John Deere 500, 650, 650EX and 650EXT Trail Buck Utility ATV Technical Manual (TM2160)

John Deere 500, 650, 650EX and 650EXT Trail Buck Utility ATV Technical Manual (TM2160 MAY 2004)

This comprehensive technical manual provides detailed service procedures, diagnostics, and testing information for the John Deere 500, 650, 650EX, and 650EXT Trail Buck Utility ATV models. From engine performance and CVT systems to electrical troubleshooting, drive train repairs, and body/frame servicing, this manual is a vital tool for technicians and ATV owners aiming for optimal performance and maintenance accuracy.

Model Covers:

John Deere 500 Trail Buck Utility ATV

John Deere 650 Trail Buck Utility ATV

John Deere 650EX Trail Buck Utility ATV

John Deere 650EXT Trail Buck Utility ATV

File Format: PDF

Size: 38.47 MB

No. of pages: 312

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Included Sections:

Safety and General Information

• Safety signage interpretation and protective measures
• Battery and fluid handling, fire prevention, and worksite safety
• Tool usage guidelines and environmental compliance practices

Engine and Cooling Systems

• Engine specifications for 500 and 650 models
• Engine removal, installation, diagnostics, and repairs
• Cooling system inspections, leak testing, radiator and thermostat service

Fuel and Air Intake Systems

• Fuel tank servicing, pressurization, valve replacement, and line routing
• Carburetor adjustments, fuel pump checks, and throttle/choke cables
• Air filter cleaning, air intake component maintenance

Ignition, Charging, and Oil Systems

• Stator, rotor, and vehicle speed sensor diagnostics
• Oil pressure testing, oil pump, strainer, and regulator service
• Spark plug inspection and ignition timing procedures

Transmission and CVT

• 650 model gear shifting components and crankcase procedures
• CVT assembly for 500 model including clutch, pulley, and belt replacement
• Transmission oil seals, shifting indicators, and gearbox servicing

Electrical Systems and Troubleshooting

• Wiring schematics, component locations, and system operation theory
• Battery service, fuse replacement, connector servicing, and power outlets
• Ignition switch, winch, headlamp, taillight, and speedometer diagnostics

Drive Train and Axles

• Front and rear drive shaft servicing, differentials, and propeller shafts
• Axle disassembly, hub, knuckle, and wheel bearing repairs
• Oil replacement procedures for differentials

Steering and Suspension

• Handlebar, tie-rod, column, and brake handle service
• Rear shock, swing arm, and component location guidance

Braking System

• Hydraulic brake system diagnostics and servicing
• Master cylinder, brake pads, discs, levers, and cables
• Brake hoses, light switch, and parking brake repairs

Body and Frame Components

• Seat, console, fender, mudguard, luggage rack, and skid plate service
• Plastic maintenance and repair, decals replacement
• Frame structure, removable braces, and rear extensions

This John Deere 500, 650, 650EX and 650EXT Trail Buck Utility ATV Technical Manual is a vital resource for performing diagnostics, repairs, and preventive maintenance with confidence and accuracy.