Textron Stampede 900 2017 User manual

Technician’s Repair and Service Manual
668061-B
2018

SAFETY
For any questions on material contained in this manual, contact
an authorized representative for clarification.
Read and understand all labels located on the vehicle. Always
replace any damaged or missing labels.
The STAMPEDE 900 is an off road vehicle. Familiarize yourself
with all laws and regulations concerning the operation of this vehi-
cle in your area.
The following symbols appear throughout this manual and on your
vehicle. Your safety is involved when these symbols are used.
Become familiar with their meanings before reading the manual.
DANGER indicates a hazardous situation
that, if not avoided, will result in death or
serious injury.
WARNING indicates a hazardous situation,
if not avoided, could result in death or seri-
ous injury.
CAUTION indicates a hazardous situation
that, if not avoided, could result in minor
or moderate injury.
Failure to comply with the warnings in this
manual can result in severe injury or
death.
Read this entire manual carefully before
operating this vehicle. Do not attempt to
operate this vehicle until you have thor-
ough knowledge of the controls and features.
Regular inspections and 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 900 is designed and
manufactured for off road use only. Use on public streets, roads or
highways is illegal in most areas and increases the risk of an acci-
dent involving other vehicles and people. This vehicle does not
meet FMVSS (Federal Motor Vehicle Safety Standards) for public
street, road or highway use.
Check all laws and regulations before choosing an area to oper-
ate the STAMPEDE 900.
Noise Control System
Do not modify the engine, intake or exhaust components. Modifi-
cations to these components can affect compliance with
ROHVA1-2016 and local noise level requirements. Modifications
to these components can also affect the emissions control sys-
tem.
Spark Arrestor And Use On Public
Lands
The TEXTRON OFF ROAD vehicle has a spark arrester that was
tested and qualified to be in compliance with the USFS standard
5100-1. Federal law requires that this spark arrester be installed
and functional when the vehicle is operated on public lands.
Off road vehicle operation on public lands in the USA is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Go
to www.www.gpo.gov/fdsys to see federal regulations.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed
beyond the factory specifications. Such modifications can cause serious personal injury or death. Textron Specialized Vehicles, Inc. pro-
hibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehi-
cle.
Textron Specialized Vehicles, Inc. reserves the right to incorporate engineering and design changes to products in this manual, without
obligation to include these changes on units sold previously.
The information contained in this manual may be revised periodically by Textron Specialized Vehicles, Inc., and therefore is subject to
change without notice.
TEXTRON SPECIALIZED VEHICLES, INC. DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABIL-
ITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
These are the original instructions as defined 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: [phone] FAX: [phone]
Service Parts PHONE: [phone]
International:
PHONE: [phone] FAX: [phone]
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Repair and Service Manual
668061
REPAIR AND SERVICE MANUAL
4X4 ALL TERRAIN VEHICLE
STAMPEDE 900
STARTING MODEL YEAR 2017
CALIFORNIA Proposition 65 Warning
WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which
contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth
defects and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new
and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes and particulates,
all identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.
This vehicle has been designed and manufactured in the United States of America (USA). The Standards and Specifi-
cations listed in the following text originate in the USA unless otherwise indicated.

GENERAL INFORMATION
ii Repair and Service Manual 668061
The use of non-Original Equipment Manufacturer (OEM) approved parts may void the warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehi-
cle warranty.
When servicing the engine, all adjustments and replacement components must be per original vehicle specifications in
order to maintain the United States of America Federal and State emission certification applicable at the time of manu-
facture.
BATTERY PROLONGED STORAGE
Batteries 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 falls below -75°F (- 60°C).
For winter storage, the battery must be clean, fully charged and disconnected from any source of electrical drain.
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recy-
cling. For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dis-
pose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state
environmental officials regarding disposal information.

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SAFETY INFORMATION
668061
SAFETY INFORMATION
This manual has been designed to assist in the maintenance of the vehicle in accordance with procedures developed
by the manufacturer. Following these procedures and troubleshooting tips will ensure the best possible service from the
product. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully
observed:
GENERAL
Many vehicles are used for a variety of tasks beyond their original intended use; therefore it is impossible to anticipate
and warn against every possible combination of circumstances that may occur. Warnings cannot replace good com-
mon sense driving practices. Common sense driving practices do more to prevent accidents and injury than warnings
and instructions can provide.
The manufacturer strongly suggests anyone operating the vehicle read the entire owner’s manual provided with the
purchase of the vehicle, paying particular attention to the CAUTIONS, WARNINGS and DANGERS within.
For any questions or concerns, contact your dealer.
Textron Specialized Vehicles, Inc. reserves the right to make design changes without obligation to make these changes
on units previously sold and the information in this manual is subject to change without notice.
Textron Specialized Vehicles, Inc. is not liable for errors in this manual or for incidental or consequential damages that
result from the use of the material in this 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 Motor Vehicle Safety Stan-
dards and is not intended for operation on public streets.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity. Do not exceed number of occupants indicated.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle,
decrease it’s stability, increase the speed or extend the stopping distance beyond the fac-
tory specification. Such modifications can result in serious personal injury or death.
Modifications that increase the speed and/or weight of the vehicle will extend the braking distance and may reduce the
stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and disclaims
responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
Speed should be moderated by the environmental conditions, terrain and common sense.
GENERAL OPERATION
ALWAYS:
• Use the vehicle in a responsible manner and keep the vehicle in safe operating condition.
• Read and observe all warnings and operation instruction labels on the vehicle.
• Follow all safety rules in the area where the vehicle is being operated.
• Reduce speed to compensate for poor terrain or conditions.
• Apply brakes to control speed on steep grades.
• Reduce speed in damp or wet areas.
• Use caution when approaching sharp or blind turns.
• Use caution when driving over loose terrain.
• Use caution when driving in areas where pedestrians are present.

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SAFETY INFORMATION
668061
MAINTENANCE
ALWAYS:
• Replace damaged or missing warning, caution or information labels.
• Maintain the vehicle according to the manufacturer’s periodic service schedule. See SCHEDULED MAINTE-
NANCE CHART on page 166.
• Ensure that repairs are performed by trained and qualified persons.
• Follow the manufacturer’s maintenance procedures.
• Use insulated tools near the battery to prevent sparks or battery explosion.
• Check the polarity of the battery terminals and be sure to rewire the battery correctly.
• Use specified replacement parts. Never use replacement parts of lesser quality.
• Use recommended tools.
• Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the
safety 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 get under a vehicle that is supported by a jack alone.
• Never service a vehicle in an area where exposed flame is present or persons are smoking.
• Be aware that a vehicle that is not performing properly is a potential hazard and must not be operated.
• Test drive vehicle after repairs or maintenance in a safe area, free of vehicular and pedestrian traffic.
• Keep complete records of the maintenance history of the vehicle.
VENTILATION
ALWAYS:
• Store the vehicle in a well ventilated area to prevent gasoline fumes from accumulating.
• Fuel the vehicle in an area free from flame or sparks. Pay particular attention to natural gas or propane water
heaters and furnaces.
• Service or operate the vehicle in a well ventilated area to prevent the accumulation of exhaust gases.

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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GENERAL INFORMATION AND ROUTINE MAINTENANCE
SERIAL NUMBER AND VIN LOCATION
Fig. 1 Serial Number and VIN Location
Two serial 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 basis. The information on these labels must be provided to obtain correct
replacement components for the vehicle.
Frame VIN
(vehicle frame
under seat)
Front
Serial Number Label on Steering Column
Serial Number
Labels under Front
Cowl Access Panel
MAIN SERIAL NUMBER LABEL
Certification Statement

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668061
STARTING THE VEHICLE WITH A DIS-
CHARGED BATTERY
The stator is not designed to charge a discharged battery.
If the vehicle is equipped with additional lights and/or a
strobe light that is used when the vehicle is not in motion,
the stator may not be adequate to maintain battery
charge. If the vehicle battery has discharged, it must be
charged with a 12V charger rated at 10 amp or less.
Observe all instructions provided by the manufacturer of
the charger.
SERVICING THE VEHICLE
Do not attempt any type of servicing
operations before reading and
understanding all notes, cautions,
warnings and dangers in this manual.
Any servicing requiring adjustments to be made to
the powertrain while the engine is running must be
made with all four wheels raised.
Wear eye protection when working on the vehicle. In
particular, use care when working around the bat-
tery, or using solvents or compressed air.
To reduce the possibility of causing an electrical
arc, which could result in a battery explosion, turn
off all electrical loads from the battery before
removing any heavy gauge battery wires.
To prevent the possibility of powertrain failure,
never operate the vehicle at full throttle for more
than 4 - 5 seconds while vehicle is in a “no load”
condition.
Before a new vehicle is put into operation, it is recom-
mended the items shown in the INITIAL SERVICE
CHART be performed (See Fig. 2).
Vehicle battery must be fully charged before initial use.
Fig. 2 Initial Service Chart
ROUTINE MAINTENANCE
This vehicle will give years of satisfactory service, if it
receives regular maintenance.
NOTICE: To prolong vehicle life, some maintenance
items must be serviced more frequently on vehicles
used under severe driving conditions 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 bottom. Full access to powertrain may
be obtained by removing the skid plate and body panels.
Some service procedures may require the vehicle to be
lifted. See “LIFTING THE VEHICLE” on page 19.
Always install a positive stop to pre-
vent severe injury that could result
if the truck bed lift mechanism
should unexpectedly fail.
Use insulated wrenches to prevent the possibility of
a dropped wrench shorting out the battery, which
could result in an explosion and severe personal
injury or death.
To prevent accidental starting, disconnect the nega-
tive battery cable before servicing.
For maintenance procedures relating to the engine, fuel
system, transmission, and rear axle or suspension, refer
to the particular section. See the TABLE OF CONTENTS
for section location.
BRAKES
This vehicle is equipped with four-wheel hydraulic disc
brakes. Check the fluid level at intervals specified in the
SCHEDULED MAINTENANCE CHART. If fluid leaks are
noticed or the brake pedal seems soft, check the fluid
level immediately. If the brake pedal is soft, the brake sys-
tem should be bled to remove air from the brake lines.
See “BLEEDING AND FLUSHING” on page 68.
After the vehicle is put into service, the brakes must be
checked by periodically conducting a brake performance
test.
To prevent severe injury or death
resulting from operating a vehicle
with an improperly operating brake
system, the brake system must be properly main-
tained. All driving brake tests must be done in a safe
location with regard for the safety of all personnel.
For test method and brake service, refer to BRAKES sec-
tion.
ITEM SERVICE OPERATION
Battery Charge battery.
Seats Remove protective plastic covering.
Brakes Check operation, adjust if necessary.
Check hydraulic brake fluid level.
Tires Check air pressure, adjust if necessary.
See GENERAL SPECIFICATIONS for
tire pressure.
Fuel Fill with correct fuel. See RECOMMENDED
LUBRICANTS AND FLUIDS.
Engine Check oil level.

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TIRES
NOTICE: The standard tires on this vehicle are uni-
directional. The front tires are narrower than the
rear tires. Tires must not be moved or rotated from
their original position.
Tire condition must be inspected. Inflation pressures must
be checked while the tires are cool. See GENERAL
SPECIFICATIONS on page 161. Be sure to install the
valve dust cap after checking or inflating a tire. See
WHEEL AND TIRE SERVICE on page 53.
LIGHT BULB REPLACEMENT
See LIGHTS on page 137.
CARE AND CLEANING OF VEHICLE
Keeping the vehicle clean is not only beneficial to its
appearance, but can also help extend the life of various
components. See BODY on page 15.
Washing the Vehicle
To prevent damage, do not use a
pressure washer or abrasive sol-
vents to clean this vehicle.
• Use an automotive type cleaner or mild soap to wash
the vehicle. Harsh cleaners can scratch the finish.
• Do not use a pressure washer to wash your vehicle.
High water pressure can damage components.
• Use clean or new cloths and pads for washing.
Reused cloths and pads can contain dirt particles
that will scratch the finish.
• Cleaning vinyl seats and plastic or rubber trim
requires the use of a mild soap solution applied with
a sponge or soft brush. Wipe with a damp cloth.
• Clean any areas where mud or other debris can col-
lect. Loosen sediment 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.
• Lubricate all grease fittings after washing the vehicle.
• Start engine and let it run for a few minutes to dry
any water that may have entered the engine or
exhaust system.
NOTICE: Some products, including insect repellents
and chemicals, will damage plastic surfaces. Do not
allow these types of products to contact the vehicle.
1. With an automotive type wash cloth, wash from the
top to the bottom.
2. To prevent the soap from drying on the vehicle, rinse
with clean water frequently.
3. To prevent water spots, dry with a chamois before
the water dries.
TEXTRON OFF ROAD does not recommend the use of a
pressure washer. High pressure water can damage com-
ponents, chip paint and remove labels. If the use of a
pressure washer cannot be avoided, avoid directing the
water stream at the following items:
• wheel bearings
• body panels
• radiator
• labels and decals
• transmission seals
• switches and controls
• brakes
• electrical components and wiring
Polishing the Vehicle
• Do not use medium to heavy duty compounds on the
finish.
• Use clean or new cloths and pads for polishing. Old
or reused cloths and pads can contain dirt particles
that will scratch the finish.
CANOPY AND WINDSHIELD
The canopy does not provide pro-
tection from rollover or falling
objects.
The windshield does not provide protection from
tree limbs or flying objects.
The canopy and windshield are designed for weather pro-
tection only. See WEATHER PROTECTION on page 49.
Roll over protection is provided by the ROPS. See ROLL-
OVER PROTECTION SYSTEM (rops) on page 37.

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668061
TRANSPORTING THE VEHICLE
To prevent personal injury to occu-
pants of other highway vehicles, be
sure that the vehicle and contents
are secured to trailer.
Do not ride on a vehicle being transported.
This vehicle is not designed to be towed.
It is recommended that the vehicle be moved by placing
the entire vehicle on a trailer, flatbed truck or other suit-
able transport.
Always check that the vehicle and contents are secured
before transporting the vehicle. The rated capacity of the
trailer must exceed the weight of the vehicle (See GEN-
ERAL SPECIFICATIONS on page 161. Place the shifter
in the P (park) position and remove the key from the vehi-
cle. Secure the vehicle to the trailer using ratchet tie
downs.
PROLONGED STORAGE
Battery
During periods of storage, the battery must be maintained
to prevent discharge. If a battery is left in a discharged
state, sulfating will cause permanent damage to the bat-
tery. In order to prevent damage, the battery should be
recharged.
Engine
To reduce the possibility of severe
injury or death resulting from a pos-
sible explosion:
Do not handle fuel in an area that is not adequately
ventilated. Do not smoke near the fuel tank or refuel
near open flame or electrical items which could pro-
duce 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 refueling, inspect the fuel cap for leaks or
breaks that could result in fuel spillage.
Always wear safety glasses while refueling to pre-
vent possible eye injury from gasoline or gasoline
vapor.
Keep hands, clothing and jewelry away from moving
parts. Use care not to contact hot objects. Raise the
vehicle and support on jack stands before attempt-
ing to run the engine.
Preparing the engine for a prolonged storage period of 30
days or longer requires some simple steps to prevent var-
nish, gum and corrosion in the throttle body and in the
engine.
1. Perform all periodic routine maintenance per the
periodic service schedule.
2. Place the shifter in the P (park) position.
3. Add a commercially available fuel stabilizer to the
fuel tank. Follow the manufacturer’s mixing instruc-
tions.
4. Start the engine and let it run for several minutes in a
well ventilated area to allow the fuel stabilizer to be
mixed through the fuel system.
5. Allow the engine to run until the system is depleted
of fuel.
6. Turn the key switch to the OFF position and remove
the key.
7. Remove both ignition coils from the plugs.
8. Remove both spark plugs.
9. Add a conventional cylinder fogging oil or one ounce
of 30 weight oil to each spark plug hole.
10. Inspect the spark plugs prior to installation. Replace
if needed.
11. Rotate the engine several times with the starter. This
will allow the fogging oil to coat the cylinders.
12. Install the ignition coils onto the spark plugs.

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HARDWARE
Periodically inspect the vehicle for loose fasteners. Fas-
teners should be tightened with care and in accordance
with the Torque Specifications table (Ref. Fig. 3).
Three classes of standard hardware and three classes of
metric hardware are used in vehicle.
• Grade 2 hardware is unmarked.
• Grade 5 hardware can be identified by the three
marks on the hexagonal head.
• Grade 8 hardware is identified by six marks on the
head.
The class specification is marked on 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 all hardware in accordance with this chart.
This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when
installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
4
(5)
8
(11)
15
(20)
24
(33)
35
(47)
55
(75)
75
(102)
130
(176)
125
(169)
190
(258)
Grade 5
Grade 8
6
(8)
13
(18)
23
(31)
35
(47)
55
(75)
80
(108)
110
(149)
200
(271)
320
(434)
480
(651)
6
(8)
18
(24)
35
(47)
55
(75)
80
(108)
110
(149)
170
(230)
280
(380)
460
(624)
680
(922)
BOLT SIZE
Class 5.8
(Grade 2)
M4 M5 M6 M8 M10 M12 M14
1
(2)
2
(3)
4
(6)
10
(14)
20
(27)
35
(47)
55
(76.4)
Class 8.8
(Grade 5)
2
(3)
4
(6)
7
(10)
18
(24)
35
(47)
61
(83)
97
(131)
Class 10.9
(Grade 8)
3
(4)
6
(8)
10
(14)
25
(34)
49
(66)
86
(117)
136
(184)
5.8
8.8
10.9

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Notes:
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TABLE OF CONTENTS
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SAFETY INFORMATION
GENERAL ........................................................................................................................ III
GENERAL OPERATION.................................................................................................. III
MAINTENANCE ............................................................................................................... IV
VENTILATION.................................................................................................................. IV
GENERAL INFORMATION AND ROUTINE MAINTENANCE
SERIAL NUMBER AND VIN LOCATION........................................................................ 11
STARTING THE VEHICLE WITH A DISCHARGED BATTERY ..................................... 12
SERVICING THE VEHICLE............................................................................................ 12
ROUTINE MAINTENANCE............................................................................................. 12
POWERTRAIN MAINTENANCE..................................................................................... 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 STORAGE............................................................................................... 14
Battery ................................................................................................................ 14
Engine ................................................................................................................ 14
HARDWARE ................................................................................................................... 15
TORQUE SPECIFICATIONS.......................................................................................... 15
SAFETY
NOTICES, CAUTIONS, WARNINGS AND DANGERS .................................................. 17
IMPORTANT SAFETY WARNING.................................................................................. 17
MODIFICATIONS TO VEHICLE ..................................................................................... 17
GENERAL MAINTENANCE............................................................................................ 17
BEFORE SERVICING THE VEHICLE ............................................................................ 17
LIFTING THE VEHICLE.................................................................................................. 19
Lifting Front of Vehicle ....................................................................................... 19
Lifting Rear of Vehicle ........................................................................................ 19
Lowering Vehicle ................................................................................................ 19

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BODY
GENERAL........................................................................................................................ 21
Painting ...............................................................................................................21
Repairing Scratches ............................................................................................21
Complete Panel Repair .......................................................................................21
Decal Replacement .............................................................................................21
Cowl Removal .....................................................................................................22
Standard Brush Guard Removal .........................................................................24
Premium Brush Guard Removal .........................................................................25
Rocker Panel Removal .......................................................................................26
Side Panel and Rear Fender Liner Removal ......................................................26
Quarter Panel and Front Fender Liner Removal .................................................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
Cargo Tray Removal ...........................................................................................33
Rear Closeout Panel Removal ............................................................................33
Front Closeout Panel Removal ...........................................................................33
Extended Cab Door Removal .............................................................................33
Skid Plate Removal .............................................................................................34
FRAME
GENERAL........................................................................................................................ 38
Door Hinge Removal ...........................................................................................38
Dash Support Removal .......................................................................................38
Hand Hold Removal ............................................................................................39
Front Shock Tower Brace Removal ....................................................................39
Rear Shock Tower Brace Removal .....................................................................39
Seat Frame Removal ..........................................................................................41
B-Pillar Crossmember Removal ..........................................................................41

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ROLLOVER PROTECTION SYSTEM (ROPS)
Removing the ROPS as a Complete Unit .......................................................... 44
INSTALLING ROPS COMPONENTS ............................................................................. 44
A. ROPS Side Tube Installation ......................................................................... 44
B. ROPS Extended Cab Tubes Installation ........................................................ 44
C. Rear Cross-tube Installation .......................................................................... 44
E. Front Cross-tube Installation .......................................................................... 46
F. Seat Back Support Installation ....................................................................... 46
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
Installing Canopy Clamps .................................................................................. 56
Installing the Canopy .......................................................................................... 57
WHEELS AND TIRES
WHEEL AND TIRE SERVICE......................................................................................... 59
Tire Tread Depth ................................................................................................ 60
Tire Repair ......................................................................................................... 60
Tire Replacement ............................................................................................... 60
Wheel Removal .................................................................................................. 60
Wheel Installation ............................................................................................... 60
BRAKES
MAINTENANCE .............................................................................................................. 64
Daily Brake Performance Test ........................................................................... 64
Brake System Inspection ................................................................................... 64
Brake Fluid ......................................................................................................... 64
MASTER CYLINDER ...................................................................................................... 65
Master Cylinder Replacement ............................................................................ 65

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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

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STEERING WHEEL ........................................................................................................ 89
RIDE HEIGHT ADJUSTMENT........................................................................................ 89
REAR AXLE AND SUSPENSION
REAR SUSPENSION...................................................................................................... 92
Maintenance ....................................................................................................... 92
Wheel Bearing Test ............................................................................................ 92
Hub Removal ..................................................................................................... 92
Rear Spindle Removal ....................................................................................... 93
CV Shaft Replacement ....................................................................................... 94
CV Joint Boot Replacement ............................................................................... 94
Rear Strut Assembly Replacement .................................................................... 95
Lower Control Arm Assembly Replacement ....................................................... 95
Upper Control Arm Assembly Replacement ....................................................... 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) ......................................... 98
Rear Differential Replacement ........................................................................... 99
Adjusting the Shift Lever Cable ........................................................................ 102
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
GENERAL ..................................................................................................................... 105
CLUTCHES................................................................................................................... 105
Primary Clutch .................................................................................................. 105
Secondary Clutch ............................................................................................. 105
Increased Load ................................................................................................ 105
Equilibrium ....................................................................................................... 105
CVT BELT ..................................................................................................................... 107
CVT Belt Break-in ............................................................................................ 107
CVT Belt Inspection ......................................................................................... 107
CVT Belt Replacement ..................................................................................... 107
Primary Clutch Removal ................................................................................... 107
Primary Clutch Installation ................................................................................ 108
Secondary Clutch Removal .............................................................................. 109

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Secondary Clutch Installation ...........................................................................109
Draining the CVT ..............................................................................................109
PROP-SHAFT
GENERAL .........................................................................................................112
Prop-shaft Maintenance ....................................................................................112
Prop-shaft Removal ..........................................................................................112
ENGINE
GENERAL...................................................................................................................... 116
ENGINE DESCRIPTION................................................................................................ 116
Engine Specifications ........................................................................................116
ENGINE BREAK-IN ....................................................................................................... 116
ENGINE MAINTENANCE .............................................................................................. 116
ENGINE OIL .................................................................................................................. 116
Engine 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 PLUGS.............................................................................................................. 119
Spark Plug Inspection and Replacement ..........................................................119
ENGINE COMPRESSION TEST ................................................................................... 120
ENGINE REMOVAL....................................................................................................... 121
EXHAUST SYSTEM REMOVAL.................................................................................... 123
AIR INTAKE
ENGINE AIR INTAKE .................................................................................................... 128
Air Filter Maintenance .......................................................................................128
Air Filter Housing Removal ...............................................................................128
COOLING SYSTEM
COOLING SYSTEM....................................................................................................... 132
Coolant ..............................................................................................................132
Reservoir Coolant Level ....................................................................................132
Radiator Coolant Level .....................................................................................132

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Coolant Replacement ....................................................................................... 133
Coolant Reservoir Removal ............................................................................. 133
Radiator and Cooling Fan ................................................................................ 133
Radiator Removal ............................................................................................ 134
Thermostat and Water Pump ........................................................................... 135
FUEL SYSTEM
GENERAL ..................................................................................................................... 138
FUEL ............................................................................................................................. 138
FUEL SYSTEM SERVICE ............................................................................................ 138
Fuel Tank Removal .......................................................................................... 138
Fuel Pump Assembly ....................................................................................... 139
ELECTRICAL SYSTEM
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
Battery Removal ............................................................................................... 143
LIGHTS ......................................................................................................................... 143
Headlight Bulb Replacement ............................................................................ 143
Headlight Beam Adjustment ............................................................................. 144
Brake Light Bulb Replacement ......................................................................... 144
Information Display Removal ........................................................................... 145
Engine Control Unit (ECU) ............................................................................... 145
Voltage Regulator Removal ............................................................................. 149
Solenoid Controller Removal ............................................................................ 149
WIRING DIAGRAMS..................................................................................................... 150
FAULT TESTING
General ............................................................................................................ 161
Voltmeter .......................................................................................................... 161

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Continuity Check ...............................................................................................161
Testing a Switch for Continuity .........................................................................161
Testing the Ignition System ...............................................................................161
Testing Fuses ...................................................................................................161
Powertrain Performance ...................................................................................162
STARTER FAULT TESTING ......................................................................................... 164
SUSPENSION AND STEERING FAULT TESTING ...................................................... 164
GENERAL SPECIFICATIONS
SCHEDULED MAINTENANCE
Initial Service Requirements .............................................................................171
Severe Use Conditions .....................................................................................171
SCHEDULED MAINTENANCE CHART ........................................................................ 172
RECOMMENDED LUBRICANTS AND FLUIDS............................................................ 174
REPLACEMENT OF MAINTENANCE ITEMS............................................................... 174
APPENDIX A
FAULT CODES................................................................................................................. A
DIAGNOSTIC MANUAL.................................................................................................... A
EPAS FAULT CODES ...................................................................................................... C
CAN ..................................................................................................................... E