Toro 500 EFI Manuel utilisateur

Side By Side Off Road Utility Vehicle

500 EFI & 700 EFI

LCE/Residential Products

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

®™ Trademarks of Toro

Table of Contents

General Information ........................................................ 2

General Specifications.........................................................2

Torque Specifications ..........................................................3

Torque Conversions (ft-lb/N-m)............................................5

Gasoline - Oil - Lubricant.....................................................5

Genuine Parts......................................................................6

Special Tools........................................................................6

Preparation For Storage ......................................................6

Preparation After Storage....................................................6

Periodic Maintenance...................................................... 7

Periodic Maintenance Chart ................................................7

Lubrication Points ................................................................8

Air Inlet Pre-Filter.................................................................8

Air Filter ...............................................................................8

Valve/Tappet Clearance.......................................................9

Testing Engine Compression.............................................10

Spark Plug .........................................................................10

Muffler/Spark Arrester .......................................................10

Engine/Transmission Oil - Filter.........................................11

Front Differential - Rear Drive Lubricant ............................12

Driveshaft/Coupling ...........................................................13

Nuts/Bolts/Cap Screws......................................................13

Headlight/Taillight-Brakelight .............................................13

Shift Lever..........................................................................14

Hydraulic Brake System ....................................................15

Burnishing Brake Pads ......................................................16

Checking/Replacing V-Belt ................................................17

Steering/Frame/Controls............................................... 19

Steering Wheel ..................................................................19

Tie Rods ............................................................................19

Steering Assembly.............................................................20

Upper Steering Shaft .........................................................21

Intermediate Steering Shaft Assembly ..............................22

Steering Knuckles..............................................................23

Accelerator Pedal ..............................................................25

Shift Lever..........................................................................25

Shift Cable .........................................................................25

LCD Gauge........................................................................26

Checking/Adjusting Front Wheel Alignment.......................27

Front Bumper Assembly ....................................................28

Hood ..................................................................................28

Fenders..............................................................................29

Floor ..................................................................................29

Dashboard .........................................................................30

Belly Panel.........................................................................30

Exhaust System.................................................................31

Cargo Box..........................................................................31

Taillight Assembly ..............................................................32

Seat ...................................................................................32

Troubleshooting .................................................................33

Engine/Transmission .................................................... 34

Troubleshooting .................................................................35

Removing Engine/Transmission ........................................37

Servicing Engine (500) ......................................................40

Servicing Engine (700) ......................................................77

Installing Engine/Transmission ........................................115

Fuel/Lubrication/Cooling............................................ 118

Throttle Body................................................................... 118

Gas Tank .........................................................................119

Gas/Vent Hoses ..............................................................121

Oil Filter/Oil Pump ...........................................................121

Liquid Cooling System ....................................................122

Radiator........................................................................... 122

Thermostat ...................................................................... 123

Fan ..................................................................................123

Water Pump ....................................................................124

Troubleshooting ...............................................................125

Electrical System ........................................................ 126

Battery.............................................................................126

Accessory Receptacle/Connector ...................................126

Brakelight Switch.............................................................127

Engine Coolant Temperature (ECT) Sensor.................... 127

Fan Motor ........................................................................128

Power Distribution Module (PDM) ................................... 128

Ignition Coil .....................................................................128

EFI Sensors/Components ...............................................129

Speed Sensor .................................................................130

RPM Limiter ....................................................................131

Ignition Switch .................................................................131

Headlight Switch .............................................................131

Drive Select Switch .........................................................132

Reverse Override Switch.................................................132

Front Drive Actuator ........................................................132

Stator Coil .......................................................................133

Starter Motor ...................................................................134

Starter Relay ...................................................................134

Electronic Control Module (ECM).................................... 135

Fuel Pump/Fuel Level Sensor ......................................... 135

Regulator/Rectifier ..........................................................136

Headlights .......................................................................137

Taillight-Brakelight ...........................................................137

Ignition Timing ................................................................. 137

Tilt Sensor .......................................................................137

Throttle Position Sensor (TPS)........................................139

EFI Diagnostic System.................................................... 139

Troubleshooting ...............................................................144

Drive System ............................................................... 145

Front Drive Actuator ........................................................145

Front Differential ..............................................................146

Drive Axles ...................................................................... 157

Rear Gear Case ..............................................................160

Hub.................................................................................. 162

Hydraulic Brake Caliper...................................................164

Universal Joints ............................................................... 167

Troubleshooting Drive System......................................... 169

Troubleshooting Brake System........................................ 170

Suspension.................................................................. 171

Shock Absorbers ............................................................. 171

Front A-Arms ................................................................... 171

Rear A-Arms ................................................................... 174

Wheels and Tires ............................................................ 175

Troubleshooting ...............................................................176

General Information

NOTE: Some photographs and illustrations used in

this manual are used for clarity purposes only and

are not designed to depict actual conditions.

General Specifications

Specifications subject to change without notice.

MISCELLANY

Tire Size (front)

(rear)

26 x 10R-14

26 x 12R-14

Tire Inflation Pressure 1.12 kg/cm² (16 psi) - 500

1.41 kg/cm² (20 psi) - 700

Spark Plug Type NGK CR7E - 500

NGK CPR8E - 700

Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)

-500

0.5-0.6 mm (0.019-0.024 in.)

- 700

Gas Tank Capacity 31 L (8.2 U.S. gal.)

Coolant Capacity 2.9 L (3.0 U.S. qt)

Front Differential Capacity 275 ml (9.3 fl oz)*

Rear Drive Capacity 250 ml (8.5 fl oz)*

Engine Oil Capacity (approx) (500)

(700)

3.3 L (3.5 U.S. qt) - Overhaul

2.8L(3.0U.S.qt)-Change

2.5 L (2.6 U.S. qt) - Overhaul

1.9 L (2.0 U.S. qt) - Change

Gasoline (recommended) 87 Octane Regular

Unleaded

Engine Oil (recommended) Toro ACX All Weather Syn-

thetic

Front Differential/Rear Drive Lubricant

(One inch below plug threads)

SAE Approved 80W-90 Hyp-

oid

Belt Width (minimum) 28.5 mm (1.12 in.) - 500

35.0 mm (1.38 in.) - 700

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/27W (4)

ELECTRICAL SYSTEM

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Cap 5000 ohms

Ignition Coil Resistance (primary)

(secondary)

Less than 5.0 ohms - 500

Less than 1 ohm - 700

12k-19k ohms - 500

1.8M ohms - 700

Ignition Coil Primary Voltage Battery Voltage

Stator Coil Resistance (CKP Sensor)

(AC generator)

104-156 ohms

Less than 1 ohm

AC Generator Output (no load) 60 AC volts @ 5000 RPM

Crankshaft Position Sensor AC Voltage 2.5 volts or more - 500

2.0 volts or more - 700

CYLINDER, PISTON, AND RINGS (500)

Piston Skirt/Cylinder Clearance 0.025-0.055 mm

Piston Diameter 8 mm from Skirt End 88.96-88.98 mm

Piston Ring Free End Gap (max) (1st)

(2nd)

11.6 mm

10.1 mm

Bore x Stroke 89.0 x 71.2 mm

Cylinder Trueness (max) 0.01 mm

Piston Ring End Gap - Installed (min) 0.15 mm

Piston Ring to Groove Clearance (max) (1st/

2nd)

0.06 mm

Piston Ring Groove Width (1st)

(2nd)

(oil)

1.01-1.03 mm

1.21-1.23 mm

2.01-2.03 mm

Piston Ring Thickness (1st)

(2nd)

0.97-.99 mm

1.17-1.19 mm

Piston Pin Bore (max) 20.008 mm

Piston Pin (min) 19.994 mm

CYLINDER, PISTON, AND RINGS (700)

Piston Skirt/Cylinder Clearance (min) 0.06 mm

Cylinder Bore 101.992-102.008 mm

Piston Diameter 15 mm from Skirt End 101.930-101.949 mm

Piston Ring Free End Gap (1st/2nd) 12.5 mm

BorexStroke 102x85mm

Cylinder Trueness (max) 0.01 mm

Piston Ring End Gap - Installed (min) 0.38 mm

Piston Ring to Groove Clearance (max)

(1st/2nd)

0.03 mm

Piston Ring Groove Width (1st/2nd)

(oil)

1.202-1.204 mm

2.01-2.03 mm

Piston Ring Thickness (1st/2nd) 1.970-1.990 mm

Piston Pin Bore (max) 23.0 mm

Piston Pin Outside Diameter (min) 22.99 mm

VALVES AND GUIDES (500)

Valve Face Diameter (intake)

(exhaust)

35.0 mm

30.5 mm

Valve/Tappet Clearance (intake)

(cold engine) (exhaust)

0.10 mm

0.17 mm

Valve Guide/Stem (intake)

Clearance (max) (exhaust)

0.10 mm

0.30 mm

Valve Guide Inside Diameter 5.000-5.012 mm

Valve Seat Angle (intake/exhaust) 45°

Valve Spring Free Length (min) 44.73 mm

Valve Spring Tension @ 35.2 mm 17.23 kg (37.98 lb)

VALVES AND GUIDES (700)

Valve Face Diameter (intake)

(exhaust)

31.6 mm

27.9 mm

Valve/Tappet Clearance (intake)

(cold engine) (exhaust)

0.1016 mm

0.1524 mm

Valve Guide/Stem Clearance 0.013 mm

Valve Guide Inside Diameter 5.000-5.012 mm

Valve Head Thickness (min) 2.3 mm

Valve Seat Angle 45° +15’/+30’

Valve Spring Free Length (min) 38.7 mm

Valve Spring Tension @ 31.5 mm 19.0 kg (42 lb)

Torque Specifications

NOTE: Torque specifications have the following tol-

erances:

* w/Blue Loctite #243 ** w/Red Loctite #271

*** w/Green Loctite #270 **** w/“Patch-Lock”

CRANKSHAFT (500)

Connecting Rod (small end) (max) 20.021 mm

Connecting Rod (big end side-to-side)

(max) 0.7 mm

Connecting Rod (big end width) 21.95-22.00 mm

Connecting Rod (small end deflection)

(max) 3.0 mm

Crankshaft (web-to-web) 60.9 mm

Crankshaft Runout (max) 0.03 mm

CRANKSHAFT 700)

Connecting Rod (small end inside (max)

(diameter)

23.021 mm

Connecting Rod (big end side-to-side)(min) 0.6 mm

Connecting Rod @ 150 mm (max)

(small end deflection)

0.3 mm

Crankshaft (web-to-web) (min) 71 mm

Crankshaft Runout (max) 0.03 mm

CAMSHAFT AND CYLINDER HEAD (500)

Cam Lobe Height (min) (intake)

(exhaust)

34.71 mm

34.48 mm

Camshaft Journal Holder(right & center)

Inside Diameter (left)

22.01-22.04 mm

17.51-17.54 mm

Camshaft Journal Outside(right & center)

Diameter (left)

17.466-17.480 mm

21.966- 21.980 mm

Camshaft Runout (max) 0.03 mm

Cylinder Head/Cover Distortion (max) 0.05 mm

CAMSHAFT AND CYLINDER HEAD (700)

Cam Lobe Height (min) 33.53 mm

Camshaft Journal Oil Clearance (max) 0.04 mm

Camshaft Runout (max) 0.05 mm

Cylinder Head/Cover Distortion (max) 0.05 mm

Torque (ft-lb) Tolerance

0-15 ±20%

16-39 ±15%

40+ ±10%

EXHAUST COMPONENTS

Part Part Bolted To Torque

ft-lb N-m

Exhaust Pipe Cylinder Head 20 27

Spark Arrester Muffler 50

in.-lb

O2 Sensor Exhaust Pipe 19 26

BRAKE COMPONENTS

Brake Disc** Hub 15 20

Brake Hose Caliper 20 27

Brake Hose Master Cylinder 20 27

Master Cylinder Frame 25 34

Caliper**** Knuckle 20 27

Rear Driveline **** Rear Differential 12 16

ELECTRICAL COMPONENTS

Coil* Frame 811

DRIVE TRAIN COMPONENTS

Part Part Bolted To Torque

ft-lb N-m

Rear Differential/Gear Case Frame 38 48

Front Engine Mounting

Bracket

Frame 45 61

Rear Engine Mounting Bracket Frame 45 61

Engine Mounting Through-Bolt Frame 40 54

Front Differential Frame/Differential Bracket 38 52

Rear Output Flange Rear Driven Flange 40 54

Input Shaft Assembly Gear Case Housing 23 31

Pinion Housing Differential Housing 23 31

Secondary Shaft Bearing

Housing

Crankcase 28 38

Rear Cradle Frame 25 34

Driveshaft (Front/Rear) Engine 20 27

Shift Cable Bracket Engine 811

Front Input Drive Flange Front Drive Yoke Flange 20 27

Differential Housing Cover*** Differential Housing 23 31

Thrust Button** Gear Case Cover 811

Drive Bevel Gear Nut*** Shaft 87 118

Lock Collar Differential Housing 125 170

Hub Nut Front/Rear Shaft/Axle (min) 200 272

Oil Drain Plug Front Differential - Rear

Drive 45

in.-lb

Oil Fill Plug Front Differential - Rear

Drive 16 22

Oil Drain Plug Engine 16 22

Wheel (Aluminum) Hub 80 108

Wheel (Steel) Hub 40 54

STEERING COMPONENTS

Steering Wheel** Steering Wheel Shaft 25 34

Steering Wheel Shaft*** Intermediate Shaft (Upper) 31 42

Intermediate Shaft (Lower)*** Steering Pinion Shaft 36 49

Rack and Pinion Assembly Frame 35 48

Tie Rod Rack 37 50

Tie Rod End** Knuckle 30 41

Jam Nut Tie Rod End 10 14

Intermediate Shaft Coupler Intermediate Shaft 31 42

Steering Shaft Housing (6

mm)

Frame 811

Steering Shaft Housing (8

mm)

Frame 20 27

CHASSIS/ROPS ASSEMBLY

Shift Axle Support Frame 48

in.-lb

Front/Rear ROPS Tube Arm Rest/Steering Support 35 48

Top ROPS Support Front/Rear ROPS Tubes 35 48

Rear ROPS Tube Lower ROPS Support 35 48

Shift Cable Shift Arm Stud 834

Shift Cable Mounting/Adjuster Shift Cable 20 27

Cargo Box Hinge Cargo Box Frame 20 27

Side Panel/Spacer Cargo Box Frame 25 34

Tilt Pivot Bushing Cargo Box Frame 15 20

Latch Striker Cargo Box Liner 60

in.-lb

SUSPENSION COMPONENTS

A-Arm Frame 35 48

Knuckle Ball Joint 35 48

Shock Absorber Frame/Upper A-Arm 35 48

Shock Absorber (Front) Lower A-Arm 20 27

Shock Absorber (Rear) Lower A-Arm 35 48

Knuckle A-Arm 35 48

Sway Bar Bracket (Rear) Frame 35 48

ENGINE/TRANSMISSION (500)

Part Part Bolted To Torque

ft-lb N-m

Clutch Shoe** Crankshaft 147 199

Clutch Cover/Housing Assembly Crankcase 811

Crankcase Half (6 mm) Crankcase Half 10 13.5

Crankcase Half (8 mm) Crankcase Half 21 28

Cylinder Nut Crankcase Half 811

Cylinder Head (Cap Screw) Crankcase 28 38

Cylinder Head Nut Cylinder 20 27

Cylinder Head Cover Cylinder Head 811

Oil Pump Drive Gear** Crankshaft 63 86

Driven Pulley Nut** Driveshaft 147 199

Ground Wire Engine 811

Rotor/Flywheel Nut Crankshaft 107 146

Cam Sprocket** Camshaft 11 15

Valve Adjuster Jam Nut Valve Adjuster 7 9.5

Starter Motor** Crankcase 811

Oil Fitting Engine 811

Starter One-Way Clutch** Rotor/Flywheel 26 35

Oil Pump** Crankcase 811

Movable Drive Face Nut** Clutch Shaft 147 199

Output Shaft Flange Nut Output Shaft 59 80

Cam Chain Tensioner Guide Cylinder 11 15

Valve Inspection Cover Cylinder Head Cover 811

Cam Chain Tensioner Cylinder 10 13.5

Magneto Cover Crankcase 811

Water Pump Cover/Housing Magneto Cover 811

Water Pump Drive Gear Crankshaft 28 38

Air Filter Frame 12 16

Oil Strainer Cap Crankcase 10 13.5

V-belt Cover Crankcase 811

ENGINE/TRANSMISSION (700)

Part Part Bolted To Torque

ft-lb N-m

Clutch Shoe** Crankshaft 221 300

Clutch Cover/Housing Assem-

bly

Crankcase 811

Crankcase Half (6 mm) Crankcase Half 10 13.5

Crankcase Half (8 mm) Crankcase Half 20 27

Cylinder Head (Cap Screw) Crankcase 40 54

Cylinder Head Nut (6 mm) Cylinder 811

Cylinder Head Nut (8 mm) Cylinder 18 24

Valve Cover Cylinder Head 811

Driven Pulley Nut Driveshaft 162 220

Movable Drive Face Nut** Driveshaft 165 224

Ground Wire Engine 811

Magneto Cover Crankcase 811

Crankshaft Spacer Crankshaft 28 38

Oil Pump** Crankcase 811

Oil Pump Drive Gear** Crank Balancer Shaft 62 84

Output Shaft Flange Nut** Output Shaft 62 84

One-Way Clutch** Rotor/Flywheel 26 35

Outer Magneto Cover Side Cover 811

Magneto Rotor Nut** Crankshaft 105 143

Cam Sprocket** Camshaft 11 15

Speed Sensor Housing Crankcase 811

V-Belt Cover Crankcase 811

Output Yoke Nut** Secondary Driven Output

Shaft 74 100

Output Shaft Flange Yoke/

Nut**

Output Shaft 59 80

Secondary Shaft Bearing

Housing

Crankcase Half 28 38

Stator Coil* Magneto Cover 13 18

Intake Manifold Boot Clamp Intake Boot 30 in.-

3.4

Water Pump Engine 811

Oil Strainer Cap Crankcase 10 13.5

Air Filter Frame 12 16

Shift Cam Plate** Camshaft 811

Crankshaft Bushing Crankshaft 25 34

Torque Conversions

(ft-lb/N-m)

Gasoline - Oil - Lubricant

RECOMMENDED GASOLINE

The recommended gasoline to use in this vehicle is 87

minimum octane regular unleaded. In many areas, oxy-

genates are added to the gasoline. Oxygenated gasolines

containing up to 10% ethanol or 5% methane are accept-

able gasolines.

When using ethanol blended gasoline, it is not necessary

to add a gasoline antifreeze since ethanol will prevent the

accumulation of moisture in the fuel system.

RECOMMENDED ENGINE/

TRANSMISSION OIL

The recommended oil to use is Toro 0W-40 All Weather

synthetic engine oil, which has been specifically formu-

lated for use in this engine. Although Toro 0W-40 All

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.

OILCHARTJ

RECOMMENDED FRONT

DIFFERENTIAL/REAR DRIVE

LUBRICANT

NOTE: Toro recommends the use of genuine Toro

lubricants.

The recommended front differential/rear drive lubricant

is SAE approved 80W-90 hypoid. This lubricant meets

all of the lubrication requirements of this vehicle.

FILLING GAS TANK

Since gasoline expands as its temperature rises, the gas

tank must be filled to its specified capacity only. Expan-

sion room must be maintained in the tank particularly if

the tank is filled with cold gasoline and then moved to a

warm area.

Tighten the gas tank cap securely after filling the tank.

ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m

11.4 26 35.4 51 69.4 76 103.4

22.7 27 36.7 52 70.7 77 104.7

34.1 28 38.1 53 72.1 78 106.1

45.4 29 39.4 54 73.4 79 107.4

56.8 30 40.8 55 74.8 80 108.8

68.2 31 42.2 56 76.2 81 110.2

79.5 32 43.5 57 77.5 82 111.5

810.9 33 44.9 58 78.9 83 112.9

912.2 34 46.2 59 80.2 84 114.2

10 13.6 35 47.6 60 81.6 85 115.6

11 15 36 49 61 83 86 117

12 16.3 37 50.3 62 84.3 87 118.3

13 17.7 38 51.7 63 85.7 88 119.7

14 19 39 53 64 87 89 121

15 20.4 40 54.4 65 88.4 90 122.4

16 21.8 41 55.8 66 89.8 91 123.8

17 23.1 42 57.1 67 91.1 92 125.1

18 24.5 43 58.5 68 92.5 93 126.5

19 25.8 44 59.8 69 93.8 94 127.8

20 27.2 45 61.2 70 95.2 95 129.2

21 28.6 46 62.6 71 96.6 96 130.6

22 29.9 47 63.9 72 97.9 97 131.9

23 31.3 48 65.3 73 99.3 98 133.3

24 32.6 49 66.6 74 100.6 99 134.6

25 34 50 68 75 102 100 136

CAUTION

Do not use white gas. Only recommended gasoline addi-

tives should be used.

CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These oils

can adversely affect clutch operation. Also, not recom-

mended are racing, vegetable, non-detergent, and cas-

tor-based oils.

CAUTION

Any lubricant used in place of the recommended lubri-

cant could cause serious front differential/rear drive

damage.

! WARNING

Always fill the gas tank in a well-ventilated area. Never

add fuel to the gas tank near any open flames or with

the engine running. DO NOT SMOKE while filling the

gas tank.

! WARNING

Do not overflow gasoline when filling the gas tank. A

fire hazard could materialize. Always allow the engine to

cool before filling the gas tank.

! WARNING

Do not over-fill the gas tank.

Genuine Parts

When replacement of parts is necessary, use only genuine

Toro parts. They are precision-made to ensure high quality

and correct fit. Refer to the appropriate Illustrated Parts Man-

ual for the correct part number, quantity, and description.

Special Tools

A number of special tools must be available to the techni-

cian when performing service procedures in this manual.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Toro Ser-

vice Department.

Preparation For Storage

1. Clean the seat cushions with a damp cloth and allow

to dry.

2. Clean the vehicle thoroughly by washing dirt, oil,

grass, and other foreign matter from the entire vehi-

cle. Allow the vehicle to dry thoroughly. DO NOT

get water into any part of the engine or air intake.

3. Either drain the gas tank or add a fuel stabilizer to the

gas in the gas tank.

4. Clean the interior of the air filter housing.

5. Plug the hole in the exhaust system with a clean cloth.

6. Apply light oil to the upper steering shaft bushing

and plungers of the shock absorbers.

7. Tighten all nuts, bolts, cap screws, and screws. Make sure

rivets holding components together are tight. Replace all

loose rivets. Care must be taken that all calibrated nuts,

cap screws, and bolts are tightened to specifications.

8. Fill the cooling system to the bottom of the stand

pipe in the radiator neck with properly mixed cool-

ant.

9. Disconnect the battery cables (negative cable first);

then remove the battery, clean the battery posts and

cables, and store in a clean, dry area.

NOTE: For storage, use a battery maintainer or

make sure the battery is fully charged (see Battery

section in this manual).

10. Store the vehicle indoors in a level position.

Preparation After

Storage

Taking this vehicle out of storage and correctly preparing

it will assure many miles and hours of trouble-free riding.

Toro recommends the following procedure.

1. Clean the vehicle thoroughly.

2. Clean the engine. Remove the cloth from the exhaust

system.

3. Check all control wires and cables for signs of wear

or fraying. Replace if necessary.

4. Change the engine/transmission oil and filter.

5. Check the coolant level and add properly mixed

coolant as necessary.

6. Charge the battery; then install. Connect the battery

cables making sure to connect the positive cable first.

7. Check the entire brake systems (fluid level, pads,

etc.), all controls, headlights, taillight, brakelight,

and headlight aim; adjust or replace if necessary.

8. Check the tire pressure. Inflate to recommended

pressure as necessary.

9. Tighten all nuts, bolts, cap screws, and screws mak-

ing sure all calibrated nuts, cap screws, and bolts are

tightened to specifications.

10. Make sure the steering moves freely and does not

bind.

11. Check the spark plug. Clean or replace as necessary.

Description p/n

Crankcase Separator/Crankshaft Remover 132-3161

Gear Case Seal Installer Tool 132-3162

Magneto Rotor Remover Set 132-3164

Valve Clearance Adjuster 132-3165

Driven Clutch Holder 132-3166

Clutch Cover Seal Installation Tool 132-3167

Slide Hammer 6 mm Adapter 132-3168

Spanner Wrench 132-3188

Fuel Pressure Tester Kit 132-3198

CVT Pulley Holder 132-3180

CAUTION

Prior to storing the vehicle, it must be properly serviced

to prevent rusting and component deterioration.

CAUTION

Avoid storing outside in direct sunlight and avoid using

a plastic cover as moisture will collect on the vehicle

causing rusting.

CAUTION

Before installing the battery, make sure the ignition

switch is in the OFF position.

Periodic Maintenance

This section has been organized into sub-sections which show

common maintenance procedures for the Toro ROV.

Periodic Maintenance

Chart

A = Adjust I = Inspect C = Clean R = Replace T = Tighten L = Lubricate

* 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.

Item

Initial Service

After Break-In

(First Month or

100 Miles)

Every

Day

Every Month or

Every 100 Miles

Every 3

Months or

Every 300

Miles

Every 6

Months or

Every 500

Miles

Every Year or

Every 1500

Miles

Needed

Battery II C

Fuses IR

Air Filter II* R

Valve/Tappet Clearance IIA

Engine Compression I

Spark Plug I I I R (4000 Mi or

18 Mo)

Muffler/Spark Arrester CR

Gas Hoses I I R (2 Yrs)

Throttle Cable Ends/Accelerator Pedal Pivot II C-L A-R

Engine-Transmission Oil Level I A

Engine-Transmission Oil/Filter R R*/R**/R*** R

Front Differential - Rear Drive Lubricant I I R (4 Yrs)

Tires/Air Pressure II R

Steering Components II I R

V-Belt IlR

Suspension (Ball joint boots, drive axle

boots front and rear, tie rods, differential

and rear drive bellows)

II R

Nuts/Bolts/Cap Screws TT A

Ignition Timing I

Headlight/Taillight-Brakelight II R

Switches II R

Shift Lever IA-L

Gauges/Indicators II R

Frame/Welds II l

Electrical Connections lC

Complete Brake System (Hydraulic) II

Brake Pads II* R

Brake Fluid I I R (2 Yrs)

Brake Hoses I I R (4 Yrs)

Coolant/Cooling System I I R (2 Yrs)

Wheel Lug Nuts TT

Lubrication Points

It is advisable to lubricate certain components periodi-

cally to ensure free movement. Apply light oil to the

components using the following list as reference.

A. Accelerator Pedal Pivot/Cable Ends

B. Brake Pedal Pivot

C. Shift Cable

Air Inlet Pre-Filter

This vehicle is equipped with a foam pre-filter to filter

dirt from the inlet air prior to reaching the main air filter.

1. Raise the cargo box; then gently squeeze the pre-fil-

ter cover and lift it up to expose the pre-filter.

HDX237A

2. Loosen the clamp securing the pre-filter.

HDX235

2. Remove the pre-filter assembly and wash thoroughly

in warm, soapy water; then rinse and dry.

3. Install and secure with the clamp. Tighten securely;

then with the pre-filter cover installed, lower the

cargo box.

Air Filter

NOTE: To access the air filter, raise the cargo box.

1. Remove dirt and debris from around the filter hous-

ing.

2. Unsnap the four spring-clip fasteners and remove the

air filter cover.

HDX050A

3. Remove the two knobs securing the filter; then

remove the metal hold-down and filter.

HDX226A

4. Fill a wash pan larger than the element with a soapy

water; then dip the element in the soapy water and

wash it.

5. Squeeze the element by pressing it between the

palms of both hands to remove excess soapy water.

Do no twist or ring the element or it will tear.

6. Dry the element.

7. Put the element in a plastic bag; then pour in air filter

oil and work the oil into the element.

CAUTION

Failure to inspect the air filter frequently if the vehicle is

used in dusty, wet, or muddy conditions can damage

the engine.

Ce manuel convient aux modèles suivants

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