JD Buck Utility 500, 500EX 500EXT ATV TM2153 Complete Workshop Service Repair Manual

TM2153 MAY 2004 JOHN DEERE WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION 2153 May 2004 Buck Utility ATV 500, 500EX and 500EXT TECHNICAL MANUAL North American Version Litho in U.S.A.

Manual Description This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: • Table of Contents • Specifications and Information • Identification Numbers • Tools and Materials • Component Location • Schematics and Harnesses • Theory of Operation • Operation and Diagnostics • Diagnostics • Tests and Adjustments • Repair • Other NOTE: Depending on the particular section or system being covered, not all of the above groups may be used. The bleed tabs for the pages of each section will align with the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section through the last section. We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us. Introduction All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT© 2004 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT© 2004 INTRODUCTION Technical Data Engine Steering Safety Drive Train Electrical Suspension Brakes Body / Frame Introduction

Introduction - 4 INTRODUCTION

Safety - 1 SAFETY Safety Recognize Safety Information MIF This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe servicing practices. Understand Signal Words A signal word - DANGER, WARNING, or CAUTION - is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. Replace Safety Signs MIF Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. Handle Fluids Safely - Avoid Fires Be Prepared For Emergencies MIF • When you work around fuel, do not smoke or work near heaters or other fire hazards. • Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. • Make sure machine is clean of trash, grease, and debris. • Do not store oily rags; they can ignite and burn spontaneously. • Be prepared if a fire starts. • Keep a first aid kit and fire extinguisher handy. • Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. Use Care In Handling and Servicing Batteries MIF

Safety - 2 SAFETY Prevent Battery Explosions • Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. • Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. • Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). Prevent Acid Burns • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid acid burns by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10 - 15 minutes. 4. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. Wear Protective Clothing MIF Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Service Machines Safely MIF Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications. Park Machine Safely MIF Before working on the machine: 1. Lower all equipment to the ground. 2. Stop the engine and remove the key. 3. Disconnect the battery ground strap. 4. Hang a “DO NOT OPERATE” tag in operator station.

Safety - 3 SAFETY Support Machine Properly and Use Proper Lifting Equipment MIF If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual. Work In Clean Area Before starting a job: 1. Clean work area and machine. 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts. Using High Pressure Washers Directing pressurized water at electronic/electrical components or connectors, bearings, hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle. Illuminate Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. Work In Ventilated Area MIF Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. Warning: California Proposition 65 Warning Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Service Tires Safely MIF Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can

Safety - 4 SAFETY structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts. Service Cooling System Safely MIF Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off machine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. Handle Chemical Products Safely MIF Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment. Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. Live With Safety MIF Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

Specifications Table of Contents - 5 SPECIFICATIONS TABLE OF CONTENTS Specifications Table of Contents Fastener Torques..............................................7 Metric Fastener Torque Values ......................7 Inch Fastener Torque Values .........................8 General Information..........................................9 Gasoline .........................................................9 Gasoline Storage............................................9 4 - Cycle Gasoline Engine Oil ......................10 Break-In Engine Oil - 4-Cycle Gasoline........10 Gear Case Oil ...............................................11 Gear Transmission Grease ..........................12 Alternative Lubricants ...................................12 Lubricant Storage .........................................12 Mixing of Lubricants .....................................12 Oil Filters ......................................................12 Coolant Specifications ...................................13 Gasoline Engine Coolant ..............................13 Gasoline Engine Coolant Drain Interval .......13 Specifications - Buck UATV...........................14 Engine Specifications - 500 ..........................14 Electrical Specifications................................17 Carburation Specifications ...........................18 Cooling Specifications ..................................18 Drive Train Specifications.............................18 Steering Control Specifications ....................19 Suspension Specifications ...........................19 Brakes Specifications ...................................19 Tires and Wheels Specifications ..................19 Dimension Specifications .............................20 Capacities Specifications .............................20 Torque Specifications ...................................21

Specifications Table of Contents - 6 SPECIFICATIONS TABLE OF CONTENTS

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JD Buck Utility 500, 500EX 500EXT ATV TM2153 Complete Workshop Service Repair Manual

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