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A new ignitor is an expensive item, and although it is probably the prime suspect, are you sure the linkages on top of the engine are all moving as they should? Is the plate they are all mounted on securely attached to the engine?

Still needing help with 4x2 gator running but wont accelerate
Utility Vehicles UTV/ATV
Replies 11 Post by spyder

spyder has posted a new photo.

Subject: Cargo bed power lifter - 6X4.

Description: <br>Cargo bed power lifter - 6X4

Cargo bed power lifter - 6X4 - New Pix by spyder
Photos
Replies 1 Post by spyder

Hi there, I'm not actually the person who put the file there. However, I've just clicked on the link I gave, and it worked for me, albeit with a little extra clicking to select Free User rather than RapidPro, but having done that and then waiting for about 30 seconds the download started in the normal way. I'm using Firefox - don't know if that makes a difference.

4x2 repair manual
Utility Vehicles UTV/ATV
Replies 7 Post by spyder

Hi - whilst I don't currently have a power lift on my Gator, I've been planning to install one. I believe that the top end of the actuator just rides in the channel in the middle of the cargo bed at the back. I've had a look in the tech. manual and also at the parts list at the Deere.com site. There is no mention of an upper bracket. I've uploaded a picture of the actuator taken from the manual - see it in my pictures.

pics of mounting brackets for power lift
Utility Vehicles UTV/ATV
Replies 3 Post by spyder

spyder has posted a new photo.

Subject: Gator.

Description: <br>Gator cargo tray power lifter.

Gator - New Pix by spyder
Photos
Replies 1 Post by spyder

You will have to remove the crankshaft to do the job, so yes you will be removing the cover, water pump, big ends, etc. You will (probably) need new gaskets. Whether or not the main bearing is damaged you will see once the crankshaft is out.

The main bearing is just a bush which is pressed in. You might need to take the engine to a machine shop to get the old bush pressed out and new one replaced.

Don't be dismissive about the tech. manual - it is the Bible when it comes to Gator maintenance! [b]Provided you follow the manual EXACTLY you shouldn't have any problems.[/b]

I'd suggest you read the appropriate section(s) a couple of times before you start and print off the page about the order of insertion of the crankcase bolts and their torque settings. Likewise, the torque settings for the big ends.

Don't forget to check the oil breather. You'll probably need a new gasket here also.

Cheers

oil leak on crankside of 6x4 gator
Utility Vehicles UTV/ATV
Replies 4 Post by spyder

In case you haven't already found it, here is the link to the tech. manual:

http://rapidshare.com/files/338458124/Gator_Utility_Vehicles_4x2_And_4x6-TM1518.pdf

Cheers

6x4 brakes
Utility Vehicles UTV/ATV
Replies 11 Post by spyder

The wire should plug into the engine harness - it powers a small heating element in the carburettor.
As for finding the manufacturing date of the Gator, any JD dealer should be able to tell you that from the serial number.

wire on carb
Utility Vehicles UTV/ATV
Replies 2 Post by spyder

It is on the front of the engine (the side with the oil filler) - about 1/2 to 2/3 of the way down. There is nothing else down there, so it's pretty easy to spot and to get at.

Gator 6x4 FD620D oil pressure sending unit location
Utility Vehicles UTV/ATV
Replies 3 Post by spyder

Hi Bruce,
you could try just winding it around one of the spark plug leads a few times - depending on the input impedance of the meter it might work.....

Tuning my engine and need to hook up a tach
Utility Vehicles UTV/ATV
Replies 3 Post by spyder

Hi, I think I already replied to your previous post. I omitted to say that John Deere have a very good online parts list:

http://jdpc.deere.com/jdpc/servlet/com.deere.u90490.partscatalog.view.servlets.HomePageServlet_Alt

Just enter the keyword 'Gator'.

Help w gator restoration
Utility Vehicles UTV/ATV
Replies 4 Post by spyder

Hi there,
the tech manual is TM1518. Somewhere in this forum is a link to download it. Try searching for TM1518.
If the transmission is grinding, your idle speed is too high.
Probably, most of the parts you will need will have to come from JD, but if you need engine parts then they will be available from a number of sources, esp. if it is a gas model. The engine is a Kawasaki FD620D and is used in a wide variety of ATVs, lawn mowers, etc. The only JD-specific part of the engine is the crankshaft.
Ditto for the diesel model - the engine being a Yanmar (sorry, can't remember the model off hand).

Help w gator restoration
Utility Vehicles UTV/ATV
Replies 2 Post by spyder

I have this same condition in my 6X4 - in my case i know that there are two badly worn links in one of the chains and they are the source of the noise.

6X4 gator making a clinking noise when driving
Utility Vehicles UTV/ATV
Replies 5 Post by spyder

Checked the thermostat?

Cooling problem
Utility Vehicles UTV/ATV
Replies 10 Post by spyder

[QUOTE=stboo6;173880] Oh yeah! Do you think it could be just a bad Ignition Switch ? [/QUOTE]
Maybe, but it's probably more likely to be dirty connections. I recently restored a Gator that had been sitting in somebody's shed for several years since the engine blew, and the electrics were a mess - dirty or corroded contacts all over, and the fusible links were corroded away completely. Your first step will be to to see if you have 12 volts getting to the switch.

Gator will not start
Utility Vehicles UTV/ATV
Replies 9 Post by spyder

See Page 92 in the manual.

1997 gator 6x4 throttle sticking
Utility Vehicles UTV/ATV
Replies 5 Post by spyder

Hi there - almost 30 mph is a bit fast; should probably be just under 20, but depends on the clutch.
I seem to recall from a previous post that you have the tech. manual? I've been through the process of adjusting the governor and linkages after rebuilding one of these engines. Took a couple of attempts, but (without instruments) I got there in the end without too much drama. I too had a LOT of smoke pouring out of the exhaust at first, but it cleared after running for a couple of times (while I did the adjustments). If you take out the dipstick or the oil filler cap, you will get air puffing out. This is normal. There is a mechanism at the top of the engine that lets pressure out via a simple reed valve when the pistons come down into the crankcase, but stops air coming back in when the pistons go back up. This creates a partial vacuum in the crankcase that helps keep the oil in. Depending on the year of the machine, you may or may not have a hose running from the breather outlet to the carburettor.

fd620d blowby
Utility Vehicles UTV/ATV
Replies 6 Post by spyder

Hi Jspec - just wondered how you are getting on with the water pump - have you bought a whole new pump? If so, did you buy it from JD or somewhere else and how much did it cost you?

Just picked up a 2000 6x4 with motor issues
Utility Vehicles UTV/ATV
Replies 22 Post by spyder

Apart from the solenoid in the starter motor itself, there is a small relay which is normally situated on the side of the engine compartment just underneath the ignition module. With the tray up, you should be able to hear a faint click from this relay when you turn the key to the 'start' position.
This relay connects power to the small wire that goes to a push-on connector on the starter motor. To check the starter motor itself, unplug this small wire. Then, WITH THE MACHINE IN NEUTRAL AND THE KEY IN THE OFF POSITION, touch a piece of wire between the battery positive terminal and the now-exposed lug on the starter motor. If the starter motor is okay, it should spin up. And, if it does, the problem must be one of the following...
A/. The small relay
B/. The switch inside the transmission
C/. A dirty contact on the plug or socket that connects the main wiring harness to the engine wiring harness
D/. A dirty contact on the key switch connector
E/. a faulty key switch.

Cheers

Gator wont start
Utility Vehicles UTV/ATV
Replies 3 Post by spyder

Just one more thought.... there are three fusible links at the battery end of the wiring harness. They were somewhat corroded in an old 6X4 that I recently restored.
With the engine running, reach down and give the harness a good shake. If the engine dies, the prob is somewhere in this area. Good luck...

6x4 electrical shuts down then starts working again
Utility Vehicles UTV/ATV
Replies 6 Post by spyder