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Service Manual FOREWORD

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Service Manual FOREWORD LCE/Residential Products Side By Side Off Road Utility Vehicle 500 EFI & 700 EFI Service Manual FOREWORD This Toro Service Manual contains service, maintenance, and troubleshooting information for the 2015 Toro UTV500/ UTV700. The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. This service manual is designed primarily for use by a Toro USD (Unlisted Service Dealer). The procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed. The technician should use sound judgement when determining which procedures can be completed based on their skill level and access to appropriate special tools. All Toro publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of serious personal injury or even death. A CAUTION identifies unsafe practices which may result in vehicle-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the vehicle. The symbol NOTE: identifies supplementary information worthy of partic- ular attention. The symbol AT THIS POINT directs the technician to certain and specific procedures to pro- mote efficiency and to improve clarity. 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. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Toro © 2015 Toro April 2015 ®™ Trademarks of Toro 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 ....................................................122 Special Tools........................................................................6 Radiator...........................................................................122 Preparation For Storage ......................................................6 Thermostat ......................................................................123 Preparation After Storage....................................................6 Fan ..................................................................................123 Periodic Maintenance...................................................... 7 Water Pump ....................................................................124 Periodic Maintenance Chart ................................................7 Troubleshooting ...............................................................125 Lubrication Points ................................................................8 Electrical System ........................................................ 126 Air Inlet Pre-Filter.................................................................8 Battery.............................................................................126 Air Filter ...............................................................................8 Accessory Receptacle/Connector ...................................126 Valve/Tappet Clearance.......................................................9 Brakelight Switch.............................................................127 Testing Engine Compression.............................................10 Engine Coolant Temperature (ECT) Sensor....................127 Spark Plug.........................................................................10 Fan Motor ........................................................................128 Muffler/Spark Arrester .......................................................10 Power Distribution Module (PDM) ...................................128 Engine/Transmission Oil - Filter.........................................11 Ignition Coil .....................................................................128 Front Differential - Rear Drive Lubricant ............................12 EFI Sensors/Components ...............................................129 Driveshaft/Coupling ...........................................................13 Speed Sensor .................................................................130 Nuts/Bolts/Cap Screws......................................................13 RPM Limiter ....................................................................131 Headlight/Taillight-Brakelight .............................................13 Ignition Switch .................................................................131 Shift Lever..........................................................................14 Headlight Switch .............................................................131 Hydraulic Brake System ....................................................15 Drive Select Switch .........................................................132 Burnishing Brake Pads ......................................................16 Reverse Override Switch.................................................132 Checking/Replacing V-Belt ................................................17 Front Drive Actuator ........................................................132 Steering/Frame/Controls............................................... 19 Stator Coil .......................................................................133 Steering Wheel ..................................................................19 Starter Motor ...................................................................134 Tie Rods ............................................................................19 Starter Relay ...................................................................134 Steering Assembly.............................................................20 Electronic Control Module (ECM)....................................135 Upper Steering Shaft.........................................................21 Fuel Pump/Fuel Level Sensor .........................................135 Intermediate Steering Shaft Assembly ..............................22 Regulator/Rectifier ..........................................................136 Steering Knuckles..............................................................23 Headlights .......................................................................137 Accelerator Pedal ..............................................................25 Taillight-Brakelight ...........................................................137 Shift Lever..........................................................................25 Ignition Timing .................................................................137 Shift Cable .........................................................................25 Tilt Sensor .......................................................................137 LCD Gauge........................................................................26 Throttle Position Sensor (TPS)........................................139 Checking/Adjusting Front Wheel Alignment.......................27 EFI Diagnostic System....................................................139 Front Bumper Assembly ....................................................28 Troubleshooting ...............................................................144 Hood ..................................................................................28 Drive System ............................................................... 145 Fenders..............................................................................29 Front Drive Actuator ........................................................145 Floor ..................................................................................29 Front Differential ..............................................................146 Dashboard .........................................................................30 Drive Axles ......................................................................157 Belly Panel.........................................................................30
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