2 6 0

1 9 0

3 3 0

2 5 0

5 1 0

3 7 5

6 5 0

4 7 5

7 2 5

5 4 0

9 2 5

6 7 5

8 5 0

6 2 5

1 0 7 5

M24

330

250

425

310

650

475

825

600

925

675

1150

850

1075

800

13

M27

490

360

625

450

950

700

1200

1700

1250

1600

11

M30

675

490

850

625

1300

950

M33

900

675

1150

850

1750

1300

M36

1150

850

1450

1075

2250

these

hand

torque

DO

NOT

use

92

190

125

140

260

240

195

175

330

75

55

140

105

130

95

130

225

165

205

150

260

109

275

200

350

225

320

240

400

250

60

28

lb-ft

a

23

125

80

N•m

aLubricated

M10

88

47

12

aDry

375

875

1650

1350

1200

2200

1650

275

2850

values

if

a

165

350

1000

1350

2500

2100

70

475

1850

1650

95

440

2300

1850

3200

120

560

1700

3150

2350

different

325

torque

4

2150

2350

4050

300

290

3000

3

When

b

value or tightening procedure is given for a specific values shoul application. Torque values listed are for general use only head. a d oe t a a rr ri a e - ft ay cp teo rl o . cCkh e T ingdh ti n ec nl u to h e±d1 0o%r sv e an t ec d n cu kt s t it go h tt hn ee sf su lol f t o r q u e fasteners periodically. DO NOT use air powered wrenches. value.

Shear bolts are designed to fail under predetermined loads. a “Lubricated” means coated with a lubricant such as Always replace shear bolts with identical grade. engine oil, or fasteners with phosphate and oil coatings.

Fasteners should be replaced with the same grade. Make “Dry” me sure fastener threads are clean and that you properly start Specif thread engagement. This will prevent them from failing Reference: JDS - G200. when tightening.

Specifications

Fastener

Torques

-

7

SPECIFICATIONS FASTENER TORQUES Inch Fastener Torque Values 1 or 2b

SAE Grade and Head Markings

8

5.2

5.1

5

8.2

No Marks

5

2 SAE Grade and Nut Markings

8

No Marks

MIF

Grade

1Grade

Lubricated SIZE 1/4

3.7

5/16 3/8

14 22

9/16

lb-ft

36

5/8

67

3/4

120

87

7/8

190

140

1

50

7

9

15

25

18

16

27

20

35

26

44

33

35

53

45 62

150

9.5

20

31

85

lb-ft

11

20

60

N•m

15

22

39

N•m

44

67

5.5

32

50

55

N•m

13.5

10

28

21

26

50

36

35 63

lb-ft 17

80

58

100

75

63

110

80

120

90

150

115

125

90

155

115

175

130

225

70

105

78

135

100

170

125

215

160

215

190

140

240

175

300

225

375

280

140

240

175

490

360

lb-ft

N•

12.5

52

95

190

N•m

a

46

56

175

aLubricated

70

85

41

12

aDry

75

110

240

26

8.2

lb-ft

9

12

or

aLubricated

7.5

6

8

aDry

4.5

13

42

5.2Grade

3.5

17

25

or

lb-ft

7

28

5.1

N•m

10

16

48

4.7

5,

aLubricated

5.5

10

33

aDry

2.8

7.7

7/16 1/2

N•m

2bGrade

625

160

160 300

425

450

225

310

700

550

500

400

875

6

290

210

360

270

290

210

360

270

725

540

925

675

1050

750

1300

9

1-1/8

470

300

510

375

470

300

510

375

900

675

1150

850

1450

1075

1

1-1/4

570

425

725

530

570

425

725

530

1300

950

1-3/8

750

550

950

700

750

550

950

700

1700

1250

1-1/2

1000

725

1250

DO

NOT

use

these

925 hand

990

725

torque

1250

930

values

if

2250 a

1650

1200

2150

1650

different

2050

1550

2850

2700

2100

torque

150

20

3600

head.

v g thht ee d n i on rg spe rr or ca e dd u -r tey p i se gl io vcekn nf uo tr s at os pt eh cei ffi uc l l t o r q u e Ta i gl u h et e on r t toi o te application. Torque values listed are for general use only value. and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches.a “Lubric engine oil, or fasteners with phosphate and oil coatings.

Shear bolts are designed to fail under predetermined loads.

“Dry” means plain or zinc plated (yellow dichromate Always replace shear bolts with identical grade.

Specification JDS117) without any lubrication.

Fasteners should be replaced with the same grade. Make b “Grade 2” applies for hex cap screws (Not Hex Bolts) up sure fastener threads are clean and that you properly start to 152 mm (6 in.) long. “Grade 1” applies for hex cap thread engagement. This will prevent them from failing screws over 152 mm (6 in.) long, and for all other types of when tightening. bolts and screws of any length.

When bolt and nut combination fasteners are used, torque Reference: JDS - G200 values should be applied to the NUT instead of the bolt Specifications

Fastener

Torques

-

8

SPECIFICATIONS GENERAL INFORMATION General Information Gasoline 4 - Cycle Engines

c CAUTION: Avoid Injury! Gasoline is

MIF

HIGHLY FLAMMABLE, handle it with care.

DO NOT refuel machine while: indoors, always fill gas tank outdoors; machine is near an open flame or sparks; engine is running, STOP engine; engine is hot, allow it to cool sufficiently first; smoking.

Help prevent fires: fill gas tank to bottom of filler neck only; be sure fill cap is tight after fueling; clean up any gas spills IMMEDIATELY; keep machine clean and in good repair - free of excess grease, oil, debris, and faulty or damaged parts; any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling:•ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter.

IMPORTANT: Avoid damage! California Proposition 65 Warning: Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Gasoline Storage IMPORTANT: Avoid damage! Keep all dirt, scale, water or other foreign material out of gasoline.

Keep gasoline stored in a safe, pro gasoline in a clean, properly mark GASOLINE”) POLYETHYLENE PLASTI WITHOUT any metal screen or filte NOT use de-icers to attempt to rem or depend on fuel filters to remov Use a water separator installed in BE SURE to properly discard unsta gasoline. When storing the machin recommended that you add John D Conditioner and Stabilizer (TY1597 the gasoline. BE SURE to follow di and to properly discard empty con

To avoid engine damage: •DO

NOT

mix

oil

with

gasoline;

•ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher; •fill

gas

prevent tank; •keep

up

tank

at

the

end

condensation with

of

from

specified

each

day's

forming

service

operation

inside

a

to

help

partially

filled

intervals.

Use of alternative oxygenated, gasohol blended, unleaded gasoline is acceptable as long as: •the ethyl or grain alcohol blends DO NOT exceed 10% by volume or •methyl tertiary

butyl

ether

exceed 15% by volume RFG (reformulated) gasoline

(MTBE) is

blends

DO

NOT

acceptable

for

all

machines

designed for use of regular unleaded fuel. Older machines (that were designed for leaded fuel) may see some accelerated valve and seat wear.

Specifications

General

Information

-

9

SPECIFICATIONS GENERAL INFORMATION 4 - Cycle Gasoline Engine Oil

Break-In Engine Oil - 4-Cycle Gasoline

Use the appropriate oil viscosity based on the expected air ONLY use a quality t e m p e r a t u r e r a n g e d u r i n g t h e p e IMPORTANT: r i o d b e Avoid t w e damage! en in trebuilt or remanufactured r e c o m m e n d e d o i l c h a n g e s . O p e r a break-in t i n g oil ou side o f t h e s e engines 5 hours r e c o m m e n d e d o i l a i r t e m p e r a t u r efor rthe a nfirst ge s m (maximum) a y c a u sofeoperation. DO NOT use oils with heavier viscosity weights than premature engine failure.

SAE 5W-30 or oils meeting specifications API SG The following John Deere oils are P Rthese EFE Rwill R Enot D allow : or SH, oils rebuilt or remanufactured engines to break-in properly.

•PLUS - 4® - SAE 10W-40; •TORQ - GARD SUPREME® - SAE 5W-30.

The following John Deere oil is PR The following John Deere oils are also recommended, •BREAK - IN ENGINE OIL. based on their specified temperature range: John Deere BREAK - IN ENGINE OIL •TURF - GARD® - SAE 10W-30; special additives for aluminum an •PLUS - 4® - SAE 10W-30; to allow the power cylinder compo liners as well) to “wear-in” while p •TORQ - GARD SUPREME® - SAE 30. components, valve train and gears O t h e r o i l s m a y b e u s e d i f a b o v e EJ no gh inn eD er e eb r eu i ol d i l si nasr ter uncot ti o n s s h o u l d a v a i l a b l e , p r o v i d e d t h e y m e e t o nd ee t oe fr m t hi n e ef oi fl l o w ei n sp c iga l r e q u i r e m e n t s specifications: John Deere BREAK - IN ENGINE OIL • S A E 1 0 W - 4 0 - A P I S e r v i c e C l a s s ir fei cc oa m t im o ne sn dS eG d o fr o h r i ng oh ne -r J; o h n D e e r e d t ic oa ns t S iGr oonr thyi pg eh se. r ; • S A E 5 W - 3 0 - A P I S e r v i c e C l a s s i f ai n ca •SAE

10W-30

•SAE

30

-

API

-

API

Service

Service

C l a s s iThe f i cfollowing a t i o nJohn s SDeere G o oil r ishalso i g recommended: her;

GARD - SAE C l a s s i f i c a t•TORQ i o n -S C oSUPREME® r highe r . 5W-30.

If the above recommended John De available, use a break-in engine o specification during the first 5 ho operation:

SAE 10W-30

SAE 30 SAE 5W-30

SAE 10W-40

•SAE

5W-30

-

API

Service

Classific

IMPORTANT: Avoid damage! After the break-in period, use the John Deere oil that is recommended for this engine.

PREFERRED AIR TEMPERATURE MIF

Specifications

General

Information

-

10

5W30 or 10W30

SAE 5W-30

BREAK-IN OIL

JDM J20C

SPECIFICATIONS GENERAL INFORMATION

PREFERRED

PREFERRED

AIR TEMPERATURE

AIR TEMPERATURE MIF

MIF

Hydrostatic Transmission and Hydraulic Oil Use the appropriate oil viscosity based on these air temperature ranges. Operating outside of these recommended oil air temperature ranges may cause premature hydrostatic transmission or hydraulic system failures.

IMPORTANT: Avoid damage! Use only the oils recommended. HY-GARD® - JDM J20C can be mixed with 5W30 or 10W30 in this application.

Do not use LOW VISCOSITY HY - GARD® oil.

The following John Deere transmission and hydraulic oil is PREFERRED: •HY-GARD® - JDM J20C. The following John Deere oil is also recommended if above preferred oil is not available: •5W30 or 10W30.

Other oils may be used if above recommended John Deere oils are not available, provided they meet one of the following specifications: •John

Deere

Standard

JDM

J20C. Specifications

General

Information

-

11

SPECIFICATIONS GENERAL INFORMATION Gear Case Oil

Gear Transmission Grease

U s e t h e a p p r o p r i a t e o i l v i s c o s i t yU sb ea st ehde of o n l lt oh w e ia n igr g e a r g r e a s e b a s e t e m p e r a t u r e r a n g e s . O p e r a t i n g or ua tnsgi e d .e Oo pf e tr ha et si ne g o u t s i d e o f t h e r e r e c o m m e n d e d o i l a i r t e m p e r a t u r te e m r a pn egreast umr a e y r ac n ag u se e m a y c a u s e p r e m premature gear case failure. transmission failure.

IMPORTANT: Avoid damage! ONLY use a quality oil in this gear case. DO NOT mix any other oils in this gear case. DO NOT use BIO-HY-GARD® in this gear case.

The

following

•API

Service

LUBRICANT®

gear

-

cT ah s ee o R gE FJ Eo Rh Rn E D D e: e r e f oi ll l ios w Pi n

gear

gre

8 0• N WO- 9 . LAY HIGH-TEMPERATURE EP N 0- C JDM J13E4, NLGI Grade 2.

The following John Deere gear case oil is also r e c o m m e n d e d i f a b o v e p r e f e r r e d Oot ihl e irs gnr oe ta sa ev sa i m l aaby l eb: e u s e d i f a b o v grease is not available, provided t •GL-5 GEAR LUBRICANT® - SAE 85W-140. specification: Other gear case oils may be used if above recommended d tJ hDeMy J 1 3 E 4 , N J o h n D e e r e g e a r c a s e o i l s a r e n o• tJ oa hv n aiD l aebel ree, S p tr a on v idda er d meet the following specification: Classification

SAE

GL

-

5.

JDM J13E4 NLGI Grade 2

GEAR

Deere

SAE 80W-90

SAE 85W-140

•GL-5

John

IMPORTANT: Avoid damage! ONLY use a quality gear grease in this transmission. DO NOT mix any other greases in this transmission. DO NOT use any BIO - GREASE in this transmission.

AIR TEMPERATURE

PREFERRED

MIF

AIR TEMPERATURE MIF

Alternative Lubricants Use of alternative lubricants could cause reduced life of the component.

If

alternative

lubricants

to

be

is

used,

it

are

recommended tt h a t tuhge h fl a ctory fill be sh w oi tr co h ing y removed before S p e c i f i c a t i otno s aGn ey n ae lr tael r Inna ftoi rv m 1 2t . e al tu ibo rni c-a n

SPECIFICATIONS COOLANT SPECIFICATIONS Synthetic Lubricants

Coolant Specifications

Synthetic lubricants may be used in John Deere equipment if they meet the applicable perfo r m a n Engine ce req uirements Gasoline Coolant (industry classification and/or military specification) as The engine cooling system when fi shown in this manual. dilution mixture of anti-freeze and The recommended air temperatuw r ea tl e im r nd protect r ipt rs o av n i dd e s e yr ev ai cr e -rou ea r i on rt al i n e d r pa is t ts ihnogw, na n d w i n t e l u b r i c a n t c h a n g e i n t e r v a l s s h o u lcdy lbi n e dm - 3 s4 t° aFt) e. d o n i n t h e o p e r a t o r ’ s m a n u a l , u n l e s st o o t -h3e7r°wC i s( e lubricant label.

The following John Deere coolant i Avoid mixing different brands, grades, or types of oil. Oil •COOL-GARD® PRE-DILUTED SUMMER COOLANT manufacturers blend additives in their oils to meet certain (TY16036). specifications and performance requirements. Mixing co l ae nr t f u s an tci tsi foi n e is n sgp o e fc i f i c a t i o n d i f f e r e n t o i l s c a n i n t e r f e r e w i t h T thhi es p r oo p L i g h t D u t y E n g i n e S e r v i c e” and is these additives and degrade lubricant performance.

Deere Lawn and Grounds Care/Golf equipment, including aluminum bl cooling systems.

Lubricant Storage

T iheen c a yb oovnel yp rwehf e en rre pn re-diluted an All machines operate at top effic cd lea l u b r i c a n t s a r e u s e d . U s e c l e a n s t• a od r ae gq eu actoen h t ae iant e tr rs a tnos f e r handle all lubricants. Store them in an area protected from • ci on rartoi so ino. n S- tr o e sr e i s td ar n dust, moisture, and other contam u tm cs hoe nm i c a l s f o r t h e i r s i d e s . M a k e s u r e a l l c o n t a i •nc eo rm s paar tei bpi rl o ao r ko el idn g s y s t e m i tpye rwl iyt hm c as to their contents. Dispose of all old, used containers and •protection during extreme cold an their contents properly. operations •chemically

Mixing of Lubricants

pure

water

for

better

s

•compliance with ASTM D4656 (JDM i cdas t ioor n ts y p e s o f I n g e n e r a l , a v o i d m i x i n g d i f f e r e ns tp ebcr iaf n lubricants. Manufacturers blend additives in their lubricants If above preferred pre-diluted coo to meet certain specifications and performance following John Deere concentrate requirements. Mixing different lubricants can interfere with t h e p r o p e r f u n c t i o n i n g o f t h e s e •COOL-GARD® a d d i t i v e sCONCENTRATED a n d l u b r SUMMER icant p r o p e r t i e s w h i c h w i l l d o w n g r a d eCOOLANT t h e i r CONCENTRATE™ i n t e n d e d (TY16034). specified performance.

If either of above recommended en available use any Automobile and Service ethylene glycol base coola specification: •ASTM D4985 (JDM H24A2).

Oil Filters IMPORTANT: Avoid damage! Filtration of oils is critical to proper lubrication performance.

Always change filters regularly.

The

following

•AUTOMOTIVE FILTERS. Most

John

John AND

Deere

Deere LIGHT

filters

Read container instructions as oil

filters

TRUCK

ENGINE

PREFERRED: OIL and

anti-

drainback valves for better engine protection.

Other oil filters may be used if above recommended

John

Deere oil filters are not following specification: •ASTB

Tested

In

contain

are

label completely stated.

pressure

available,

Accordance

With

provided

SAE

Specifications

relief

they

meet

the

J806.

Coolant

Specifications

-

13

be

SPECIFICATIONS COOLANT SPECIFICATIONS IMPORTANT: Avoid damage! To prevent engine damage, DO NOT use pure anti-freeze or less than a 50% anti-freeze mixture in the cooling system. DO NOT mix or add any additives/ conditioners to the cooling system in Lawn and Grounds Care/Golf and Turf Division equipment.

Water used to dilute engine coolant concentrate must be of high quality - clean, clear, potable water (low in chloride and hardness - Table 1) is generally acceptable. DO NOT use salt water.

Deionized or distilled water is ideal to use.

Coolant that is not mixed to these specified levels and water purity can cause excessive scale, sludge deposits, and increased corrosion potential.

Property

Requi rements

Total

Solids,

Total

Hardness,

Chloride Sulfate

(as

(as

Maximum340

ppm

(20

grns/gal)

Maximum170

ppm

(10

Maximum40

ppm

(2.5

Cl),

SO4),

Maximum100

ppm

grns/gal) grns/gal)

(5.8

grns/gal)

Mix 50 percent anti-freeze concentrate with 50 percent distilled or deionized water. This mixture and the pre-diluted mixture (TY16036) will protect the cooling system down to 37°C (-34°F) and up to 108°C (226°F).

Certain geographical areas may require lower air temperature protection. See the label on your anti-freeze container or consult your John Deere dealer to obtain the latest information and recommendations.

Gasoline Engine Coolant Drain Interval When using John Deere Pre-Diluted (TY16036) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 36 months or 3,000 hours of operation, whichever comes first.

When using John Deere Concentrate (TY16034) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 24 months or 2,000 hours of operation, whichever comes first.

If above John Deere Automobile and Light Duty Engine Service coolants are not being used; drain, flush, and refill the cooling system according to instructions found on product container or in equipment operator’s manual or technical manual.

Specifications

Coolant

Specifications

-

14

SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Specifications - Trail Buck Engine Specifications - 500 Stroke (500 cc Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 mm (2.5 in.) Displacement (500 cc Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498 cc (30.4 cu in.) Horsepower @ 7200 rpm (500 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.6 kW (37 hp)

Engine Specifications - 650 Stroke (650 cc Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 mm (3.2 in.) Displacement (650 cc Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644 cc (39.3 cu in.) Horsepower @ 7100 rpm (650 cc Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 kW (42hp)

Engine Specifications - 500 and 650 General Specifications Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotax 4-TEC, 4 stroke Over Head Camshaft (OHC), Liquid cooled Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric with Optional Recoil Number of Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Number of Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 valves Decompressor Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Bore (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm (3.9 in.)

Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5:1 Maximum HP RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7000 ± 100 rpm Lubrication . . . . . . . . Wet sump with replaceable oil filter (lubrication of engine and transmission simultaneously) Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow Air Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 stage foam filter Exhaust System Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nelson, stainless steel Exhaust System Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .USDA approved Valves Intake Valve Opening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.0° BTDC Intake Valve Closing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.0° ABDC Exhaust Valve Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.0° BBDC Exhaust Valve Closing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.0° ATDC Intake Valve Stem Diameter (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.961 mm (0.2347 in.)

Intake Valve Stem Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.975 mm (0.2352 in.)

Intake Valve Stem Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.930 mm (0.2330 in.)

Exhaust Valve Stem Diameter (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.946 mm (0.2341 in.)

Exhaust Valve Stem Diameter (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.960 mm (0.2346 in.)

Exhaust Valve Stem Diameter (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.930 mm (0.2330 in.)

Valve Guide Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.060 mm (0.2386 in.)

Valve Spring Free Length (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.45 mm (1.789 in.)

Valve Spring Free Length (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.00 mm (1.693 in.)

Intake Valve Seat Contact Width (New). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 to 1.30 mm (0.043 to 0.0051 in.)

Intake Valve Seat Contact Width (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 mm (0.07 in.)

Exhaust Valve Seat Contact Width (New). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 to 1.55 mm (0.049 to 0.061 in.)

Exhaust Valve Seat Contact Width (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.078 in.)

Specifications

Specifications

-

Trail

Buck

-

15

SPECIFICATIONS SPECIFICATIONS - TRAIL BUCK Pistons Piston Measurement (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.951 to 99.969 mm (3.935 to 3.936 in.)

Piston Measurement (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.80 mm (3.929 in.)

Piston/Cylinder Clearance (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.031 to 0.059 mm (0.001 to 0.002 in.)

Piston/Cylinder Clearance (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 mm (0.004 in.)

Piston Ring Type 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rectangular Piston Ring Type 2nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taper-face Piston Ring Type 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Scraper Ring Piston Ring End Gap Rectangular (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

Piston Ring End Gap Taper-face (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

Piston Ring End Gap Oil Scraper Ring (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

Piston Ring End Gap Rectangular (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)

Piston Ring End Gap Taper-face (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)

Piston Ring End Gap Oil Scraper Ring (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)

Piston Ring End Gap All (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in.)

Piston/Ring Groove Clearance Rectangular (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 mm (0.001 in.)

Piston/Ring Groove Clearance Taper-face (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in.)

Piston/Ring Groove Clearance Oil Scraper Ring (New minimum). . . . . . . . . . . . . . . . . . . . . . . . 0.020 mm (0.0008 in.)

Piston/Ring Groove Clearance Rectangular (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070 mm (0.0028 in.)

Piston/Ring Groove Clearance Taper-face (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 mm (0.0024 in.)

Piston/Ring Groove Clearance Oil Scraper Ring (New maximum) . . . . . . . . . . . . . . . . . . . . . . . 0.055 mm (0.0021 in.)

Rocker Arm Rocker Arm Bore Diameter (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.007 mm (0.7877 in.)

Rocker Arm Bore Diameter (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.020 mm (0.7881 in.)

Rocker Arm Bore Diameter (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.035 mm (0.7887 in.)

Rocker Arm Shaft Diameter (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.980 mm (0.7866 in.)

Rocker Arm Shaft Diameter (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.007 mm (0.7877 in.)

Rocker Arm Shaft Diameter (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.965 mm (0.7860 in.)

Cylinder Cylinder Screw M11 (Service limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.5 mm (8.524 in.)

Cylinder Bore (New). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.00 mm (3.94 in.)

Cylinder Taper (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.)

Cylinder Taper (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 mm (0.004 in.)

Cylinder Out of Round (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 mm (0.0004 in.)

Cylinder Out of Round (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.)

Camshaft and Cam Camshaft Bearing Journal PTO Side (New minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.967 mm (0.9829 in.)

Camshaft Bearing Journal PTO Side (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.980 mm (0.9835 in.)

Camshaft Bearing Journal PTO Side (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.960 mm (0.9827 in.)

Camshaft Bearing Journal Magneto Side (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.927 mm (1.5719 in.)

Camshaft Bearing Journal Magneto Side (New maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.935 mm (1.5722 in.)

Camshaft Bearing Journal Magneto Side (Wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.920 mm (1.5716 in.)

Camshaft Bore PTO Side (New minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.987 mm (0.9837 in.)

Camshaft Bore PTO Side (New maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.000 mm (0.9842 in.)

Camshaft Bore PTO Side (Wear limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.020 mm (0.9850 in.)

Specifications

Specifications

-

Trail

Buck

-

16

For the full PDF version of this manual, Please click on the above download PDF button.