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From bitter experience, I can confirm that a simple thing like the radiator cap can cause some confusing overheating issues!

Gator 6x4 Overheating problem
Utility Vehicles UTV/ATV
Replies 13 Post by spyder

Hi, copy this and paste into your address bar:

http://www.equinet.co.nz/manual/Gator_Utility_Vehicles_4x2_And_4x6-TM1518.pdf

Cheers,
Chaz

TH6X4 wiring diagram
Utility Vehicles UTV/ATV
Replies 18 Post by spyder

Greeting from New Zealand. We live in a very remote and mountainous part of the country. I bought a 6X4 Gator in very poor condition a couple of years ago and completely rebuilt it. It now gets used almost daily for carting everything from building materials to firewood to sheep, and frankly I couldn't do without it. I've put a decent winch on it with a wireless remote and I've also installed a one kilowatt sine-wave inverter which occasionally comes in very handy. Some other non-standard accessories include a fire extinguisher, a drink bottle and a first-aid kit. The Gator has a low centre of gravity and will carry large loads relatively safely and go places where most ATVs wouldn't.

Looking to buy Utility Vehicle is JD Gator Best buy
Utility Vehicles UTV/ATV
Replies 4 Post by spyder

If the Gator is a 6X4 with a Kawasaki engine, you need to replace the water pump. You could just replace the seal inside the pump, but it is a LOT easier to just replace the whole thing (this is the voice of bitter experience talking!).You will need a new water pump gasket also. The engine will have to be removed from the Gator, but not dismantled apart from the water pump. The block is aluminium, so I'd recommend getting a copy of the technical manual TM1518 and pay attention to the torque settings for the bolts.
If you're reasonably at home with engines you may decide to take the opportunity to replace a few other things while the engine is out. I'd definity do the two oil seals and the main bearing (behind the flywheel). Optionally also replace the rings but only if the engine is smokey - by the time you buy the rings, head gaskets, other engine seals and gaskets you will probably be looking at several hundred dollars.

water in oil on john deere gator
Utility Vehicles UTV/ATV
Replies 3 Post by spyder

Hi there,
you will find the technical manual here:

http://www.equinet.co.nz/manual/Gator_Utility_Vehicles_4x2_And_4x6-TM1518.pdf

You will see that there is a fusible link at the battery... I'd suspect that it could be the culprit.

need help please
Utility Vehicles UTV/ATV
Replies 4 Post by spyder

Like the Gator, it will just freewheel when going downhill, hence picking up speed.
I'm not sure about this being a cause of your problem, but did you put the belt on the right way round? It has an arrow pointing towards the front.

AMT 622 No Speed
Utility Vehicles UTV/ATV
Replies 4 Post by spyder

On the earlier (pre 2005) 6X4s, the parking brake and foot brake are connected together. Adjusting the brakes is pretty easy, but you should refer to the technical manual TM1518 for instructions. Somewhere on this forum there is a link to a downloadable copy.

What is an e- brake on a John Deere Gator
Utility Vehicles UTV/ATV
Replies 3 Post by spyder

It (The carb)will probably benefit greatly from a jolly good clean out.
You need to take out the jets and blow it with compressed air. There may be some white deposits of corrosion in the bowl. Clean it out thoroughly. Given its age and the fact that you need to go to a certain amount of trouble anyway, it's worth spending a little money to replace the needle valve and the float. Also the float bowl seal.

gator carb flooding no spark issue
Utility Vehicles UTV/ATV
Replies 6 Post by spyder

Somewhere in this forum is a link to download the technical manual TM1518..... it will tell you everything you could ever want to know about your Gator.
Removing and cleaning the carburettor is actually a fairly straightforward job - when you know how. You will need a source of conpressed air.

John Deere Gator starts and stalls
Utility Vehicles UTV/ATV
Replies 5 Post by spyder

[QUOTE=dmmakela;184203] How do you check the alternator on the John Deere 6x4 gator. Gas engine. I have checked the battery and thevoltage regulator and both read good. but machine dies all the time even when running, and if you leave the headlights on for just a couple of minutes with the machine turned off it will die. . [/QUOTE]
With the engine revving quite fast you will typically measure up to 14.5 or 15 volts across the battery - assuming the connections are clean.
How have you checked the battery? Just measuring the voltage won't show if it is actually any good (unless the voltage is way down).
If the battery is good it should run the headlights for at least a couple of hours without the motor running.

John Deere Gator alternator check
Utility Vehicles UTV/ATV
Replies 4 Post by spyder

Thanks for the response. I will certainly be replacing the needle ... however it is only 100 hours old.

John Deere Gator Carburettor problem
Utility Vehicles UTV/ATV
Replies 3 Post by spyder

Hi there - small world indeed!! We are situated fairly high up in the hills to the east of Taihape and we enjoy a huge view of tens of miles of rolling hills, valleys, etc with Mount Ruapehu dominating the skyline - and not another house in sight!! Self sufficient in most thing including electricity.
Back to Gators. The TH is the air cooled model, right? Mine is the earlier 6X4 liquid cooled Kawasaki engine model, but similar in most ways. Unless you sank it way down to the cargo bed, you probably won't have gotten water into the engine, but taking out the spark plugs and cranking the engine over should confirm this. The critical parts (apart from the engine)are probably going to be the ignition unit and some of the relays. Will the Gator crank over? If not, you probably have a malfunctioning relay.
You might even find that it will come right when it all dries out, but I'd definitely check for water in the engine asap.

John Deere Gator How to start after submerging in water
Utility Vehicles UTV/ATV
Replies 9 Post by spyder

Have you checked the bolts holding the engine and transaxle to the frame? Also, there is a rod that goes between the two - is it connected properly (not loose)?

John Deere Gator clutch replacement decsion
Utility Vehicles UTV/ATV
Replies 3 Post by spyder

One of my nephews has a plastic moulding business. I got him to have a look at the cracked bonnet on my Gator and he says the material is HDPE (High density polyethylene) - it can be welded but not glued (or even successfully painted for that matter).

John Deere Gator Fender Plastic Type
Utility Vehicles UTV/ATV
Replies 10 Post by spyder

You are right, they are not particularly complex machines - but pretty much all the parts are JD-specific and therefore expensive. The exceptions to this are engine parts if you have the gasoline version. The engine is a standard Kawasaki FD620D model. The only thing that makes this particular variant of the engine different is a taper on the drive shaft where the primary clutch is fitted. I have no experience with the diesel version, but I believe the same thing applies.I'd recommend that you get hold of the technical manual TM1518. Somewhere on this forum is a link to download a PDF version of it.
I've recently done a full restoration of a 6X4 that was badly rusted and had a siezed engine when acquired. I rebuilt the engine with new rings, bearings, oil pump, water pump, seals, etc. I also had to replace the king pin bushes and tie rod ends and do some work on the clutches. Oh, plus a few other things like repair the fuel pump, the starter motor, the wiring harness, the seats, the cargo bed ....
With the addition of some new guards and bonnet, it now looks and performs like a new machine.

New Old Gator What to expect
Utility Vehicles UTV/ATV
Replies 2 Post by spyder

What has actually happened to the engine?

john deere amt 622 engine
Utility Vehicles UTV/ATV
Replies 4 Post by spyder

Have you got the wiring diagram?

Gator 6x4 radiator fan and cranking
Utility Vehicles UTV/ATV
Replies 5 Post by spyder

Full tech manual available at this link:-

http://www.equinet.co.nz/john%20deere/TM1518.pdf

Will not shut off Unless
Utility Vehicles UTV/ATV
Replies 7 Post by spyder

[QUOTE=Wheatland;179609] OK so I have verified the engine is getting too much fuel. If I pinch off the fuel line going to the carb the engine will speed up to full RPM. If I do not pinch it, the engine gets to about 30% throttle and then starts to sputter badly. The only "adjustment I can find on top of the carb is the idle adustment screw and another that is setup to only turn about 180 degrees. Adjusting this screw makes no difference in how the engine runs. It idles beautifully. Just will not speed up enough to make the Gator move at more than a crawl. Could this be the vacuum fuel pump? I have read a few places that say these can fail in various ways.Thanks [/QUOTE]
Sounds like the needle valve in the float bowl isn't working properly. Could be worn, or maybe has a bit of crud holding it open.That being the case though, yoy should have fuel coming out the overflow pipe.

Kawaski Motor
Utility Vehicles UTV/ATV
Replies 17 Post by spyder

[QUOTE=bpenn12;179440] Can someone please tell me where I can go to download the TM1518 for my JD Gator.Many thanks.P.S.I found the address for the download but the RapidShare.com site says it's no longer available.Any suggestions from anybody? Please help this old Great-Grandpa/DAV/US Army/7yrs/'50s. [/QUOTE]
Copy and paste this into your address bar:-

http://www.equinet.co.nz/john deere/TM1518.pdf

Cheers

TM - 1518 for John Deere Gator
Utility Vehicles UTV/ATV
Replies 3 Post by spyder