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Textron Stampede 900 2017, Repair And Service Manual, Page: 16 / 237

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Repair and Service Manual

TABLE OF CONTENTS

668061

Brake Pad Replacement  .....................................................................................66

Rotor Replacement  .............................................................................................67

BLEEDING AND FLUSHING ........................................................................................... 68

Bleeding ..............................................................................................................68

Bleeding Sequence .............................................................................................68

Flushing the Brake System  .................................................................................69

BRAKE AND ACCELERATOR PEDALS ......................................................................... 69

Brake Pedal Removal And Installation ................................................................69

Accelerator Pedal Removal  ................................................................................70

FRONT CV SHAFT, SUSPENSION AND STEERING

FRONT SUSPENSION .................................................................................................... 74

Maintenance .......................................................................................................74

Wheel Bearing Test  ............................................................................................74

Front Hub Removal .............................................................................................74

Front Spindle Removal  .......................................................................................75

FRONT AXLE .................................................................................................................. 77

CV Shaft Replacement  .......................................................................................77

CV Joint Boot Replacement ................................................................................77

Front Strut Assembly Replacement  ....................................................................77

Lower Control Arm Assembly Replacement  .......................................................78

Upper Control Arm Assembly Replacement  .......................................................79

Stabilizer Bar Removal  .......................................................................................80

FRONT DIFFERENTIAL  ................................................................................................. 80

Front Differential Oil Check .................................................................................80

Front Differential Oil Replacement ......................................................................81

Front Differential Replacement  ...........................................................................81

STEERING....................................................................................................................... 82

Steering Wheel Replacement  .............................................................................84

Steering Column Removal  ..................................................................................85

Steering Shaft Replacement (Non-EPAS)  ..........................................................85

Electric Power Assist System (EPAS) (If Equipped) ...........................................86

Steering Rack Replacement  ...............................................................................87

Rack Ball Joint Replacement  ..............................................................................87

MAINTENANCE............................................................................................................... 88

Wheel Alignment .................................................................................................88

Summary of Contents for Stampede 900 2017

Page 1: ...Technician s Repair and Service Manual 668061 B 2018...

Page 2: ...d maintenance along with good operating techniques will help ensure your safe enjoyment of the capabilities and reliability of this vehicle Manufacturer s Intended Use The TEXTRON OFF ROAD STAMPEDE 90...

Page 3: ...d by 2006 42 EC CONTACT US TEXTRON SPECIALIZED VEHICLES INC 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 www textronoffroad com North America Technical Assistance Warranty PHONE 1 800 774 3...

Page 4: ...self discharge over time The rate of self discharge varies depending on the ambient temperature the age and condition of the battery A fully charged battery will not freeze unless the temperature fal...

Page 5: ...is manual This vehicle conforms to the current applicable standard for safety and performance requirements This vehicle is designed and manufactured for off road use It does not conform to Federal Mot...

Page 6: ...ety of personnel nor jeopardize the safe operation of the vehicle Lift the vehicle in accordance with the manufacturer s instructions Chock the wheels and support the vehicle with safety stands Never...

Page 7: ...l number and manufacture date code VIN plates are on the vehicle One is on the rear crossmember the other is on the frame below the seat wrap panel See Fig 1 Design changes take place on an ongoing ba...

Page 8: ...ions such as extreme temperatures extreme dust debris condi tions or frequent use with maximum load POWERTRAIN MAINTENANCE Access the powertrain by raising or removing the truck bed and the seat botto...

Page 9: ...ediment packed in closed areas to ease it s removal taking care not to chip or otherwise damage paint Removal of oil tar asphalt etc requires the use of a commercially available vinyl rubber cleaner L...

Page 10: ...e a spark Store the vehicle in a clean dry area Do not store in the same area as a stove furnace water heater or other appliance that uses a a pilot light or has a device that can create a spark When...

Page 11: ...metric hardware TORQUE SPECIFICATIONS Fig 3 Torque Specifications ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Unless otherwise noted in text tighten...

Page 12: ...r and Service Manual GENERAL INFORMATION ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 13: ...INTENANCE 12 BRAKES 12 TIRES 13 LIGHT BULB REPLACEMENT 13 CARE AND CLEANING OF VEHICLE 13 Washing the Vehicle 13 Polishing the Vehicle 13 CANOPY AND WINDSHIELD 13 TRANSPORTING THE VEHICLE 14 PROLONGED...

Page 14: ...l 26 Door Removal 27 Door Handle and Latch Assembly Removal 28 Striker Plate Removal 29 Floorboards 29 SEATING 30 Seat Bottom Removal 31 Seat Back Removal 31 Seat Closeout Removal 31 EXTENDED CAB 32 C...

Page 15: ...G Tighten ROPS Hardware 46 SEATBELT INSTALLATION 47 Headrest Installation 48 TRUCK BED TRUCK BED REMOVAL 52 Decal Replacement 53 WEATHER PROTECTION GENERAL 55 CANOPY 55 Installing Mounting Brackets 55...

Page 16: ...t Spindle Removal 75 FRONT AXLE 77 CV Shaft Replacement 77 CV Joint Boot Replacement 77 Front Strut Assembly Replacement 77 Lower Control Arm Assembly Replacement 78 Upper Control Arm Assembly Replace...

Page 17: ...ement 96 Stabilizer Bar Removal 96 REAR DIFFERENTIAL 97 Oil Change 97 Rear Differential Oil Check 97 Rear Differential Oil Replacement Upper Chamber 97 Rear Differential Oil Replacement Lower Chamber...

Page 18: ...Oil Type and Capacity 116 Checking the Engine Oil Level 116 CHANGING ENGINE OIL AND FILTER 117 Remove Engine Oil 117 Replace the Oil Filter 118 Refill Engine Oil 118 AIR FILTER MAINTENANCE 118 SPARK P...

Page 19: ...M MAIN HARNESS 141 Power Supply 141 Circuits and Controls 141 Testing Engine Starting Circuit 141 VOLTAGE TEST FOR BATTERY 142 BATTERY 142 Battery Cleaning 142 Battery Charging 142 Battery Storage 142...

Page 20: ...ain Performance 162 STARTER FAULT TESTING 164 SUSPENSION AND STEERING FAULT TESTING 164 GENERAL SPECIFICATIONS SCHEDULED MAINTENANCE Initial Service Requirements 171 Severe Use Conditions 171 SCHEDULE...

Page 21: ...9 Repair and Service Manual Notes TABLE OF CONTENTS 668061...

Page 22: ...10 Repair and Service Manual TABLE OF CONTENTS Notes 668061...

Page 23: ...ld expose them to injury should an unexpected situation occur Always use the appropriate tools listed in the tool list and wear approved safety equipment MODIFICATIONS TO VEHICLE Do not modify the veh...

Page 24: ...d at a battery terminal Batteries are heavy Use proper lifting techniques when moving them Always lift the battery with a commercially available battery lifting device Use care not to tip the battery...

Page 25: ...Ref Fig 2 2 Put a jack under the center of the vehicle frame at the differential mounting plate Ref Fig 1 3 Raise the vehicle with the jack 4 Install a jack stand under each side of the vehicle frame...

Page 26: ...14 Repair and Service Manual SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 27: ...the following steps must be taken 1 Thoroughly clean the surface to be repaired with alcohol and allow to dry 2 Apply tape to the area surrounding the damaged area to prevent over spray of paint 3 Sh...

Page 28: ...cal and pull straight up to remove See Fig 1 2 Remove the nuts 25 that secure the grill 24 to the front fascia 3 Remove the grill 3 Disconnect the headlights from the wire harness 4 Remove the plastic...

Page 29: ...d control switches See ELECTRICAL SYSTEM on page 135 4 Remove the passenger hand hold See FRAME on page 31 5 Remove the rocker panel See Rocker Panel Removal on page 20 6 Remove the quarter panels and...

Page 30: ...ool List Qty Ratchet 1 Socket 17mm 1 Wrench 17mm 1 Torque Wrench ft lbs 1 1 Remove two bolts 3 and nuts 4 that secure the brush guard 1 to the bracket 2 See Fig 3 2 Remove four bolts 3 and nuts 4 that...

Page 31: ...upper shield 11 to the lower shield 12 Remove the upper shield 11 3 The grill 14 can be removed from the upper shield by removing two plastic rivets 15 4 Remove the two bolts 22 that secure the lower...

Page 32: ...1 Remove the rocker panel See Rocker Panel Removal on page 20 2 Remove the screw 9 and plastic rivets 13 that secure the side panel 3 to the frame See Fig 6 Remove the side panel 3 Remove the screws 9...

Page 33: ...e Wrench ft lbs 1 1 Remove the bolts 15 nuts 16 and hinge plate 8 that secure the door 1 to the upper and lower door hinges See Fig 8 2 Remove the door from the vehicle 3 Installation is the reverse o...

Page 34: ...re the cover plate 1 to the door See Fig 9 2 Remove the screws 12 that secure the cover plate 1 to the latch mount bracket 10 and to the door 3 Remove the door handle assembly 4 Remove the screws 3 an...

Page 35: ...11 Floorboards Tool List Qty Screwdriver Flat Tip 1 Torx Bit T30 1 Ratchet 1 1 Remove the rocker panel See Rocker Panel Removal on page 20 2 Remove the plastic rivets 11 that secure the cup holder 5 t...

Page 36: ...al BODY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 668061 SEATING Fig 12 Seat Components Seat Frame Front of...

Page 37: ...al Tool List Qty Ratchet 1 Torx Bit T45 1 Torque Wrench in lbs 1 1 Remove the four bolts 21 that secure the seat back 14 to the seat back supports 12 See Fig 12 2 Remove the seat back from the vehicle...

Page 38: ...n before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 668061 EXTENDED CAB Fig 13 Extended Cab Components Heat Shields Heat Shields Front of Vehicle 1 11 2...

Page 39: ...on is the reverse order of removal 4 Tighten the hardware to the torque specified below Front Closeout Panel Removal Tool List Qty Ratchet 1 Torx Bit T30 1 1 Remove the air filter and CVT air intake h...

Page 40: ...ist Qty Ratchet 1 Torx Bit T30 1 Torque Wrench in lbs 1 1 Remove the screws 4 that secure the skid plate 1 and skid guard bracket 2 to the bottom of the frame See Fig 15 2 Slide the rear of the skid p...

Page 41: ...29 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers BODY 668061...

Page 42: ...30 Repair and Service Manual BODY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 43: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 31 Repair and Service Manual 668061 FRAME Fig 1 Frame Overview 1 20 30 30 22 24 26 27 22 19 19 7 8 31 31 8 16...

Page 44: ...2 Remove the bolt 18 and nut 19 that secure the A pillar cap bracket 16 to the top of the door hinge bracket 20 Remove the A pillar cap bracket 3 Remove the bolts 29 and nuts 30 that secure the door h...

Page 45: ...ion is the reverse order of removal Front Shock Tower Brace Removal Fig 4 Shock Tower Brace Tool List Qty Ratchet 1 Socket 13mm 1 Socket 17mm 1 Wrench 13mm 1 Wrench 17mm 1 Torque Wrench ft lbs 1 1 Rem...

Page 46: ...1 Wrench 17mm 1 Torque Wrench ft lbs 1 1 Remove the bolts 38 that secure the rear shock tower brace 32 to the frame 1 Ref Fig 5 Remove the brace 2 Installation is in the reverse order of removal 3 Tig...

Page 47: ...ame 1 to the vehicle frame Remove the seat frame from the vehicle 5 Installation is in the reverse order of removal 6 Tighten hardware to the torque specified below B Pillar Crossmember Removal Tool L...

Page 48: ...36 Repair and Service Manual FRAME Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 49: ...any procedure Pay particular attention to Notices Cautions Warnings and Dangers 37 Repair and Service Manual 668061 ROLLOVER PROTECTION SYSTEM ROPS Fig 1 ROPS Components A Pillar B Pillar C Pillar Fro...

Page 50: ...talla tion to allow the mounting holes to align properly 8 Tighten hardware to the torque specified below INSTALLING ROPS COMPONENTS NOTICE Loosen all ROPS hardware before installa tion to allow the m...

Page 51: ...ame side as the exposed wiring harness of the cross tube Align the mounting holes of the CHMSL 10 and the mounting bracket Insert screws 12 from the front face of the CHMSL Secure with lock nuts 14 2...

Page 52: ...and secure with bolts 8 and lock nuts 9 Finger tighten bolts to allow for adjustment Fig 6 Front Cross tube F Seat Back Support Installation Tool List Qty Socket 15mm 1 Ratchet 1 Wrench 15mm 1 1 Posit...

Page 53: ...of the seatbelt retractor is flush against the bracket toward the front of the vehi cle 2 Attach the seatbelt retractor to the bracket at the bot tom of the ROPS tube 2 Ref Fig 9 3 Insert the tab on...

Page 54: ...arnings and Dangers 668061 Fig 10 Seat Belt Latches Headrest Installation Fig 11 Headrest 1 Attach the headrest 27 to the top of the seat back support by pushing it in against the support and then sli...

Page 55: ...3 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ROLLOVER PROTECTION SYSTEM 66806...

Page 56: ...4 Repair and Service Manual ROLLOVER PROTECTION SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 66806...

Page 57: ...e attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 45 Repair and Service Manual 668061 TRUCK BED Front of Vehicle Bed Stop Bracket Gas Spring Bed Frame Frame...

Page 58: ...he down position remove the two bolts that secure the bed stop bracket to the bed frame Remove the bracket 2 Release the bed latch and lift the truck bed until the gas spring is fully extended 3 With...

Page 59: ...ty Alcohol A R Clean Cloth 1 Squeegee 1 When replacing decals on the body panels 1 Prepare the surface by cleaning with alcohol and a clean cloth Allow the surface to dry 2 Peel away the decal backing...

Page 60: ...48 Repair and Service Manual TRUCK BED Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 61: ...nt CANOPY Tool List Qty Deep Well Socket 15 mm 1 Wrench 15 mm 1 Torx Bit T27 1 Socket Extension 1 Hex Bit 6 mm 1 Torque Wrench ft lbs 1 Ratchet 1 Installing Mounting Brackets Fig 1 1 Loosen the ROPS R...

Page 62: ...ons Warnings and Dangers 668061 Installing Canopy Clamps Fig 2 1 Place canopy clamps 3 with the hinged side facing out onto each side ROPS tube Ref Fig 2 2 Close the hinges around the ROPS tubes and s...

Page 63: ...tube so they are aligned with the canopy mounting holes 3 When the canopy clamps are aligned with the can opy mounting holes tighten the canopy clamp bolts 11 to 7 9 ft lbs 10 12 N m torque 4 Secure...

Page 64: ...52 Repair and Service Manual WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 65: ...IFICATIONS on page 161 Worn improperly inflated improper sized or incorrectly installed tires will affect vehicle handling and could cause an accident resulting in severe injury or death To decrease t...

Page 66: ...lug Tire Replacement Tire replacement requires a tire mounting machine and must be done by a qualified tire center or TEXTRON OFF ROAD dealer Wheel Removal Tools List Qty Lug Wrench 19mm 1 Impact Wren...

Page 67: ...55 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers WHEELS AND TIRES 668061...

Page 68: ...56 Repair and Service Manual WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 69: ...to Notices Cautions Warnings and Dangers 57 Repair and Service Manual 668061 BRAKES Fig 1 Brake System Front of Vehicle 1 12 8 2 11 11 9 5 3 3 3 11 11 11 11 14 14 14 14 4 2 2 Part of Frame Brake Calip...

Page 70: ...WD 40 or any petro leum product to the brake discs These products are flammable and can also reduce the friction between the brake pad and caliper and increase the possibility of an acci dent that ca...

Page 71: ...ls cups Fluid will leak past the cups and show as an external leak A common symptom is a soft brake pedal meaning that it goes all the way to the floor The rubber parts wear with use or deteriorate wi...

Page 72: ...rake fluid and bleed the brake system 11 After bleeding the brake system check for leaks along all lines and at the master cylinder Brake Pad Replacement Tool List Qty Ratchet 1 Socket 14mm 1 Socket 1...

Page 73: ...brake pads 22 and place the caliper assembly 17 onto the rotor 8 Align the mounting holes on the caliper assembly with the corresponding holes on the spindle Secure with two bolts 15 and nuts 16 Tigh...

Page 74: ...ir If a line or hose was disconnected at any fitting located between the master cylinder and calipers all wheel cali pers served by the disconnected line or hose must be bled Bleeding Sequence Figure...

Page 75: ...les close the bleeder valve and release the brake pedal Tighten the bleeder valve to the maximum torque value specified below Flushing the Brake System The process of removing old brake fluid to remov...

Page 76: ...Socket 10mm 1 Wrench 10mm 1 1 Disconnect the accelerator wire from the harness 2 From under the vehicle remove the two bolts that secure the accelerator pedal to the vehicle frame Ref Figure 11 3 Remo...

Page 77: ...65 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers BRAKES 668061...

Page 78: ...66 Repair and Service Manual BRAKES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 79: ...ttention to Notices Cautions Warnings and Dangers 67 Repair and Service Manual 668061 FRONT CV SHAFT SUSPENSION AND STEERING Fig 1 Front Suspension Components 22 28 27 5 33 39 30 23 31 31 40 24 12 46...

Page 80: ...al lubrication Wheel Bearing Test To check for worn wheel bearings perform the following procedure NOTICE The axle nut must be installed at the proper torque for the wheel bearing test to be accu rate...

Page 81: ...ack Stands 4 Plastic Hammer 1 Needle Nose Pliers 1 Ratchet 1 17mm Socket 1 19mm Socket 1 Wrench 17mm 1 Wrench 19mm 1 Impact Wrench 1 Impact Socket 24mm 1 Torque Wrench ft lbs 1 1 Lift and support vehi...

Page 82: ...ly downward with a hammer to separate it from the ball joint Ref Fig 8 Fig 9 Spindle Nut and Cotter Pin Fig 10 Remove Spindle Hardware 6 Remove the cotter pin 31 and castle nut 30 that secure the spin...

Page 83: ...ines Ref Fig 11 Fig 11 Hog Ring 7 Apply anti seize to the splines of the replacement CV shaft prior to installation CV Joint Boot Replacement Tool List Qty Needle Nose Pliers 1 Wire Cutters 1 1 Remove...

Page 84: ...rom the vehicle 7 The installation of the strut assembly is the reverse of disassembly 8 Tighten the hardware to the torque values specified below Lower Control Arm Assembly Replacement Tool List Qty...

Page 85: ...orque values specified below Upper Control Arm Assembly Replacement Tool List Qty Wheel Chocks 4 Floor Jack 1 Jack Stands 4 Plastic Faced Hammer 1 Wrench 15mm 1 Wrench 17mm 1 Wrench 18mm Wrench 19mm 1...

Page 86: ...1 Socket 17mm 1 Wrench 18mm 1 Wrench 17mm 1 Torque Wrench ft lbs 1 1 Remove bolts 38 washers 37 and nuts 33 securing the stabilizer bar ends to the stabilizer bar linkages Ref Fig 1 2 Remove bolts 32...

Page 87: ...stall the fill plug Check for leaks Front Differential Replacement Tool List Qty Wheel Chocks 4 Floor Jack 1 Jack Stands 4 Ratchet 1 Socket 13mm 1 Socket 14mm 1 Wrench 13mm 1 Wrench 14mm 1 Pliers 1 Sc...

Page 88: ...section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 668061 STEERING Fig 21 Steering Components Non EPAS Steering Column Mount Weldment Part of Fra...

Page 89: ...dure Pay particular attention to Notices Cautions Warnings and Dangers 77 Repair and Service Manual 668061 Fig 22 Steering Component EPAS Steering Column Mount Weldment Front of Vehicle Brake Pedal Mo...

Page 90: ...e Fig 22 Fig 23 Steering Wheel Nut Removal 2 Remove the lock nut 6 securing the steering wheel to the steering shaft Ref Fig 23 NOTICE To prevent damage to the steering shaft do not use excessive forc...

Page 91: ...ster Remove the bolts 16 and nuts 14 that secure the steering column assembly to the vehicle Remove steer ing column Ref Fig 27 Fig 27 Steering Column Assembly The steering wheel shaft 24 and bushings...

Page 92: ...7mm 1 Torque Wrench ft lbs 1 NOTICE Mark the orientation of the steering compo nents for proper alignment during assembly 1 Disconnect the two wire harness connections on the EPAS unit Ref Fig 29 Fig...

Page 93: ...Remove the nut 28 and bolt 29 securing the steering shaft yoke to the steering rack Ref Fig 32 Fig 32 Steering Rack 3 Remove the three socket head bolts 8 and two hex bolts and nuts 7 attaching the st...

Page 94: ...teering stop 2 Rotate the wheel to the right while counting the num ber of turns required to contact the right steering stop Divide the number of turns by two This indi cates the number of steering wh...

Page 95: ...tion before each use using the following procedure 1 Park the vehicle on a level surface 2 Lightly turn the steering wheel to the left and then to the right 3 There should be 1 inch 25 mm of free play...

Page 96: ...ir and Service Manual FRONT CV SHAFT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 97: ...ticular attention to Notices Cautions Warnings and Dangers 85 Repair and Service Manual 668061 REAR AXLE AND SUSPENSION Fig 1 Rear Suspension Components 2 21 22 16 6 27 28 27 28 18 19 15 30 24 1 7 20...

Page 98: ...edure NOTICE The axle nut must be installed at the proper torque for the wheel bearing test to be accu rate 1 Lift and support the vehicle See LIFTING THE VEHICLE on page 13 2 Grasp the wheel at the t...

Page 99: ...otter pin 5 around the axle to secure See Fig 2 Rear Spindle Removal Tool List Qty Wheel Chocks 4 Floor Jack 1 Jack Stands 4 Hammer 1 Needle Nose Pliers 1 Ratchet 1 Socket 17mm 1 Socket 19mm 1 Wrench...

Page 100: ...l Removal on page 54 3 Remove the brake calipers from the rotor See Brake Pad Replacement on page 60 4 Remove the hub See Hub Removal on page 86 5 Remove the spindle assembly See Rear Spindle Removal...

Page 101: ...bolt 27 that secure the bottom of the strut assembly to the lower control arm Ref Fig 9 Fig 10 Strut Removal 5 Remove the strut assembly from the vehicle 6 The installation of the strut assembly is th...

Page 102: ...Remove the wheel See Wheel Removal on page 54 3 Remove the brake calipers from the rotor See Brake Pad Replacement on page 60 4 Remove the hub See Hub Removal on page 86 5 Remove the rear spindle See...

Page 103: ...fill and drain plugs See BODY on page 15 1 Clean the areas around the fill and drain plugs with a clean rag 2 Remove the oil drain plug located on the bottom of the differential and allow the oil to...

Page 104: ...eplace the drain plug NOTICE The lower chamber will be filled by adding oil through the PTO fill plug and then adding more oil through the vehicle speed sensor to bring the level to full capacity Fig...

Page 105: ...crewdriver Flat Tip Large 1 Ratchet Strap 1 Torque Wrench ft lbs 1 Hoist 1 To prevent injury caused by inad vertent movement of the differential a second person is required to sup port and assist in t...

Page 106: ...6 7 Lift and support the vehicle See LIFTING THE VEHICLE on page 13 8 Remove the rear wheels See Wheel Removal on page 54 9 Remove the CV shaft See CV Shaft Replacement on page 88 10 Disconnect the di...

Page 107: ...strap to secure the engine to the rear upper ROPS crossbar for support See Fig 23 Fig 23 Support Engine with Ratchet Strap 16 Remove the bolts 5 10 and 11 and nuts 6 that secure the upper passenger s...

Page 108: ...e to the torque values specified Adjusting the Shift Lever Cable Tool List Qty Wrench 18mm 2 Move the shift lever 2 through it s entire range from the P park position to the H high position If the shi...

Page 109: ...ENSION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 97 Repair and Service Manual 668061 Fig 28 Shift Cable 3 19...

Page 110: ...98 Repair and Service Manual REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 111: ...eing held at the outer diameter of the secondary clutch The secondary clutch has no weights but is held closed by a torsion spring which is joined to the movable secondary assembly As the transmission...

Page 112: ...n before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 668061 Fig 1 CVT Components 12 17 18 26 30 19 20 21 29 16 16 29 CVT Air Intake Front of Vehicle Engi...

Page 113: ...w the same guidelines as described for engine break in operation See Engine Break In on page 110 CVT Belt Inspection Fig 2 CVT Belt The CVT is located under the driver side of the truck bed Ref Fig 2...

Page 114: ...securing the pri mary clutch to the engine crankshaft Ref Fig 4 Fig 4 Primary Clutch Removal 3 Insert the clutch puller tool and tighten clockwise which will remove the clutch from the engine crank s...

Page 115: ...at the rear axle input shaft with a light coat of anti seize compound and slide the clutch onto the shaft 2 Install the clutch bolt 18 and tighten to the torque value specified Draining the CVT If wat...

Page 116: ...ir and Service Manual CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 117: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 105 Repair and Service Manual 668061 PROP SHAFT 1 Front of Vehicle 2 4 5 Rear Differential A A Front Differe...

Page 118: ...the rear U joint of each shaft See RECOMMENDED LUBRICANTS AND FLU IDS on page 168 The prop shaft components must be serviced periodically for optimum engine life and performance See SCHED ULED MAINTE...

Page 119: ...of the rear differential Ref Fig 4 Fig 4 Disconnect Rear Prop Shaft 9 Remove the front and rear prop shafts from the vehi cle 10 Installation is the reverse of removal Clean the prop shaft gearbox an...

Page 120: ...108 Repair and Service Manual PROP SHAFT Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 121: ...ection before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 109 Repair and Service Manual 668061 ENGINE Fig 1 Engine Front of Vehicle 1 2 7 19 11 13 12 7 8...

Page 122: ...raising or removing the truck bed and or removing the cargo deck panel Some service pro cedures may require the vehicle to be lifted See LIFTING THE VEHICLE on page 13 ENGINE OIL NOTICE The use of an...

Page 123: ...OIL AND FILTER Tool List Qty Ratchet 1 Socket 13mm 1 Universal Strap Wrench 1 Funnel 1 Pliers 1 Oil Drain Pan 1 Clean Cloth A R Torque Wrench ft lbs 1 For maximum performance and longevity replace the...

Page 124: ...t Qty Universal Strap Wrench 1 Oil Drain Pan 1 Clean Cloth A R 1 Remove the oil filter with universal strap wrench Ref Fig 6 2 Clean the engine sealing surface with a clean cloth Ref Fig 7 Fig 7 Oil F...

Page 125: ...ch 5mm 1 Spark Plug Socket 16mm 1 Ratchet 1 Ratchet Extension 1 Feeler Gauge 1 Anti seize Compound A R Torque Wrench ft lbs 1 1 With the engine cool remove and inspect the spark plugs See SCHEDULED MA...

Page 126: ...Clear the service counter for the service light See the Stampede 900 Owner s Manual ENGINE COMPRESSION TEST Any fuel drawn into the cylinders will be expelled through the spark plug opening and could...

Page 127: ...to Notices Cautions Warnings and Dangers 115 Repair and Service Manual 668061 ENGINE REMOVAL Fig 14 Engine Mounting Components Front of Vehicle Stator Cover Engine Rear Differential 1 22 23 24 26 24...

Page 128: ...e EXHAUST SYSTEM REMOVAL on page 117 Rear Frame Crossmember See Rear Shock Tower Brace Removal on page 33 CV Shafts See CV Shaft Replacement on page 88 Oil Tank See ENGINE on page 109 Clutch See CONTI...

Page 129: ...ar attention to Notices Cautions Warnings and Dangers 117 Repair and Service Manual 668061 EXHAUST SYSTEM REMOVAL Fig 15 Exhaust System Upper Engine Casting Front of Vehicle 3 13 14 2 20 15 15 3 18 24...

Page 130: ...rame Rotate the J hook out of the isolator hangers 3 5 Remove the nuts 12 and bolts 25 that secure the muffler support bracket 19 to the frame 6 Remove the exhaust pipe 14 7 Disconnect the oxygen sens...

Page 131: ...119 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ENGINE 668061...

Page 132: ...120 Repair and Service Manual ENGINE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 133: ...r attention to Notices Cautions Warnings and Dangers 121 Repair and Service Manual 668061 AIR INTAKE Fig 1 Air Intake Components Engine Oil Tank Engine Bay Closeout Part of Extended Cab Front of Vehic...

Page 134: ...iver seat 2 Unlatch the cover to access the air filter cartridge Ref Fig 3 3 Remove the filter from the housing Ref Fig 2 4 Inspect the filter Replace if dirty or at the first sign of filter paper det...

Page 135: ...123 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ENGINE AIR INTAKE 668061...

Page 136: ...124 Repair and Service Manual ENGINE AIR INTAKE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 137: ...ngers 125 Repair and Service Manual 668061 COOLING SYSTEM Fig 1 Cooling System Components Part of Frame Part of Frame To Engine To Engine Constant Bleed Line To Radiator To Radiator To Engine Constant...

Page 138: ...rify that the coolant level in the reservoir is between the MIN and MAX lines Ref Fig 2 2 If the level is below the MIN line add coolant 3 Remove the cap from the coolant reservoir 4 Add coolant until...

Page 139: ...o the MAX line 11 Remove the jack stands and lower the front of the vehicle as shown in the SAFETY section 12 Start the engine and allow the engine to warm up Make sure the engine speed is held at 190...

Page 140: ...in the cool ant See Coolant Replacement on page 137 5 Use pliers to remove pressure from the upper radia tor hose clamp while sliding the clamp away from the hose connection Ref Fig 7 Carefully pull t...

Page 141: ...ns Warnings and Dangers 129 Repair and Service Manual 668061 10 Remove the two bolts and nuts that secure the radia tor to the frame Ref Fig 9 Lift the radiator up and out of the vehicle Fig 9 11 Inst...

Page 142: ...130 Repair and Service Manual COOLING SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 143: ...ion before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 131 Repair and Service Manual 668061 FUEL SYSTEM Fig 1 Fuel System Components 2 6 11 11 14 11 11 3...

Page 144: ...15 Do not mix oil with gasoline NOTICE Some fuels called oxygenated or reformu lated gasoline are gasoline blended with alcohols or ethers Excessive amounts of these blends can damage the fuel system...

Page 145: ...fuel tank 9 Installation is in reverse order of removal NOTICE Make sure that the fuel line and vent line are not kinked or restricted by wire ties etc Fuel Pump Assembly Tool List Qty Strap Wrench 1...

Page 146: ...134 Repair and Service Manual FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 147: ...A reading of battery voltage indicates that the power wire is in good condition 4 Check the starter Inspect the starter for continuity and functionality replace if required NOTICE The power wire supp...

Page 148: ...lated wrenches to prevent direct contact of a wrench with the battery terminals Direct contact of a bare wrench with the battery terminals can cause an explosion resulting in severe injury or death Al...

Page 149: ...1 that secure the battery cables 8 and 9 to the battery 1 Ref Fig 1 3 Remove the bolt 5 and nut 6 from the battery tray 3 Remove the battery hold down bracket 2 4 Lift the battery up and out of the ve...

Page 150: ...n 20 cm below the mark on the wall 7 Check both headlights in low and high if equipped beam settings 8 If a headlight needs to be adjusted locate the three adjustment screws in the back of the headlig...

Page 151: ...2 Remove screws 17 that secure the information dis play to the instrument panel Ref Fig 6 3 Installation is the reverse order of removal Engine Control Unit ECU Fig 7 Engine Control Unit ECU Tool List...

Page 152: ...L SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 668061 Fig 8 Engine Electrical Connections Front of Vehic...

Page 153: ...and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 141 Repair and Service Manual 668061 Fig 9 Dash Electrical Components Instrument Pan...

Page 154: ...n before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 668061 Fig 10 Part of Seat Frame Part of Frame Front of Vehicle 1 27 21 22 Front of Vehicle Part of...

Page 155: ...e seat frame Remove the voltage regulator 4 Installation is in the reverse order of removal Starter Relay Removal Tool List Qty Ratchet 1 Socket 10mm 1 1 Remove the nuts 25 securing the starter motor...

Page 156: ...K BLUE BLACK VIOLET VIOLET RED RED PINK BROWN BLACK GREEN WHITE WHITE LIGHT GREEN GRAY WHITE BLUE CONN2 REAR FRONT H TO H CONN M CONN15 ACC RR DIFF CONN BROWN GREEN BROWN RED BLACK RED BLUE BLACK VIOL...

Page 157: ...D NC NC NC NC NC NC NC NC NC CANL CANH NC NC NEUTRAL SW OUTPUT NC NC NC NC NC A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4 M4 M3 M2 M1 L4 L3 L2 L1 K4 K3 K2 K1 J4 J3 J2 J1 H4...

Page 158: ...SOR C A B F E D MPE 850 HARN OIL PRESSURE SW to LCD ENGINE RPM to LCD VEHICLE SPD to ECU BRAKE SW to ECU SEATBELT SW to ECU CANH CANL CANH CANL STARTER RELAY COIL 2 STARTER RELAY COIL 1 NEUTRAL SWITCH...

Page 159: ..._FCI BLACK BLUE BLUE BLACK RED RED VIOLET BROWN BLACK WHITE ORANGE RED VIOLET RED BLACK RED BLACK WHITE BLACK WHITE BLACK GREEN BLACK RED VIOLET YELLOW WHITE BLUE WHITE BLACK YELLOW PINK GREEN BLACK Y...

Page 160: ...EHICLE SPEED CAM SPARE OUT 4 OIL QUALITY SPORT SW WATER TEMP LED INJ1 REVERSE LIMITER VEHICLE SPEED GRD FAN RELAY INJ2 MAP DN GND CAM GND INTAKE MANIFOLD FLAP INJ4 2ND AIR VALVE SPARE OUT 1 INJ3 CPV S...

Page 161: ...HITE WHITE LIGHT GREEN SP9 SP10 SP18 GREEN WHITE WHITE WHITE LIGHT GREEN CONN1 REAR ENG H TO H CONN F RED YELLOW BLACK RED RED WHITE CONN8 STARTER RELAY SP15 SP8 SP17 SP16 SP5 SP3 SP1 BLACK BLACK BLAC...

Page 162: ...34 42 46 3 7 11 15 19 23 27 31 35 39 43 47 4 8 12 16 20 24 28 32 36 39 44 48 38 BLACK PUSH ON 3 USB F 1 4 18 22AWG PUSH ON 4 USB F 1 4 18 22AWG PUSH ON 1 12V OUTLET F 1 4 18 22AWG PUSH ON 1 12V OUTLE...

Page 163: ...CONN3 LCD MODULE RING3 GND 10 10AWG RING1 ACC 12V 10 10AWG RING2 DIR BATT 10 10AWG RED ORANGE VIOLET BLACK DARK GREEN BROWN GREEN BROWN RED RED BLACK BLACK VIOLET CONN19 THROTTLE SNSR CONN2 FRONT REA...

Page 164: ...N CONN 11 CHMSL HARN CONN 16 PLUG BLACK BLUE GREEN BLUE RED BLUE BLACK BLUE CONN 10 FUEL PUMP SENSOR BLACK GREEN BLACK WHITE GREEN BLACK BLUE SP4 SP6 1 2 3 4 FP GND FS SGND TL SL CL TPS TPSS GSS GSSS...

Page 165: ...153 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ELECTRICAL SYSTEM 668061...

Page 166: ...154 Repair and Service Manual ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 167: ...park position before discon necting power by removing the negative connection to the battery To check for continuity set the DVOM to the K setting and select Continuity The meter will give an audible...

Page 168: ...engine damage Inspect and repair Crankcase over filled with oil Drain and fill to recommended level with approved oil STARTER ROTATES BUT VEHICLE WILL NOT START OR HARD TO START Weak Battery Recharge...

Page 169: ...tem Check and repair if required Poor quality gasoline Use correct fuel check bulk storage tank for proper storage and handling See GENERAL SPPECIFICATIONS Air leak allowing dirt to enter system Repai...

Page 170: ...RECTION UNEVEN TIRE WEAR Incorrect tire pressure Inflate to recommended pressure See GENERAL SPECI FICATION Improper alignment Incorrect toe in Align front tires PLAY IN STEERING Steering wheel loose...

Page 171: ...159 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers FAULT TESTING 668061...

Page 172: ...160 Repair and Service Manual FAULT TESTING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 173: ...m Cargo Box L x W x H 32 in x 49 in x 12 in 81 cm x 124 cm x 30 cm Ground Clearance no load 11 25 in 28 6 cm Cargo Box Load Capacity 600 lbs 272 kg Extended Cab L x W 17 in x 49 5 in 43 cm x 126 cm Ex...

Page 174: ...teering Self compensating rack and pinion optional EPAS Tire Size standard front 26 x 9 14 Off road performance Tire Size standard rear 26 x 11 14 Off road performance Tire Size optional front 27 x 9...

Page 175: ...163 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers GENERAL SPECIFICATIONS 668061...

Page 176: ...164 Repair and Service Manual GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 177: ...able vehicle operation If not familiar with safe service and adjustment procedures have your dealer perform the operations Initial Service Requirements Perform the additional inspection or maintenance...

Page 178: ...r Daily Inspect Clean or replace as needed Coolant Daily Check level Headlights and tail lights Daily Check operation Replace bulbs as needed Engine oil and filter Initial Service Replace oil and filt...

Page 179: ...Yearly Pressure test system Cooling system 100 Yearly Inspect for leaks Engine mounts 100 Yearly Inspect See repair manual for replacement Exhaust muffler 100 Yearly Inspect See repair manual for repl...

Page 180: ...m Capacity Lubricants Fluids Notes Engine oil 3 qt 2 8 L Mobil 1 0W40 Full Synthetic meeting at least API SJ or ACEA A3 B3 Engine Coolant 8 qt 7 6 L Ethylene Glycol silicate and nitrate free coolant s...

Page 181: ...169 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers SCHEDULED MAINTENANCE 668061...

Page 182: ...170 Repair and Service Manual SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 668061...

Page 183: ...X A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers A Repair and Service Manual APPENDIX A FAULT CODES DIAGNOSTIC...

Page 184: ...B APPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Repair and Service Manual...

Page 185: ...occur at 9V Bridge Off C1006 Battery Voltage High This fault will set if the battery voltage rises above 16 5V Recovery will occur at 16V Bridge Off C1007 Temperature High This fault will set if the...

Page 186: ...wn the unit after 5 minutes of power with no engine RPM Recovery will occur on detection of a run ning engine Bridge Off C1021 Rotor Encoder Variance This fault monitors the rotor encoder position to...

Page 187: ...M Max This fault will set if an RPM is detected above the engine RPM max calibration for longer than the max time calibration This fault is only checked for the CAN and discrete signal type selection...

Page 188: ...Notes F APPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Repair and Service Manual...

Page 189: ...9135 I2 846 UTV NA 80 This diagnostic manual is valid for the following engine models en_English DIAGNOSTIC MANUAL 4 Stroke Engine Read the introductory chapter before performing the task on the engin...

Page 190: ......

Page 191: ...to make continual improvements as part of the ongoing technical development of its products All documentation is therefore subject to technical modifications Reprints and translations in whole or in...

Page 192: ...t 10 4 2 Temperature warning light 10 4 3 Malfunction indicator light MIL 11 5 Troubleshooting with trouble codes 12 5 1 Displaying trouble codes 12 5 2 Description of trouble codes 13 6 Test procedur...

Page 193: ...Meaning NOTICE The signal word NOTICE indicates potential property damage Information The signal word Information indicates specific features and recommendations 1 2 Change management Textron Motors G...

Page 194: ...personnel have read and understand all introductory chapters and in particular the chapter on safety Observe all generally applicable laws and regulations in addition to the information in this diagno...

Page 195: ...eplace defective components All the components in your engine have been carefully tested and fulfill strict quality and safety requirements Textron Motors offers spare parts to the highest quality Ens...

Page 196: ...mmable Vapors may ignite and cause an explosion Do not smoke in the vicinity of the engine and do not allow open flames or sparks near the engine or the fuel system Always turn off the engine before f...

Page 197: ...e Description Textron Motors diagnostic interface module Diagnostic cable Figure Description USB cable Data on USB flash drive Textron Motors Diagnostic Software english Manual german and english 3 2...

Page 198: ...rted There is no malfunction The oil pressure warning light Illuminates until the required oil pressure is achieved Illuminates while the engine is running NOTICE Oil pressure too low Serious engine d...

Page 199: ...L or wiring is defective Check the wire harness See the vehicle manufacturer s documentation Check the malfunction indicator light MIL and wiring See the vehicle manufacturer s documentation Flashes w...

Page 200: ...shooting with trouble codes 5 1 Displaying trouble codes Connect the notebook to the engine und start Textron Motors Diagnostic Software See the vehicle manufacturer s documentation and Textron Motors...

Page 201: ...Rough engine running Engine does not start or stalls Sensor crankshaft Check wiring in the wire harness to the affected part See the vehicle manufacturer s documentation Replace the affected part See...

Page 202: ...on P0101 Mass Air Flow Calculation Plausibility Error Implausible values in air mass calculation Loss of power Starting difficulties Sensor intake manifold pressure temperature Check wiring in the wir...

Page 203: ...eplace the affected part See the vehicle manufacturer s documentation P0113 Intake Air Temperature Sensor Circuit High Open Open circuit or short circuit to plus at part or wire harness Loss of power...

Page 204: ...ess Unusual or no throttle response Throttle body Check wiring in the wire harness to the affected part See the vehicle manufacturer s documentation Replace the affected part See the vehicle manufactu...

Page 205: ...ess to the affected part See the vehicle manufacturer s documentation Replace the affected part See the vehicle manufacturer s documentation P0133 O2 Sensor Circuit Slow Response Sensor 1 Sensor lambd...

Page 206: ...start Rough engine running Injector 1st cylinder Check wiring in the wire harness to the affected part See the vehicle manufacturer s documentation Replace the affected part See the vehicle manufactur...

Page 207: ...or no throttle response Throttle body Check wiring in the wire harness to the affected part See the vehicle manufacturer s documentation Replace the affected part See the vehicle manufacturer s docume...

Page 208: ...start or stalls Relay fuel pump Check wiring in the wire harness to the affected part See the vehicle manufacturer s documentation Replace the affected part See the vehicle manufacturer s documentatio...

Page 209: ...r 2nd cylinder Check wiring in the wire harness to the affected part See the vehicle manufacturer s documentation Replace the affected part See the vehicle manufacturer s documentation P0300 Random Mu...

Page 210: ...nock Check bolting of the affected part See the vehicle manufacturer s documentation Check wiring in the wire harness to the affected part See the vehicle manufacturer s documentation Replace the affe...

Page 211: ...part See the vehicle manufacturer s documentation Replace the affected part See the vehicle manufacturer s documentation P0352 Ignition Coil 2 Control Circuit Low Open Open circuit or short circuit t...

Page 212: ...ternal Control Module A D Processing Performance Internal Monitoring_3 Error Contact the vehicle manufacturer or Textron Motors directly P0615 Starter Relay Circuit Open Open circuit at part or wire h...

Page 213: ...itoring Error Contact the vehicle manufacturer or Textron Motors directly P0626 Alternator Voltage Too High Charging voltage too high Voltage regulator Generator Check the voltage regulator See chapte...

Page 214: ...anufacturer s documentation Replace the affected part See the vehicle manufacturer s documentation P063D Auto Configuration Throttle Input Lower position is not reached Throttle body Check wiring in t...

Page 215: ...documentation P0643 Sensor Reference Voltage 1 Circuit High Short circuit to plus at 5 V power supply from engine control unit Affected connections 32 pol C4 E4 B4 The power supply is outside from 5 V...

Page 216: ...he battery See the vehicle manufacturer s documentation P0685 ECM Main Relay Control Circuit Open Open circuit at part or wire harness The engine cranks but does not start Relay main Check wiring in t...

Page 217: ...acturer s documentation P1604 ECU Internal Warm Restart Failure Contact the vehicle manufacturer or Textron Motors directly P2100 Throttle Actuator Control Motor Circuit Open Open circuit at part or w...

Page 218: ...art See the vehicle manufacturer s documentation P2118 Throttle Actuator Control Motor Range Error The throttle body is blocked Unusual or no throttle response Throttle body WARNING The throttle body...

Page 219: ...the affected part See the vehicle manufacturer s documentation P2127 Pedal Position Sensor 2 Circuit Low Open Open circuit or short circuit to ground at part or wire harness Unusual or no throttle re...

Page 220: ...nufacturer s documentation P2301 Ignition Coil 1 Control Circuit High Short circuit to plus at part or wire harness Rough engine running Engine does not start or stalls Ignition coil 1st cylinder Chec...

Page 221: ...black wires Check all electrical contacts for corrosion and proper mechanical connection Make a diode test with all relevant wires Diode test with multimeter Cross checking Diode tester probe Diode t...

Page 222: ...rosion and proper mechanical connection Make a continuity test with all relevant wires Continuity test with multimeter d Continuity is required Resistance 0 3 ohm 0 1 ohm at 20 C No continuity is perm...

Page 223: ...Checking crankshaft reluctor 6 3 Checking crankshaft reluctor Crankshaft reluctor 1 Gap 2 missing teeth 2 Marking for valve timing 3 Perform a visual inspection of the crankshaft reluctor If mechanica...

Page 224: ...at Information The thermostat is fitted with a wax element Opening temperature from 82 C 179 F The thermostat is fully open at 88 C 190 F Thermostat closed 1 Thermostat opened 2 Perform a visual inspe...

Page 225: ...st procedures at engine 6 5 Checking cam spike at rocker arm 6 5 Checking cam spike at rocker arm Cam spike at rocker arm 1 Perform a visual inspection of the cam spike at rocker arm If mechanical def...

Page 226: ...pressure with oil pressure tester according to the manufacturer s instructions Required oil pressure while idle Minimum 1 5 bar Maximum 5 5 bar 0 5 bar Increase engine speed The oil pressure increases...

Page 227: ...sure too low no Replace the oil pressure valve yes Oil pressure valve always opened See the repair manual no Replace the oil pressure pump yes The oil pressure pump is defective Clean the lubrication...

Page 228: ...E J K L O M P Q N A1 64P A1 32P 1 2 3 4 4 3 2 1 1 2 3 2 1 4 Engine control unit additional part Connector pin assignment Switch oil pressure 1 Connector pin assignment 7 Components overview 7 Compone...

Page 229: ...C B A 4 1 3 2 5 1 2 Connector pin assignment Connector pin assignment Connector pin assignment 7 Components overview Sensor crankshaft 3 Sensor camshaft 4 Sensor coolant temperature 5 The intake mani...

Page 230: ...42 DHB MPE850 UTV Rev A 409135 4 1 3 2 2 1 7 6 8 Sensor Lambda 1 6 additional part Connector pin assignment Sensor knock 7 Connector pin assignment 7 Components overview Starter 8...

Page 231: ...43 DHB MPE850 UTV Rev A 409135 9 B C A 10 11 3 5 1 2 12 Connector pin assignment stator 7 Components overview Generator 9 Stator 10 Rotor 11 Connector pin assignment Relay starter 12 additional part...

Page 232: ...7 in 200 mm 7 9 in A B A B C Connector pin assignment Ignition coil 1st cylinder 13 Ignition coil 2nd cylinder 14 Injector 1st cylinder 15 Injector 2nd cylinder 16 Connector pin assignment Voltage re...

Page 233: ...45 DHB MPE850 UTV Rev A 409135 17 4 5 6 1 2 3 7 Components overview Throttle body 17 Connector pin assignment...

Page 234: ...46 DHB MPE850 UTV Rev A 409135 Appendix Overview of revisions Overview of revisions Revision Date Chapter Description Note Rev A 17 12 2015 1st edition diagnostic manual Appendix...

Page 235: ...arning light description 10 R Relay starter components overview 43 S Sensor camshaft components overview 41 Sensor coolant temperature components overview 41 Sensor crankshaft components overview 41 S...

Page 236: ......

Page 237: ...able from a local Distributor an authorized Branch Genuine E Z GO Parts Accessories Department or at www textronoffroad com CONTACT US TEXTRON SPECIALIZED VEHICLES INC 1451 Marvin Griffin Road Augusta...

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