John Deere 625i Gator Utility Vehicle XUV Repair Technical Manual - TM107019

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John Deere 625i Gator Utility Vehicle XUV Repair Technical Manual - TM107019

TM107019 - 625i Gator Utility Vehicle XUV Technical Manual (Repair).pdf

Complete repair manual for John Deere 625i Gator Utility Vehicle XUV, with all the shop information to maintain, diagnostic, repair, service like professional mechanics.

John Deere 625i Gator Utility Vehicle XUV workshop service repair manual includes:
* 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.

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

PRODUCT DETAILS:
Total Pages: 1,427 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

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

Oil Pressure Test

Radiator Cap Pressure Test

Thermostat Test

Section 230: Fuel and Air Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Fuel System Components (SN -060000)

Fuel System Components (SN 060001-)

Throttle Body and Fuel Components

Air Intake and Exhaust

Group 10: Theory of Operation

Summary of References

Fuel Injection Air System

Fuel Pressure Regulator Operation

Group 15: Test and Adjustments

Summary of References

Service Equipment and Tools

Specifications

Adjust Throttle Cable

Adjust Idle Speed

Adjust Sub-Throttle Stop Screw

Check and Adjust E-Throttle Sensor

Test Fuel Pump/Regulator Pressure

Section 240: Electrical Operations, Tests, and Adjustments

Group 05: Component Location

Summary of References

Electrical Components

Load Center Components (SN 060001-)

Main Wiring Harness (SN 100001-) Components

Display Panel Pinout Diagram Legend

Display Panel Pinout Diagram

Group 10: Theory of Operation (SN -060000)

Summary of References

Power Circuit Operation (SN -060000)

Power Port Circuit Operation (SN -060000)

Cranking Circuit Operation (SN -060000)

Ignition Circuit Operation (SN -060000)

Fuel Pump Circuit Operation (SN -060000)

Fuel Injector Circuit Operation (SN -060000)

ECU Sensor and Diagnostic Circuit Operation (SN -060000)

Charging Circuit Operation (SN -060000)

4WD Clutch Circuit Operation (SN -060000)

Engine Oil Pressure Light Circuit Operation (SN -060000)

Hour Meter Circuit Operation (SN -060000)

Cooling System Circuit Operation (SN -060000)

Lights Circuit Operation (SN -060000)

Front Lights Operation (SN -060000)

Park Brake Circuit Operation (SN -060000)

Seat Belt Light Circuit Operation (SN -060000)

Group 15: Theory of Operation (SN 060001-)

Summary of References

Approved Software for Control Units

ECU and General Sensor Circuit Operation (SN 060001-)

Display Panel Operation (SN 060001-)

Display Panel Replacement Programming (SN 060001-100000)

Display Panel Tire Size Programming (SN 060001-)

Overtemp Input (SN 060001-)

Fuel Level (SN 060001-)

Tachometer (SN 060001-100000)

Tachometer (SN 100001-)

Speedometer (SN 060001-)

Power Circuit Operation (SN 060001-080000)

Power Circuit Operation (SN 080001-)

Power Port Circuit Operation (SN 060001-080000)

Auxiliary Power Circuit Operation (SN 080001-)

Cranking Circuit Operation (SN 060001-080000)

Cranking Circuit Operation (SN 080001-)

Ignition Circuit Operation (SN 060001-)

Fuel Pump Circuit Operation (SN 060001-)

Fuel Injector Circuit Operation (SN 060001-)

Fuel Level Circuit Operation (SN 060001-)

ECU Sensor and Diagnostic Circuit Operation (SN 060001-)

Charging Circuit Operation (SN 060001-)

4WD Clutch Circuit Operation (SN 060001-080000)

4WD Clutch Circuit Operation (SN 080001-100000)

4WD and Speedometer Circuit Operation (SN 100001-)

4WD and Speedometer Circuit Operation, Service Harness (SN 080001-100928)

Engine Oil Pressure Light Circuit Operation (SN 060001-)

Hour Meter Circuit Operation (SN 060001-)

Cooling System Circuit Operation (SN 060001-)

Lights Circuit Operation (SN 060001-080000)

Lights Circuit Operation (SN 080001-)

Park Brake Circuit Operation (SN 060001-)

Seat Belt Light Circuit Operation (SN 060001-)

Group 20: MFWD Service Kit Operation and Wiring Schematics

Summary of References

Wiring Harness AM145249

Wiring Harness AM146628

Wiring Harness AM147221

Group 25: Wiring Schematics (SN -060000)

Summary or References

Main Wiring Schematic Legend (SN -060000)

Main Wiring Schematic (SN -060000)

W2 Engine Wiring Schematic (SN -060000)

ECU Connectors (SN -060000)

Group 30: Wiring Schematics (SN 060001-)

Summary of References

Main Wiring Schematic Legend (SN 060001-)

Main Wiring Schematic (SN 060001-080000)

Main Wiring Schematic (SN 080001-093190)

Main Wiring Schematic (SN 093191-100000)

Main Wiring Schematic (SN 100001-100928)

Main Wiring Schematic (SN 100929-)

Main Wiring Schematic, Service Harness (SN 80001-100928)

Engine Wiring Schematic (SN 060001-080000)

Engine Wiring Schematic (SN 080001-)

ECU Connectors (SN 060001-)

Relay Module Pin Locations — VCU (SN 060001-100000)

Relay Module Pin Locations — VCU (SN 100001-)

Display Panel Pin Locations (SN 060001-)

Display Panel Pin Locations (SN 100001-)

Group 35: Diagnosis (SN -060000)

Diagnostic Code Light (SN -060000)

Diagnostic Codes (SN -060000)

Display Code Chart (SN -060000)

Diagnose Power Circuit (SN -060000)

Diagnose Cranking Circuit (SN -060000)

Diagnose Ignition Circuit (SN -060000)

Diagnose Fuel Pump Circuit (SN -060000)

Diagnose Fuel Injector Circuit (SN -060000)

Diagnose ECU Sensor and Diagnostic Circuit (SN -060000)

Diagnose ECU (SN -060000)

Diagnose Charging Circuit (SN -060000)

Diagnose 4WD Clutch Circuit (SN -060000)

Diagnose Engine Oil Pressure Light (SN -060000)

Diagnose Cooling System Circuit (SN -060000)

Diagnose Headlight Circuit (SN -060000)

Diagnose Park Brake Circuit (SN -060000)

Diagnose Seat Belt Light Circuit (SN -060000)

Group 40: Diagnosis (SN 060001-)

Erroneous Diagnostic Trouble Codes (SN 060001-)

On Board Diagnostics - Relay Module (SN 060001-)

Diagnostic Code Light (SN 060001-)

Diagnostic Codes (SN 060001-)

Display Code Chart (SN 060001-)

Diagnose Power Circuit (SN 060001-080000)

Diagnose Power Circuit (SN 080001-)

Diagnose Cranking Circuit (SN 060001-)

Diagnose Ignition Circuit (SN -060001)

Diagnose Fuel Pump Circuit (SN -060001)

Diagnose Fuel Injector Circuit (SN 060001-)

Diagnose ECU Sensor and Diagnostic Circuit (SN 060001-)

Diagnose ECU (SN 060001-)

Diagnose Charging Circuit (SN 060001-)

Diagnose 4WD Clutch Circuit (SN 060001-)

Diagnose Engine Oil Pressure Light (SN 060001-)

Diagnose Cooling System Circuit (SN 060001-)

Diagnose Headlight Circuit (SN 060001-)

Diagnose Park Brake Circuit (SN -060001)

On Board Diagnostics - Relay Module (SN 100001-)

Group 45: Schematics, Kits

Lights Wiring Schematic, AM140950

Lights Wiring Schematic, AM137558

Turn Signal with Flasher Schematic, AM143722

Taillight Schematic, AM137737

Backup Alarm Wiring Schematic, AM144181

Canopy Wiring Schematic, AM143139

Roof Work Lights Wiring Schematic, AM146905

Beacon Light Wiring Schematic, AM140971

Horn Wiring Schematic, VGA10903

OPS Rear Lights Wiring Schematic, AM146376

Winch Schematic

Group 50: Tests and Adjustments

Summary of References

Common Circuit Tests

Ground Circuit Tests

Charge Battery

Battery Test

Battery Load Test

Fuse Test

Bulb Test

Relay Test

Spark Test

Spark Plug Gap Adjustment

Spark Plug Cap Test

Stator Tests

Ignition Coil Test

Flywheel Magnet Test

Alternator (Optional) Regulated Output Test

Alternator (Optional) Unregulated Amperage Test

Engine Oil Pressure Switch Test

Starting Motor Solenoid Test

Starting Motor Loaded Amperage Draw Test

Starting Motor No-Load Amperage and RPM Tests

Key Switch Test

Headlight Switch Test (2 Position)

Headlight Switch Test (2 Position) (AM144577)

Light Switch Test (3 Position)

Light Switch Test (3 Position) (AM144304)

Turn Signal Lights Switch Test

Turn Signal Lights Switch Test (AM144306)

Hazard Lights Switch Test

Hazard Lights Switch Test (AM144305)

Neutral Start Switch Test

Throttle Switch Test

Brake Lights Switch Test

Horn Switch Test, Push

Horn Switch Test, Toggle

Park Brake Switch Test

Raise/Lower Switch Test

Raise/Lower Switch Test (AM142315)

4WD Switch Test

4WD Switch Test (AM142314)

Seat Belt Switch Test

Fuel Injector Test

Engine Control Relay Test

Air Pressure Sensor Test (MAP)

Air Temperature Sensor Test

Coolant Temperature Sensor Test

E-Throttle Sensor Input Voltage Test

Sub-Throttle Sensor Input Voltage Test

Sub-Throttle Sensor Output Voltage Test

Throttle Position Sensor Resistance Test

Stepper Motor Test

Pulser Coil Test

Speed Sensor Test

4WD Solenoid Test

Electronic Control Module/Relay Module (VCU) Operation

Display Panel Operation

Display Panel Replacement Programming (SN 100001-)

Odometer, Trip and Hour Meter Modes

Clock and Unit Set Programming

Display Panel Tire Size Programming

Section 250: Power Train Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Power Train Components

Front Axle

Rear Axle

MFWD Driveline

Front Drive Gear Box

EMFWD Front Differential

Transaxle, Gear

Differential

Transaxle Input

Shift Linkage

Primary (Drive) Clutch

Secondary (Driven) Clutch

Clutches and Housing

Transaxle Mounts

Group 10: Theory of Operation

Summary of References

Power Transfer Operation

Drive Clutch Operation

Clutch Operation

EMFWD Operation

MFWD Anti-Wedging (SN -100000)

Group 15: Diagnosis

Diagnose Drivetrain

Diagnose Primary Clutch

Diagnose Clutch System

Group 20: Test and Adjustments

Summary of References

Specifications

Transaxle Shift Adjustment

Differential Lock Adjustment

Transaxle Mount Shim Adjustment

Section 260: Steering and Brake Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Steering Components

Front Suspension

Rear Suspension

Brake System Components

Brake System Components - Front

Brake System Components - Rear

Park Brake Components

Park Brake Housing Components

Group 10: Theory of Operation

Summary of References

Steering System

Brake System

Group 15: Diagnosis

Diagnose Steering Pulls in One Direction

Diagnose Steering Wanders or Vibrates

Diagnose Wheel Bearing Noise

Diagnose Steering Hard in Left, Right, or Both Directions

Diagnose Steering Locks in Hard Left or Right Turn

Diagnose Steering Wheel Pulls Upwards

Diagnose Steering Wheel Spins Freely

Diagnose Noise During Turns Over Rough Terrain

Diagnose Hydraulic Brakes

Diagnose Brakes Will Not Engage or Show Poor Response

Diagnose Brake Effort Excessive

Diagnose Brakes Will Not Release

Diagnose Brakes Are Noisy or Chattering

Diagnose Excessive Brake Pad Wear

Diagnose Excessive Brake Pedal Travel

Diagnose Brakes Pull Left or Right

Diagnose Pedal Feels Hard With Little Travel

Diagnose Park Brake Will Not Engage or Hold

Diagnose Park Brake Will Not Engage or Hold (SN 80001-)

Diagnose Park Brake Will Not Release

Group 20: Tests and Adjustments

Summary of References

Other Material

Specifications

Centering Steering Rack

Centering Steering Wheel

Suspension Adjustment

Toe-In Adjustment

Rear Wheel Camber Adjustment

Check Brake Fluid Level

Check Park Brake Lubricating Oil Level

Adjust Parking Brake Cable (SN 80001-)

Master Cylinder Rod Adjustment

Bleeding Brakes

Bleeding Master Cylinder

Burnish Brakes

Section 299: Service Tools

Group 05: Service Tools and Kits

Essential or Recommended Tools

Service Kits

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