John Deere 625i Gator XUV Utility Vehicle Repair Technical Manual TM107019 PDF - MJODTM107019.zip
This is a full-coverage service guide for the John Deere 625i Gator XUV Utility Vehicle, packed with the workshop details needed to keep it running, fix it, and care for it just like a trained technician would.
Inside the John Deere 625i Gator XUV Utility Vehicle workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM107019 - 625i Gator Utility Vehicle XUV Technical Manual (Repair).pdf
TM107019 - 625i Gator Utility Vehicle XUV Technical Manual (Repair).epub
PRODUCT DETAILS:
Total Pages: 1,437 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
10 - General Information
20 - Engine Repair
30 - Fuel and Air Repair
40 - Electrical Repair
50 - Power Train Repair
60 - Steering and Brake Repair
80 - Miscellaneous Repair
90 - Operator's Station Repair
220 - Engine Operation, Tests, and Adjustments
230 - Fuel and Air Operation, Tests, and Adjustments
240 - Electrical Operation, Tests, and Adjustments
250 - Power Train Operations, Tests, and Adjustments
260 - Steering and Brake Operation, Tests, and Adjustments
299 - Service Tools
TABLE OF CONTENTS
tm107019 - Gator™ Utility Vehicle XUV 625i
Table of Contents
Foreword
Section 10: General Information
Group 05: Safety
Recognize Safety Information
Understand Signal Words
Practice Safe Maintenance
Use Proper Tools
Handle Fluids Safely—Avoid Fires
Drain Gasoline When Storing Machine
Prevent Acid Burns
Prevent Battery Explosions
Handling Batteries Safely
Prepare for Emergencies
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Service Tires Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Protect Against High Pressure Spray
Live With Safety
Group 10: General Specifications
Service Recommendations for O-Ring Boss Fittings
Service Recommendations For Flat Face O-Ring Seal Fittings
Metric Cap Screw Torque Values—Grade 7
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Group 15: Fuel and Lubricants
4 - Cycle Gasoline Engine Oil
Oil Filters
Gasoline Fuel for 4-Cycle Engines
Transmission and Hydraulic Oil
Grease
Mixing of Lubricants
Alternative and Synthetic Lubricants
Lubricant Storage
Group 20: Serial Number Locations
Product Identification Number
Section 20: Engine Repair
Group 05: Engine
Summary of References
Essential or Recommended Tools
Other Material
Specifications
Remove and Install Thermostat Housing
Remove and Install Engine Flywheel
Remove and Install Engine
Replace Sub-Throttle Sensor
Remove and Install Throttle
Remove and Install Cylinder Head
Disassemble and Inspect Cylinder Head
Remove and Install Crankcase Cover
Inspect and Replace Crankcase Breather
Inspect Oil Pump
Install Oil Pump
Remove Camshaft
Inspect Camshaft
Remove Pistons and Cylinders
Inspect Piston
Install Piston Ring
Cylinder Boring
Inspect Connecting Rod Bend and Twist
Inspect Crankshaft
Install Crankshaft
Assemble and Install Connecting Rod
Install Tappet and Camshaft
Remove, Inspect, and Install Water Pump
Remove and Install Starting Motor
Disassemble, Inspect, and Install Starting Motor
Section 30: Fuel and Air Repair
Group 05: Air Intake and Exhaust System
Summary of References
Specifications
Remove and Install Exhaust System
Removal and Install Intake Manifold
Group 10: Fuel System
Summary of References
Remove and Install Fuel Filter
Remove and Install Fuel Tank
Fuel Pump Removal and Installation
Fuel Pump Disassembly and Assembly
Section 40: Electrical Repair
Group 05: Wiring Harnesses (SN -080000)
Summary of References
Main Wiring Harness Legend (SN -060000)
Main Wiring Harness (SN -060000)
Main Harness Wire Color Codes (SN -060000)
W2 Engine Harness Wire Color Codes (SN -060000)
Main Wiring Harness Legend (SN 060001-)
Main Wiring Harness (SN 0600001-080000)
Main Wiring Harness Color Codes (SN 060001-080000)
Load Center (SN 060001-080000)
W2 Engine Wiring Harness Color Codes (SN 060001-080000)
Group 10: Wiring Harnesses (SN 080001-)
Summary of References
Main Wiring Harness (SN 080001-093190)
Main Wiring Harness Color Codes (SN 080001-093190)
Main Wiring Harness (SN 093191-100000)
Main Wiring Harness Color Codes (SN 093191-100000)
Main Wiring Harness Color Codes (Service Harness 080001-100928)
Main Wiring Harness Splices (Service Harness 080001-100928)
Main Wiring Harness (SN 100001-)
Main Wiring Harness Color Codes (SN 100001-100928)
Main Wiring Harness Color Codes (SN 100929-)
Main Wiring Harness Splices (SN 100929-)
Load Center (SN 080001-)
W2 Engine Wiring Harness Color Codes (SN 080001-)
W2 Engine Wiring Harness Legend
Group 15: MFWD Service Kit Operation and Wiring Schematics
Summary of References
Electrical Operation and Schematic (AM145249)
Electrical Operation and Schematic (AM146628)
Electrical Operation and Schematic (AM147221)
Group 20: Wiring Harnesses, Kits
Lights Wiring Harness, AM140950
Lights Wiring Harness, AM137558
Headlight Jumper Wiring Harness, AM147740
Turn Signal with Flasher Harness, AM143722
Taillight Harness, AM137737
Trailer Connector Wiring Harness
Backup Alarm Wiring Harness, AM144181
Cab Power Splitter Wiring Harness, AM140972
Canopy Wiring Harness, AM143139
Roof Work Lights Wiring Harness, AM146905
Beacon Light Wiring Harness, AM140971
Horn Wiring Harness, VGA10903
Winch Main Wiring Harness, AM144137
Winch Control Wiring Harness, AM142263
Section 50: Power Train Repair
Group 05: Transmission
Summary of References
Essential or Recommended Tools
Other Material
Specifications
Changing Transmission Oil
Remove and Install Clutch
Remove and Install Transaxle
Disassemble Transaxle
Assemble Transaxle
Group 15: Axles and Driveshaft
Summary of References
Essential or Recommended Tools
Other Material
Specifications
Remove and Install EMFWD Driveshaft
Replace EMFWD Driveshaft Boot
Remove and Install Rear Axle Halfshaft
Remove and Install Front Axle Halfshaft
CV Joint and Boots - Front Axle Halfshafts
CV Joint and Boots - Rear Axle Halfshafts
Hub Removal
Hub Installation
Group 20: Mechanical Four Wheel Drive
Summary of References
Other Material
Specifications
Disassemble and Assemble Front Drive Gearbox
Remove and Install Front Differential
Disassemble Front Differential
Assemble Front Differential
Section 60: Steering and Brake Repair
Group 05: Steering Repair
Summary of References
Other Material
Specifications
Remove and Install Steering Knuckle
Remove and Install Front Wheel Bearing
Remove and Install Ball Joint
Remove and Install Steering Wheel
Remove and Install Steering Shaft
Replace Steering Shaft Bearing
Remove and Install Steering Gearbox
Remove and Install Front Coilover Shock Absorber
Remove and Install Rear Coilover Shock Absorber
Remove and Install Tie Rod End
Remove and Install Front Suspension Arm
Remove and Install Rear Axle Bearing Carrier
Remove and Install Rear Suspension Arm
Remove and Install Front Suspension Arm Bushing
Remove and Install Rear Suspension Arm Bushing
Remove and Install Stabilizer Bar
Group 10: Brake Repair
Summary of References
Essential or Recommended Tools
Other Material
Specifications
Replace Brake Pad
Remove and Install Master Cylinder
Remove and Replace Brake Line
Remove and Install Brake Caliper
Remove and Inspect Brake Rotor
Remove and Install Brake Pedal
Replace Park Brake Control Cable
Remove and Install Park Brake Lever
Remove, Service, and Replace Park Brake
Section 80: Miscellaneous Repair
Group 05: Wheels
Summary of References
Specifications
Remove and Install Wheels
Group 10: Hood, Cargo Box, and Bumper
Summary of References
Specifications
Remove and Install Hood Latch
Remove and Install Hood
Remove and Install Front Bumper/Skid Plate
Remove and Install Cargo Box
Remove and Install Cargo Box Side
Group 15: Miscellaneous
Summary of References
Specifications
Remove and Install Headlight
Remove and Install Front Grille
Remove and Install Front Fender
Remove and Install Radiator
Drain and Flush Radiator
Fill and Bleed Coolant System
Remove and Install Cooling Fan
Remove and Install Battery
Section 90: Operator’s Station Repair
Group 05: Operator’s Station and Seat
Summary of References
Specifications
Remove and Install Dash Panel
Remove and Install Seat
Remove and Install Bench Seat
Remove and Install Seat Base Cover
Remove and Install Seat Adjuster
Remove and Install Under Seat Storage Box (Bench Seat)
Remove and Install Center Console
Remove and Install Transaxle Control Lever Housing
Group 10: Occupant Protective Structure (OPS)
Summary of References
Specifications
Remove and Install Occupant Protective Structure (OPS)
Section 220: Engine Operation, Tests, and Adjustments
Group 05: Component Location
Summary of References
Starting Motor Components
Coolant System Components
Coolant Pump System Components
Group 10: Theory of Operation
Summary of References
Governor Operation
Lubrication System Operation
Cooling System Operation
Throttle System Theory
Group 15: Diagnosis
Engine Diagnosis
Diagnose Engine
Diagnose Engine Coolant System
Diagnose Engine Fuel System
Diagnose Starter Does Not Rotate
Diagnose Starter Rotates Slowly
Group 20: Test and Adjustments
Summary of References
Service Equipment and Tools
Other Material
Specifications
Cylinder Leak-Down Test
Valve Clearance Adjustment
Crankcase Vacuum Test