Toro 500 EFI Service Manual
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Toro 500 EFI Service Manual

Side by side off road utility vehicle
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LCE/Residential Products
Side By Side Off Road Utility Vehicle
500 EFI & 700 EFI
Service Manual

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Summary of Contents for Toro 500 EFI

  • Page 1 LCE/Residential Products Side By Side Off Road Utility Vehicle 500 EFI & 700 EFI Service Manual...
  • Page 2 At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Toro- Exmark constantly refines and improves its products, no retroactive obligation is incurred.

  • Page 3: Table Of Contents

    Table of Contents General Information ............2 Fuel/Lubrication/Cooling..........118 General Specifications............2 Throttle Body ..............118 Torque Specifications ............3 Gas Tank ................. 119 Torque Conversions (ft-lb/N-m)..........5 Gas/Vent Hoses .............. 121 Gasoline - Oil - Lubricant.............5 Oil Filter/Oil Pump ............121 Genuine Parts..............6 Liquid Cooling System ............

  • Page 4: General Information

    1.9 L (2.0 U.S. qt) - Change Piston Pin Outside Diameter (min) 22.99 mm Gasoline (recommended) 87 Octane Regular Unleaded VALVES AND GUIDES (500) Engine Oil (recommended) Toro ACX All Weather Syn- Valve Face Diameter (intake) 35.0 mm thetic (exhaust) 30.5 mm Front Differential/Rear Drive Lubricant...

  • Page 5: Torque Specifications

    DRIVE TRAIN COMPONENTS CRANKSHAFT (500) Torque Connecting Rod (small end) (max) 20.021 mm Part Part Bolted To ft-lb N-m Connecting Rod (big end side-to-side) 0.7 mm (max) Rear Differential/Gear Case Frame Connecting Rod (big end width) 21.95-22.00 mm Front Engine Mounting Frame Bracket Connecting Rod (small end deflection)
  • Page 6 ENGINE/TRANSMISSION (700) ENGINE/TRANSMISSION (500) Torque Torque Part Part Bolted To Part Part Bolted To ft-lb N-m ft-lb Clutch Shoe** Crankshaft 221 300 Clutch Shoe** Crankshaft Clutch Cover/Housing Assem- Crankcase Clutch Cover/Housing Assembly Crankcase Crankcase Half (6 mm) Crankcase Half 13.5 Crankcase Half (6 mm) Crankcase Half 13.5...

  • Page 7: Torque Conversions (Ft-Lb/N-M)

    The recommended oil to use is Toro 0W-40 All Weather synthetic engine oil, which has been specifically formu- Torque Conversions lated for use in this engine. Although Toro 0W-40 All (ft-lb/N-m) Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 0W-40 synthetic oil is acceptable.

  • Page 8: Genuine Parts

    When replacement of parts is necessary, use only genuine cables, and store in a clean, dry area. Toro parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Man- ...

  • Page 9: Periodic Maintenance

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil. When using Toro 0W-40 All Weather synthetic oil, oil change interval can be increased to every 1600 km (1,000) miles or every year.

  • Page 10: Lubrication Points

    Lubrication Points Air Filter It is advisable to lubricate certain components periodi- CAUTION cally to ensure free movement. Apply light oil to the Failure to inspect the air filter frequently if the vehicle is components using the following list as reference. used in dusty, wet, or muddy conditions can damage A.

  • Page 11: Valve/Tappet Clearance

    8. Squeeze the element to remove excess oil. 2. Rotate the crankshaft to the TDC position on the compression stroke. CAUTION  NOTE: At this point, the rocker arms and adjuster A torn air filter can cause damage to the engine. Dirt and screws must not have pressure on them.

  • Page 12: Testing Engine Compression

    3. Install the spark plug; then install the timing inspec- tion plug. Spark Plug 4. Place the two tappet covers with O-rings into posi- tion. Tighten the cap screws to 8 ft-lb. A light brown insulator indicates that the plug is correct. A white or dark insulator indicates that the engine may need to be serviced.

  • Page 13: Engine/Transmission Oil - Filter

    HDX238A HDX242 2. Remove the muffler by pulling it rearward out of the  NOTE: If the screen or gasket is damaged in any vehicle. way, it must be replaced. 3. Remove the heat shield. 6. Install the exhaust pipe/spark arrester assembly and secure with the three cap screws.

  • Page 14: Front Differential - Rear Drive Lubricant

    7. Install the engine drain plug and tighten to 22 N-m (16 ft-lb). Pour the recommended oil in the fill hole (700) or oil level stick opening (500). Install the oil fill cap (700) or the oil level stick (500). 8.

  • Page 15: Driveshaft/Coupling

    3. Drain the lubricant into a drain pan by removing the drain plug from the front differential and rear drive. Headlight/Taillight- Brakelight HEADLIGHT  NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb.

  • Page 16: Shift Lever

    2. Shift the transmission into park and observe that the (P) illuminates on the LCD gauge. ADJUSTING SHIFT CABLE 1. Place the transmission in park; then tilt the cargo box. 2. Make sure the shift lever is in park; then remove the E-clip securing the cable end to the shift arm stud.

  • Page 17: Hydraulic Brake System

    REAR 700 Hydraulic Brake System  NOTE: This ROV is equipped with hydraulic brakes at all four wheels. CHECKING/BLEEDING The hydraulic brake system has been filled and bled at the factory. 1. With the master cylinder in a level position, check the fluid level in the reservoir.

  • Page 18: Burnishing Brake Pads

    CHECKING/REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thick- ness of each of the brake pads as follows. 1.

  • Page 19: Checking/Replacing V-Belt

    1. Choose an area large enough to safely accelerate the vehicle to 30 mph and to brake to a stop. 2. Accelerate to 30 mph; then depress the brake pedal to decelerate to 0-5 mph. 3. Repeat procedure 20 times until brake pads are bur- nished.
  • Page 20 GZ085 CF379   NOTE: The arrows on the V-belt should point in NOTE: At this point, the CVT cover cap screw can direction of engine rotation (forward). be removed. 2. Pinch the V-belt together near its center and slide the 3.

  • Page 21: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full- right capability. C. Steering assembly mounting bolts tight. HDX131A D. Ball joints not worn, cracked, or damaged. E.

  • Page 22: Steering Assembly

    PR784 PR785A 4. While holding the rack shaft with a wrench, tighten the tie rod joint to 37 ft-lb using an appropriate crow- Steering Assembly foot. REMOVING 1. Remove the right front wheel. 2. Remove the cotter pins and nuts securing the tie rod ends to the knuckles;...

  • Page 23: Upper Steering Shaft

    PR785 PR764A 4. Check boot clamps for security. 5. Check that the steering assembly operates smoothly with no binding from full-left to full-right position. 6. Inspect for grease seepage from the steering assembly.  NOTE: The steering assembly (rack and pinion) is not repairable and must be replaced as an assembly;...

  • Page 24: Intermediate Steering Shaft Assembly

    PR764B PR759B 3. Install the cap screw in the intermediate shaft coupler 2. Install the steering shaft housing with steering shaft and tighten to 31 ft-lb. connecting the steering shaft and intermediate shaft first; then slide the housing into place on the steering support.

  • Page 25: Steering Knuckles

    2. Inspect the bearing for pits, scoring, rusting, or pre- mature wear. Steering Knuckles 3. Inspect the knuckle for cracks, breaks, or galling of the bearing surface. REMOVING AND DISASSEMBLING ASSEMBLING AND INSTALLING 1. Secure the vehicle on a support stand to elevate the 1.
  • Page 26 PR203 PR256 3. Install the tie rod end and secure with the nut (coated 7. Install a new cotter pin and secure by spreading as with red Loctite #271). Tighten to 30 ft-lb; then shown. install a new cotter pin and spread the pin. ...

  • Page 27: Accelerator Pedal

    Accelerator Pedal REMOVING Dislodge the throttle cable holding grommet from the actuator arm; then remove two torx-head screws and nuts securing the accelerator pedal assembly to the splash panel and remove the accelerator pedal. HDX166A PR709 HDX168A INSTALLING 1. Install the shift axle supports onto the shift lever; then secure the axle supports to the frame with four cap screws and tighten to 48 in.-lb.

  • Page 28: Lcd Gauge

    2. Remove the nut securing the shift cable to the shift arm stud; then loosen the upper adjuster nut on the shift cable and remove the shift cable from the shifter assembly. HDX132A INSTALLING 1. Route the cable into position making sure there are no kinks or sharp bends.

  • Page 29: Checking/Adjusting Front Wheel Alignment

    10. Install the steering wheel boot support. PR762A 3. Remove the six screws securing the dash panel to the PR762A frame; then remove the shifter handle and shift lever 11. Install the steering boot onto the boot support. boot. 12. Install the steering wheel; then with a drop of red 4.

  • Page 30: Front Bumper Assembly

    PR087A PR086 To adjust the wheel alignment, use the following proce- dure. Front Bumper Assembly 1. Center the steering wheel; then using an open-end wrench to hold the tie rod ends, loosen the right-side and left-side jam nuts. REMOVING Remove four cap screws and nuts. Account for four lock washers and eight flat washers.

  • Page 31: Fenders

    Fenders REMOVING Remove three torx-head screws securing each fender to the frame. Account for a stiffener bracket on the front fenders. PR332A 3. Finish removing the cap screws and flange nuts (from step 2); then remove the hood assembly. CLEANING AND INSPECTING 1.

  • Page 32: Dashboard

    TC045A PR163 3. Remove the six sheet metal and three machine  NOTE: To aid in removing, insert a small wood screws securing the dash assembly to the frame; block to hold in position. then remove the shift lever grip and locking nut. 4.

  • Page 33: Exhaust System

    Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muffler/ exhaust pipe juncture. HDX257 2. Loosen but do not remove the four shoulder cap screws securing the pivot housings to the cargo box. PR131 2. Slide the muffler assembly clear of the holder pins. INSPECTING MUFFLER 1.

  • Page 34: Taillight Assembly

    INSTALLING Taillight Assembly 1. Install the new bulb in the socket and place the socket assembly into the taillight housing. Twist clockwise to lock. REMOVING 2. Connect the wire connector; then install on the ROPS tube and secure with two cap screws and lock 1.

  • Page 35: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Steering shaft binding 2. Lubricate/replace steering shaft 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 36: Engine/Transmission

    “break-in” period. The first 10 hours (or 200 This section has been organized into sub-sections which miles) are most critical to the life of this ROV. Proper show a progression for the complete servicing of the Toro operation during this break-in period will help assure ROV engine/transmission.

  • Page 37: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace guides 3. Valves mistimed 3. Retime engine 4. Piston rings worn - broken 4.
  • Page 38 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 39: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service/replace right- HDX138A side cover oil seals, front output joint oil seal, rear out- 6.
  • Page 40 8. Loosen the clamp securing the throttle body to the intake manifold boot; then remove the throttle body and set aside. 9. From the left side, disconnect the ECT sensor con- nector, speed sensor connector, and spark plug cap. HDX251 ...
  • Page 41 15. Remove the two exhaust springs at the muffler; then remove the exhaust pipe. Account for a grafoil seal in the cylinder head and a grafoil seal at the muffler. HDX147A 13. Remove the forward heat shield from the exhaust pipe;...

  • Page 42: Servicing Engine (500)

    Servicing Engine (500) ter of the compression stroke.  NOTE: Toro recommends the use of new gaskets, lock nuts, and seals and lubricating all internal com- Top-Side Components ............40 ponents when servicing the engine/transmission.
  • Page 43 FI606A FI612 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1354A 3. Remove the cap screw from the tension adjuster; then using a flat-blade screwdriver, relax the cam FI613 chain tension by rotating the adjuster screw clock- ...
  • Page 44 FI620 FI618A FI617A FI619A 7. Remove the cam chain tensioner pivot bolt and 8. Remove the four cylinder head cap screws and wash- remove the chain tensioner; then remove the two ers. Note that the two cap screws on the right side of nuts securing the cylinder head to the cylinder.
  • Page 45 12. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. FI623A AT THIS POINT  To service valves and cylinder head, see Servicing Top- FI624A Side Components sub-section.

  • Page 46: Servicing Top-Side Components

     NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install a connect- ing rod holder. CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result.
  • Page 47 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Toro recommends that the components be taken to a qualified machine shop for servicing. CAUTION CC132D If valves are discolored or pitted or if the seating sur- PISTON ASSEMBLY face is worn, the valve must be replaced.
  • Page 48 CC400D ATV-1070 2. Remove each ring by working it toward the top of 2. Inspect and measure the connecting rod small end the piston while rotating it out of the groove. inside diameter. If the measurement exceeds specifi- cations, the connecting rod must be replaced (see ...
  • Page 49 Installing Piston Rings Cleaning/Inspecting Cylinder Head CAUTION 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the The cylinder head studs must be removed for this pro- expander making sure the expander ends do not cedure.
  • Page 50  3. Place the cylinder on the surface plate covered with NOTE: To produce the proper 60° cross-hatch pat- #400 grit wet-or-dry sandpaper. Using light pressure, tern, use a low RPM drill (600 RPM) at the rate of 30 move the cylinder in a figure eight motion. Inspect strokes per minute.

  • Page 51: Installing Top-Side Components

    ATV1013A CF060A 2. The lobe heights must be greater than minimum 2. If damaged, the camshaft must be replaced. specifications. Inspecting Camshaft Bearing Installing Top-Side Journal Components 1. Inspect the bearing journal for scoring, seizure marks, or pitting. A. Piston 2.
  • Page 52 C. Cylinder Head/Camshaft D. Cylinder Head Cover/Rocker Arms  NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
  • Page 53 10. With the timing inspection plug removed and the cam chain held tight, rotate the crankshaft until the piston is at top-dead-center. 11. While holding the cam chain to the front, install the rear cam chain tensioner guide into the cylinder head. Install the pivot cap screw and washer.
  • Page 54 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed down- wards. 21. Place the cam chain tensioner assembly and gasket into the cylinder. Tighten to 10 ft-lb. 22. Using a flat-blade screwdriver, turn the tensioner screw counterclockwise to apply tension to the cam chain;...

  • Page 55: Left-Side Components

    FI602 FI538 29. Install the spark plug and tighten securely; then 2. Remove the water pump housing assembly noting install the timing inspection plug. the location of the longer cap screw. Account for a gasket and two alignment pins. Left-Side Components ...
  • Page 56 4. Remove the water pump drive gear; then remove the 8. Using the Magneto Rotor Remover Set, break the speed sensor housing assembly. Account for two rotor/flywheel loose from the crankshaft; then alignment pins, a gasket, and two seal washers. remove the puller and crankshaft protector and remove the rotor/flywheel.

  • Page 57: Servicing Left-Side Components

    Servicing Left-Side Components INSPECTING STARTER CLUTCH/ GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clock- wise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. FI559 If it moves or locks up both ways, the starter clutch 12.
  • Page 58 FI570 FI583 2. Thoroughly clean the rotor/flywheel; then install the 2. Thoroughly clean the gear hub; then apply a drop of new clutch and secure with the cap screws after green Loctite #620 to the bearing outer race and applying a drop of red Loctite #271 to the threads. press into the gear hub until even with the lower Tighten to 26 ft-lb using a crisscross pattern.

  • Page 59: Installing Left-Side Components

    REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sen- sor, and one cap screw from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor.
  • Page 60 MD1122 FI555A 2. Install the starter motor and tighten the two cap 7. Install the starter clutch gear onto the crankshaft; screws to 8 ft-lb. then install the rotor/flywheel key in the crankshaft. 3. Install the shift detent cam making sure the washer is installed.

  • Page 61: Right-Side Components

    13. Connect the coolant hoses to the water pump and secure with the hose clamps. Tighten securely. Right-Side Components AT THIS POINT  To service center crankcase components only, proceed to Removing Right-Side Components.  NOTE: For efficiency, it is preferable to remove and FI547 disassemble only those components which need to 11.
  • Page 62 KC142A MD1036 3. Mark the movable drive face and the fixed drive face 5. Using a 6 mm cap screw threaded into the fixed for installing purposes; then remove the nut holding driven face, spread the driven pulley by turning the the movable drive face onto the crankshaft.
  • Page 63 8. Using an impact screwdriver, remove the three Phil- lips-head cap screws holding the air intake plate. Remove the air intake plate. MD1286 12. Remove the left-hand threaded nut holding the cen- trifugal clutch assembly. MD1092 CAUTION 9. Remove the cap screws holding the clutch cover onto Care must be taken when removing the nut;...
  • Page 64  NOTE: Always use a new snap ring when installing the oil pump driven gear. 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. FI630 14. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT ...

  • Page 65: Servicing Right-Side Components

    KC330 MD1208 2. Place the clutch housing onto the clutch shoe/one-way AT THIS POINT  clutch. To service center crankcase components only, proceed  NOTE: It will be necessary to rotate the clutch hous- to Separating Crankcase Halves. ing counterclockwise to properly seat the one-way clutch.

  • Page 66: Installing Right-Side Components

    DRIVEN PULLEY ASSEMBLY  NOTE: The driven pulley assembly is a non-service- able component and must be replaced as a complete assembly. Installing Right-Side Components A. Oil Strainer/Oil Pump MD1060 4. Place the thrust washer and drive pin into position on 1.
  • Page 67 9. Install two alignment pins and place the clutch cover gasket into position. Install the clutch cover. MD1017 MD1115 10. Tighten the clutch cover cap screws to 8 ft-lb. MD1018 7. Install the clutch shoe assembly on the crankshaft; then install the flange nut (left-hand thread) (coated with red Loctite #271).
  • Page 68 MD1068 KC127 16. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft pro- trude through the cover plate, secure with the nut and tighten to 147 ft-lb. KC134 13. Slide the fixed drive face assembly onto the front shaft.

  • Page 69: Center Crankcase Components

    KC142A MD1012 19. If removed, install the brake pedal and tighten to 25 2. Using Crankcase Separator/Crankshaft Remover and ft-lb. tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins. Center Crankcase Components  NOTE: This procedure cannot be done with the engine/transmission in the frame.
  • Page 70 FI639A FI641A 1. Remove the secondary driven shaft assembly (A) 3. Remove the driveshaft (C); then pull the shift fork locat- noting the location of the front and rear bearing ing shaft (D) out of the crankcase locating boss and locating pins and the center bearing locating ring.

  • Page 71: Servicing Center Crankcase Components

    5. Remove the countershaft assembly (E) along with 8. Remove the secondary drive gear/secondary driven gear the shift fork assembly. retaining nut. From inside the crankcase using a rubber mallet, drive out the output shaft assembly. Account for the output shaft, a shim, a washer, and the nut. AT THIS POINT ...
  • Page 72 Checking Tooth Contact Correcting Tooth Contact   NOTE: After correcting backlash of the secondary NOTE: If tooth contact pattern is comparable to the driven bevel gear, it is necessary to check tooth con- correct pattern illustration, no correction is neces- tact.
  • Page 73 Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. H1-006 2. Acceptable width range must be within specifica- tions.
  • Page 74 FI665 FI669 3. Remove the low driven gear washer; then remove the 5. Remove the circlip securing the high driven gear; low driven gear along with the bearing and bushing. then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer.
  • Page 75 FI671A FI666 4. Place the reverse driven bushing (13) onto the shaft; then install the bearing (14), gear (15), and splined washer (16). Secure with a snap-ring. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7); then install the splined washer (8).

  • Page 76: Assembling Crankcase Half

    FI662 MD1333 3. Apply a liberal amount of oil to the crankshaft bear-  NOTE: The countershaft assembly is now ready to ing. Using a propane torch, heat the bearing until the be installed. oil begins to smoke; then slide the crankshaft assem- bly into place.
  • Page 77 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase. FI658 6. Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end, install in the crankcase.

  • Page 78: Joining Crankcase Halves

    Joining Crankcase Halves 1. Verify that the two alignment pins (A) are in place and that both case halves are clean and grease free. Apply Loctite #5900 or suitable substitute sealant to the mating surfaces. Place the right-side half onto the left-side half.

  • Page 79: Servicing Engine (700)

    Servicing Engine (700) Top-Side Components ..........77 Removing Top-Side Components ........77 Servicing Top-Side Components .........81 Installing Top-Side Components........86 Left-Side Components..........91 Removing Left-Side Components .......91 Servicing Left-Side Components.........93 Installing Left-Side Components .........95 Right-Side Components ..........98 MD1008 Removing Right-Side Components ......98 4. From the left side, install the remaining crankcase Servicing Right-Side Components ......101 cap screws;...

  • Page 80: Note: Keep The Mounting Hardware With The Covers

    CC001D CD211A 5. Loosen the cap screw on the end of the tensioner;  NOTE: Keep the mounting hardware with the covers then remove the two cap screws securing the ten- for assembly purposes or thread them back into the sioner adjuster assembly and remove the assembly.
  • Page 81 CC017D CC013D 8. While holding the chain, slide the sprocket and camshaft out of the cylinder head.  NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. CC018D 11. Remove the four cylinder head bolts. 12.
  • Page 82 CC022D CC025D C. Cylinder D. Piston  NOTE: Steps 1-12 in the preceding sub-section must precede this procedure. 13. Loosen the clamp securing the coolant hose to the union; then detach the hose. 14. Remove the two nuts securing the cylinder to the crank- case.

  • Page 83: Servicing Top-Side Components

    2. Place the valve cover on a surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 84 3. If a valve guide is out of tolerance, it must be replaced. Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Toro recommends that the components be taken to a qualified machine shop for servicing. CC132D CAUTION PISTON ASSEMBLY If valves are discolored or pitted or if the seating sur- ...
  • Page 85 CC400D ATV-1070 2. Remove each ring by working it toward the dome of 2. Insert an inside dial indicator into the piston-pin the piston while rotating it out of the groove. bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. ...
  • Page 86 Cleaning/Inspecting Cylinder Head CAUTION The cylinder head studs must be removed for this pro- cedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the com- bustion chamber or the sealing surface.
  • Page 87 Inspecting Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements.

  • Page 88: Installing Top-Side Components

    CC283D CF061A 2. Rotate the camshaft and note runout; maximum runout must not exceed specifications. Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height. CF060A 2. If damaged, the camshaft must be replaced. Installing Top-Side Components ATV1013A 2.
  • Page 89 C. Cylinder Head D. Valve Cover  NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 6. Place the chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. CF083 3.
  • Page 90 15. With the cam lobes directed down (toward the pis- ton), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket.  NOTE: Note the position of the alignment marks on the end of the camshaft.
  • Page 91 ATV1027 CD466 21. Place the C-ring into position in its groove in the cyl- CAUTION inder head. Care must be taken that the tab-washer is installed cor- rectly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result.
  • Page 92 CD501 CD471 26. Loosen the four adjuster screw jam nuts; then loosen  NOTE: The adjuster shaft will be drawn into the ten- the four adjuster screws on the rocker arms in the sioner as the adjuster screw is rotated clockwise. The valve cover.

  • Page 93: Left-Side Components

    Removing Left-Side Components A. Outer Magneto Cover B. Water Pump C. Cover D. Rotor/Flywheel 1. Remove the four cap screws securing the outer mag- neto cover to the left-side cover; then remove the CC003D outer magneto cover. 30. In a crisscross pattern starting from the center and 2.
  • Page 94 7. Using an appropriate side case puller, remove the side cover. Account for a gasket and two alignment pins. 8. Remove the nut securing the magneto rotor to the crankshaft; then install the magneto rotor puller adapter.  NOTE: The puller has left-hand threads. 9.

  • Page 95: Servicing Left-Side Components

     NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase. 13.
  • Page 96 FI576A FI580 INSPECTING STATOR COIL/ MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wir- ing, broken or missing hold-down clips, or loose cap screws. 2. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in bearing bores.

  • Page 97: Installing Left-Side Components

    FI595A CD949  NOTE: The sharp side of the snap ring should be facing outward. Installing Left-Side Components 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing out- ward as noted in removing);...
  • Page 98 CD139 PR433A PR447A CD934 4. In order on the crankshaft, install a washer, ring gear, 6. Install the shift cam stopper, spring, and two washers key, and the magneto rotor. Secure with the nut (thick washer closest to the nut); then coat the (coated with red Loctite #271).
  • Page 99 CD954A GZ253 CD927A GZ254 8. Lubricate the magneto cover gasket with fresh 13. Using a new gasket, install the speed sensor housing engine oil; then place it into position on the two onto the crankcase and secure with two cap screws. alignment pins.

  • Page 100: Right-Side Components

    Right-Side Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT  To service any one specific component, only limited dis- CF373A assembly of components may be necessary.
  • Page 101 CF632A A. Oil Pump Driven Gear D. One-Way Clutch 7. Remove the cap screws securing the clutch cover. B. Oil Pump Drive Gear E. Final Drive Carrier Bearing Note the location of the different-lengthed cap Housing C. Clutch Shoe Assembly screws for installing purposes.
  • Page 102 CF088A CD987 10. Remove the two cap screws securing the gear posi- tion switch; then remove the switch. 11. Remove the nut (left-hand threads) securing the clutch shoe assembly (C). CD993 13. Using an impact wrench, remove the cap screws securing the final drive carrier bearing housing (E);...

  • Page 103: Servicing Right-Side Components

    CD984 ATV1014 INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 1. Insert the drive into the clutch housing. 2.

  • Page 104: Installing Right-Side Components

    Installing Right-Side Components 1. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned. Tighten the new “patch-lock” cap screws to 28 ft-lb. CD991 4. Grease the driven gear pin and insert it into the shaft. Install the washer;...
  • Page 105 PR410A CF085A 6. Install the clutch cover alignment pins into the crank- 9. Apply grease to the outer edges of the clutch hous- case, apply oil to the cover gasket, and install the ing; then from inside the clutch cover, install the gasket onto the crankcase.
  • Page 106 CF270A CF366 CAUTION Make sure the movable drive face plate is fully engaged onto the splines of the clutch shaft before tightening the nut or false torque readings may occur. This will cause the assembly to loosen damaging the shaft and clutch face plate.

  • Page 107: Center Crankcase Components

    Center Crankcase Components  NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Remov- ing procedures for Top-Side, Left-Side, and Right- Side must precede this procedure.  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.
  • Page 108 DE677A CD826 5. Remove the countershaft assembly (D). Account for 8. Remove the crank balancer. a washer on each end of the countershaft.  NOTE: There is a flat spot on the crank balancer bearing flange to allow clearance past the crankshaft. CC674 ...

  • Page 109: Servicing Center Crankcase Components

    CAUTION Unless the secondary drive gear, bevel gear, or bear- ings require service, do not remove the secondary drive assembly from the case. If removed, bevel gear back- lash will have to be adjusted requiring re-shimming of the drive bevel gear shaft. 13.
  • Page 110 MT008B MT005A 5. Acceptable backlash range is 0.127-0.381 mm  NOTE: Do not use a new lock nut at this time as this (0.005-0.015 in.). procedure may have to be repeated. Correcting Backlash 5. Place the assembled shaft into the left crankshaft case;...
  • Page 111 CC290D H1-003 2. Maximum diameter must not exceed specifications. 3. Zero the indicator and rotate the crankshaft slowly. Measuring Connecting Rod CAUTION (Small End Deflection) Care should be taken to support the connecting rod when rotating the crankshaft. 1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate.
  • Page 112 COUNTERSHAFT GZ312 3. Remove the reverse driven gear dog. GZ281A CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/ or the transmission will malfunction.
  • Page 113 GZ317A GZ319 GZ318 GZ318A 2. Install the low driven gear locking washer; then 6. Remove the low driven gear. Account for a bearing, install the inner reverse driven gear washer. bushing, and thrust washer. GZ319B GZ316 Assembling 1. From the drive gear end, install a thrust washer, bushing, and bearing;...

  • Page 114: Assembling Crankcase Half

    GZ286A GZ313A GZ287 GZ312 4. Install the outer reverse driven washer; then secure 6. From the opposite end of the countershaft, install the the reverse driven gear assembly with a snap ring. high/low driven gear dog (A), thrust washer (B), bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F).
  • Page 115 MT014 CD832B 2. Apply a liberal amount of engine oil to the crank-  NOTE: It will be necessary to rotate the crank bal- shaft bearing. Using a propane torch, heat the bear- ancer until the counterweight is facing away from the ing until the oil begins to smoke;...

  • Page 116: Joining Crankcase Halves

    CC674 CC668 7. Place a washer on the end of the gear shift shaft; then 10. Install the front and rear secondary driven shaft install the shaft assembly making sure the two holes assemblies into the left side of the crankcase making on the end of the shaft are positioned vertically.

  • Page 117: Installing Engine/Transmission

    Installing Engine/ Transmission  NOTE: Toro recommends new gaskets and O-rings be installed whenever servicing the vehicle. 1. Using a suitable lifting sling and engine hoist, lower the engine into the vehicle engaging the slotted rear engine mount brackets with the engine mounts;...
  • Page 118 HDX152A HDX252A 8. Install the CVT cooling ducts on the V-bolt hous- ing and secure with clamps. Tighten securely. Install an appropriate nylon tie to secure the exhaust duct. HDX253A 11. On the left side, connect the ECT sensor connec- tor, speed sensor connector, and spark plug cap.
  • Page 119 13. Install the air filter assembly and secure to the frame 16. Connect the MAP sensor connector (A), fuel injector with four sheet metal screws; then secure the intake connector (B), ISC connector (C), and TPS connector boot with the clamp and tighten securely. (D);...

  • Page 120: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling TROUBLESHOOTING 1. Verify that the electric fuel pump is operating by lis- tening for a “whirring” sound for approximately three seconds after the ignition switch is turned to the ON position. If no sound can be heard, see Fuel Pump/Fuel Level Sensor in Electrical System.

  • Page 121: Gas Tank

    Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. REMOVING 1. Remove the seat, seat back, and seat base; then FI092A remove the floorboard.
  • Page 122 4. Remove four press-nuts securing the gas cap filler panel; then remove the gas cap and panel. Install the gas cap. PR173 PR168 5. Remove the joining cap screw and nut from the rear gas tank hold-down strap; then remove the inside hold-down strap.

  • Page 123: Gas/Vent Hoses

    7. Position the floorboard into the vehicle and secure with the appropriate hardware; then install the seat base, seat back, and seat. Gas/Vent Hoses Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the vent hoses.

  • Page 124: Liquid Cooling System

    2. Remove the Phillips-head screw on the back side of When pure coolant (no air) flows from the bleed hole, the pump and separate the pump housing and cover. install the bleed plug, tighten securely, and then fill the Note the position of the inner and outer rotors and cooling system to the bottom of the stand pipe in the radi- alignment pin for assembly.

  • Page 125: Thermostat

    INSTALLING INSPECTING 1. Place the radiator into position making sure the grom- 1. Inspect the thermostat for corrosion, wear, or spring mets are correctly installed; then secure to the mounts damage. with the two shoulder bolts and nuts. Tighten securely. 2.

  • Page 126: Water Pump

     NOTE: The fan wiring must be in the upper-right position. 2. Install the radiator. Water Pump  NOTE: The water pump is not a serviceable compo- nent. If the pump is defective or if the mechanical seal is leaking (coolant dripping from the discharge hole), the water pump must be replaced.

  • Page 127: Troubleshooting

    5. Check the entire cooling system for leakage. CAUTION After operating the vehicle for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary. 6. Install the seat base and seat. Troubleshooting Problem: Starting impaired Condition...

  • Page 128: Electrical System

    NOTE: If, after charging, the battery does not per- form to operator expectations, bring the battery to an Component data can be retrieved using the CATT II. Uti- authorized Toro ROV dealer for further troubleshoot- ing. lize the Sensor Data screen.

  • Page 129: Brakelight Switch

    Brakelight Switch Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen. The switch connector is the two-prong black connector below the master cylinder.  AR621D NOTE: The ignition switch must be in the ON position. 3.

  • Page 130: Fan Motor

    4. Install the sensor and tighten securely; then connect the leads. Fan Motor 2411-886 CAUTION This component can be tested using the CATT II. Utilize Always replace a blown fuse with a fuse of the same the Test screen. type and rating. ...

  • Page 131: Efi Sensors/Components

    RESISTANCE VOLTAGE Primary Coil CAUTION Always disconnect the battery when performing resis- 1. Set the meter selector to the DC Voltage position; tance tests to avoid damaging the multimeter. then disconnect the two wires from the coil.   NOTE: For these tests, the meter selector should be NOTE: The coil is located to the right of the engine set to the OHMS position.

  • Page 132: Speed Sensor

     NOTE: If the meter does not read as specified, replace the sensor. Speed Sensor  NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor for con- tamination, broken pins, and/or corrosion. 1. Set the meter selector to the DC Voltage position. 2.

  • Page 133: Rpm Limiter

    3. Install the new speed sensor into the housing with new O-ring lightly coated with multi-purpose grease; then RPM Limiter secure the sensor with the cap screw (threads coated with blue Loctite #242). Tighten securely. Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen.

  • Page 134: Drive Select Switch

     NOTE: If the meter does not show voltages accord- ing to the chart, make sure the front drive actuator is Drive Select Switch plugged in; then troubleshoot the switch, ignition fuses, battery connections, or wiring harness. Reverse Override Switch Component data can be retrieved using the CATT II.

  • Page 135: Stator Coil

    Stator Coil VOLTAGE (AC Generator - Regulated Output) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the positive battery post; then connect the black tester lead to the nega- tive battery post. 3.

  • Page 136: Starter Motor

    RESISTANCE (AC Generator) CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. 1. Set the meter selector to OHMS position. 2. Test between the three yellow wires for a total of three tests. 3. The meter reading must be within specification. Starter Motor AR607D ...

  • Page 137: Electronic Control Module (Ecm)

    4. Disconnect the two-wire plug from the starter relay; then connect the red tester lead to the green wire and the Fuel Pump/Fuel Level black tester lead to the black wire. Sensor Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen.

  • Page 138: Regulator/Rectifier

    5. Using duct tape or other suitable means, cover the fuel pump opening. INSPECTING AT THIS POINT If the pump has failed earlier test and must be replaced, proceed to INSTALLING. 1. Inspect the fuel screen and blow clean with low pres- sure compressed air.

  • Page 139: Headlights

    VOLTAGE (Brakelight)  NOTE: If voltage rises above 15.5 DC volts, the reg- ulator is faulty or a battery connection is loose or  NOTE: Perform this test at the socket end of the tail- corroded. Clean and tighten battery connections or light-brakelight harness (pigtail).
  • Page 140 2. Install the needle adapters to the multimeter leads; then select DC Voltage on the multimeter. 3. Connect the red tester lead to the blue/brown wire (B) and the black tester lead to the black/yellow wire (A); then turn the ignition switch ON and observe the meter.

  • Page 141: Throttle Position Sensor (Tps)

    Throttle Position Sensor (TPS) Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen.  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the FI673A LCD gauge (see EFI Diagnostic System in this sec- tion).
  • Page 142 EFI002A EFI003  NOTE: The display on the gauge will display in SAE *Fan Schedule: Fan ON @ 185 degrees F, OFF @ 175 degrees F. *High Temperature REV Limiter 5000 RPM @ 230 degrees F. (speedometer in MPH mode) or Metric (speedometer *Thermostat opens @ approximately 180 degrees F noted by a 2-5 in km/h mode), For example to read temperature in degree drop momentarily.
  • Page 143 Fuel Sensor (FUEL) Diagnostic Mode Display: vehicle speed signal. DTC: P0500 Usage: verify speedometer sensor signal from the following. 1. Speed sensor to ECM. 2. ECM (CAN) signal to gauge (speedometer/odometer). TPS (tPS) Diagnostic Mode EFI010 Display: Fuel level signal from the fuel level sensor (measured in ohms).
  • Page 144 Inlet Air Temperature (AIr) Display: System DC voltage. Diagnostic Mode DTC: P0562, P0563, P2531, P2532 Usage: Verify system voltage under following condi- tions. 1. Battery voltage with engine and accessories off (>12.2 VDC for fully charged). 2. Battery voltage with engine running (charging = 13.8 VDC or greater).
  • Page 145 Code Fault Description Possible Cause Fault Recovery Method P0132 O2 Sensor High/SP Sensor or interconnect harness shorted to battery power Correct condition* P0171 O2 Feedback Below Minimum Correction Low fuel rail pressure, dirty fuel filter, or dirty injectors Correct condition* P0172 O2 Feedback Exceeds Maximum Correction Excessive fuel rail pressure, MAP or temp sensors out-of-spec Correct condition*...

  • Page 146: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug(s) defective 2. Replace plug(s) 3. CKP sensor defective 3. Replace CKP sensor 4. ECM defective 4. Replace ECM Problem: Spark plug fouled with carbon Condition Remedy 1.

  • Page 147: Drive System

    3. Remove the mounting cap screw from above the actuator on the suspension side. Drive System GENERAL INFORMATION All gear cases are tagged beneath a cover bolt. This tag is marked with a production date code, sequence code, and a ratio code. All gear cases are 4.0:1 ratio. The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular).

  • Page 148: Front Differential

     3. While holding the actuator firmly forward, tighten NOTE: The jack stands should be placed under the the front cap screw to hold the actuator in place; then main frame to avoid contact with front suspension install but do not tighten the two remaining cap components.
  • Page 149 PR191 PR729C 8. Remove the lower and upper ball joint cap screws 13. Remove the lower differential mounting cap screw. taking care not to strip the threads on the ball joint Account for a lock nut and four washers. Note the shaft;...
  • Page 150 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. GC004A 2. Using a rubber mallet, remove the housing. Account for a gasket. Remove the fork, collar, and spring. GC010 Note the location of all the components for assem- 5.
  • Page 151 Assembling Input Shaft 4. Install the input shaft into the pinion housing; then secure the bearing with a circlip. 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside.
  • Page 152 GC015 KX175 2. Using a T-40 torx wrench, remove the cap screws 5. Remove the left differential bearing flange assembly securing the differential cover. Account for and make and account for a shim. Mark the shim as left-side. note of the ID tag location for assembling purposes. KX177 GC003 3.
  • Page 153 KX181 CC879 4. Remove any reusable parts from the gear case hous- Disassembling Pinion Gear ing; then discard the housing and lock collar. 1. Remove the internal snap ring securing the pinion Assembling Pinion Gear bearing in the housing. 1. Install the bearing onto the pinion shaft. Install the pinion shaft collar.
  • Page 154  NOTE: All bearings must be installed in the gear case and the pinion properly installed before pro- ceeding. Backlash  NOTE: Always set backlash prior to any other shim- ming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly.
  • Page 155 GC033A GC039A 4. Install the existing shim or a 0.063 in. shim on the 6. Zero the dial indicator; then while holding the pinion cover side of the ring gear; then place the assembled stationary, rock the ring gear assembly forward and gear case cover onto the gear case and secure with back and record the backlash.
  • Page 156 2. Zero the dial indicator; then push the ring gear 3. Assemble the fork and sliding collar into the cover toward the dial indicator and release. End-play assembly; then install the left bearing flange/bearing should be 0.004-0.008 in. assembly and seat firmly into the cover. 3.
  • Page 157 6. Install the shift fork shaft w/spring into the housing making sure the shaft O-ring is positioned to the inside. CD110 Removing/Installing Axle Seal  NOTE: This procedure can be performed on a rear CC892 gear case. 7. Install the shift fork assembly making sure the fork leg is facing upward.
  • Page 158 INSTALLING DIFFERENTIAL 1. Place the differential assembly into position in the frame; then install the top mounting cap screw, two washers, and lock nut. Do not tighten at this time. 2. Install the lower differential mounting cap screw, washers, and lock nut. Note the correct location for the washers. PR193 8.

  • Page 159: Drive Axles

    PR256 PR221 12. Install the wheels; then using a crisscross pattern, 5. Remove the cap screw and lock nut securing the tighten the wheel nuts in 27 N-m (20 ft-lb) incre- knuckle to the upper A-arm. Discard the lock nut. ments to the final torque shown in the table below.
  • Page 160 CF337 PR729C 2. Place the white-striped end of the CV joint into a REMOVING FRONT DRIVE AXLE vise.  NOTE: For removing a front drive axel, see Front Differential in this section. CLEANING AND INSPECTING AXLES  NOTE: Always clean and inspect the drive axle com- ponents to determine if any service or replacement is necessary.
  • Page 161 ATV-1048 CD027 3. Apply 80 grams (2/3 of contents) of grease from the 5. Install the wheel; then using a crisscross pattern, pack into the bearing housing. tighten the wheel nuts in 27 N-m (20 ft-lb) incre- ments to the final torque shown in the table below. ...

  • Page 162: Rear Gear Case

    7. Install the wheel; then using a crisscross pattern, tighten the wheel nuts in 27 N-m (20 ft-lb) incre- ments to the final torque shown in the table below. Steel Wheel 54 N-m (40 ft-lb) Aluminum Wheel (Black Nuts) 80 N-m (60 ft-lb) Aluminum Wheel (Chrome Nuts) 108 N-m (80 ft-lb) 8.
  • Page 163 GZ182A GC058A 3. Remove the snap ring retaining the input bearing and 3. If clearance is as specified, remove the ring gear and using an appropriate bearing driver, press the bearing thrust button; then place a drop of red Loctite #271 from the housing.

  • Page 164: Hub

    2. Pack the driveline boot with the appropriate grease; then secure with the boot clamps using CV Boot Clamp Tool. 3. Secure the differential to the frame with two through-bolts and secure with lock nuts and flat washers. Tighten to 38 ft-lb. 4.
  • Page 165 3. Using a socket and ratchet handle, tighten the nut until the stud is fully drawn into the hub. PR243A 5. Remove the hub assembly. PR252A 6. Remove the four cap screws securing the brake disc. INSTALLING 1. Secure the brake disc (if applicable) to the hub with the four cap screws coated with red Loctite #271.

  • Page 166: Hydraulic Brake Caliper

    NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them. ! WARNING Toro recommends only authorized Toro ROV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of control caus- ing severe injury or death.
  • Page 167 PR238 PR715 5. Remove the caliper holder from the caliper and dis- ! WARNING card the O-ring. Make sure to hold the towel firmly in place or the piston could be ejected from the housing causing injury. 7. Using an appropriate seal removal tool, carefully remove the seals from the brake caliper housing;...
  • Page 168 4. Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented.  NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly. PR717A 2. Press the piston into the caliper housing using hand pressure only.

  • Page 169: Universal Joints

    8. Fill the reservoir; then bleed the brake system (see Periodic Maintenance - Hydraulic Brake System). ! WARNING Never use brake fluid from an open container or reuse brake fluid. Moisture-contaminated brake fluid could cause vapor build-up (expansion) during hard braking resulting in greatly increased stopping distance or loss of control leading to injury or death.
  • Page 170 3. Remove the cap screws securing the driveshaft flange to the output flange; then remove the drivesh- aft. PR367B 2. Verify the yoke legs are parallel. HDX157 4. Install a U-joint separator tool on the universal joint fixed yoke; then remove the bearing cup retainers. 5.

  • Page 171: Troubleshooting Drive System

    3. Install the retainer in the bearing cup; then remove the yoke from the separator tool.  NOTE: Repeat steps 2-3 for the opposite-side bear- ing cup. 4. Remove the separator tool from the vise and install the universal joint, bearing cups, and movable yoke into the fixed yoke using the same procedure as steps 2-3 except the vise cannot be used.

  • Page 172: Troubleshooting Brake System

    Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Brake fluid leaking 2. Repair - replace hydraulic system 3. Master cylinder/brake cylinder seal worn 3. Replace seal(s) Problem: Brake pedal travel excessive Condition Remedy 1.

  • Page 173: Suspension

    Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods bent, pitted, or damaged. B. Rubber damper cracked, broken, or missing. C. Shock absorber body damaged, punctured, or leaking. CF341 D. Shock absorber eyelets broken, bent, or cracked. CLEANING AND INSPECTING E.
  • Page 174 PR257 AF626D 3. Remove the nut securing the hub. 10. Remove the cap screws securing the A-arms to the frame. 4. Remove the brake caliper. Account for two cap screws. AF610D 11. Remove the snap ring from the ball joint; then remove CD007 the ball joint from the A-arm.
  • Page 175 INSTALLING 1. Apply Loctite Primer “T” to the A-arm socket; then apply green Loctite #609 to the entire outside diame- ter of the ball joint. Install the ball joint into the A-arm and secure with the snap ring. AF628D 7. Install the tie rod end and secure with the nut (coated with red Loctite #271).

  • Page 176: Rear A-Arms

    4. Remove the cotter pin securing the hex nut; then remove the hex nut. 5. Remove the cap screws and lock nut securing the shock absorber to the frame and lower A-arm; then remove the shock absorber. 6. Remove the cap screws securing the boot guard to the lower A-arm.

  • Page 177: Wheels And Tires

    4. Apply grease on the drive axle splines; then install the ! WARNING hub assembly onto the drive axle. Use only Toro approved tires when replacing tires. Fail- ure to do so could result in unstable vehicle operation. This vehicle is equipped with low-pressure tubeless tires of the size and type listed in the General Information sec- tion.

  • Page 178: Troubleshooting

    CHECKING/INFLATING  NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and 1. Using an air pressure gauge, measure the air pressure have it repaired professionally. in each tire. Adjust the air pressure as necessary to meet the recommended inflation pressure.
  • Page 179 Printed in U.S.A. p/n 492-9346...

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