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Assembly


Prepare Vehicle For Assembly

1. Remove top and sides of shipping crate.

2. Remove seats and packaged parts from vehicle.

3. Remove tires from cargo box and sides of vehicle.


MX33312

4. Locate two shipping brackets (A) on each side of vehicle frame.

5. Remove self-tapping screws (B) on each side. Retain these four screws to install the load guard later.

c CAUTION: Avoid injury! Cargo box is heavy. Use a safe lifting device or get an assistant to help lift, install or remove cargo box.

6. Lift cargo box off vehicle frame.

7. Remove self-tapping screws (C) and shipping brackets (A) on each side. Discard the shipping brackets.

8. Install two self-tapping screws (C) back into holes on the right side of vehicle previously removed. Install one of these screws into rear hole on left side of vehicle. Discard the last screw.


MX34257

9. Remove hardware (D) on each side of rear corner of frame area.


MX31002a

10. Remove two self-tapping screws (E) on front foot platform. Discard the shipping hardware.

Install Wheels

c CAUTION: Avoid injury! The machine can fall or slip from an unsafe lifting device or supports.

• Use a safe lifting device rated for the load to be lifted.

• Lower machine onto jack stands or other stable supports and block wheels before servicing.

1. Install plastic cap on each rear axle hub.

2. Raise vehicle with a safe lifting device. Place support stands under vehicle.


MX31037

3. Attach each wheel to axle hub with valve stem to outside using five wheel bolts. Tighten wheel bolts evenly in proper sequence (A), (B), (C), (D), and (E) until snug. Finish tightening to 81 N•m (60 lb-ft) using a torque wrench.

4. Remove support stands and lower vehicle.

Checking Tire Pressure

c CAUTION: Avoid injury! Explosive separation of tire and rim parts is possible when they are serviced incorrectly:

• Do not attempt to mount a tire without the proper equipment and experience to perform the job.

• Do not inflate the tires above the recommended pressure.

• Do not weld or heat a wheel and tire assembly. Heat can cause an increase in air pressure resulting in an explosion. Welding can structurally weaken or deform the wheel.

• Do not stand in front or over the tire assembly when inflating. Use a clip-on chuck and extension hose long enough to allow you to stand to one side.

1. Check tires for damage.

NOTE: Refer to the SPECIFICATIONS section for tire pressures.

2. Check tire pressure with an accurate gauge.

3. Add or remove air, if necessary.

Install Steering Wheel

1. Remove and discard plastic protective cap from steering shaft.

2. Install steering wheel onto steering shaft. Turn steering wheel to position front wheels straight and facing forward.

3. Remove steering wheel.

4. Apply multi-purpose grease to steering shaft.


MX33317

5. Install steering wheel onto steering shaft with one spindle (A) positioned at 180? at bottom of wheel and spindles (B) at approximately 45? at top of wheel, as shown.

6. Install nut (C) and tighten to 38 N•m (28 lb-ft).


MX33318

7. Install cover (D) so the John Deere name is positioned properly.

Check Battery Voltage

c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode:

• Do not smoke or have open flame near battery.

• Wear eye protection and gloves.

• Do not jump start or charge a frozen battery. Warm battery to 16?C (60?F).

• Do not connect the negative (-) booster cable to the negative (-) terminal of the discharged battery. Connect at a good ground location away from the discharged battery.

Remove and discard the protective caps from the positive (+) and negative (-) terminals.

Battery is filled with acid and charged when it left the factory. To extend battery life, check voltage prior to delivery. Fully charge the battery if voltage is less than 12.6 volts.

Connect Battery


MX35824

1. Install red positive battery cable (A) to positive (+) terminal first using M6x16 capscrew, flat washer, and nut. Tighten the connection.

2. Install black negative battery cable (B) to negative (-) terminal last using M6x16 capscrew, flat washer, and nut. Tighten the connection.

3. Apply petroleum jelly on battery terminals to help prevent corrosion.

4. Slide protective cover down the battery positive cable and seat it over the positive (+) terminal.

Install Seats


MX35575

Picture Note: Rear position shown.

1. Remove capscrews (A) from bottom of seat base bracket on each seat.


MX31039

2. Install seat bushings (B) onto support rail so tabs face toward rear of vehicle.


MX31040

3. Position seat base bracket onto support rail so hinges (C) fit around plastic bushing tabs.


MX35575

Picture Note: Rear position shown.

4. Rotate seat bracket upward. Install original hardware in slots closest to center of vehicle to secure seat. Do not tighten completely.

5. Slide seat forward or rearward to desired position.

6. Tighten seat capscrews (A) to 10 N•m (88 lb-in).

7. Repeat for opposite side.

Install Spark Arrestor


MX31026

1. Loosen screw (A) installed in spark arrestor assembly (B) and place onto muffler exhaust pipe. Tighten screw.

Install Cargo Box with Power Lift Kit

A cargo box power lift kit is available as an option. When installing the Power Lift for Cargo Bed Kit, see the separate installation instructions included in the kit.

Continue on in the assembly instructions with “Install Load Guard” procedure after power lift kit and cargo box have been installed.

Install Cargo Box with Prop Rod

c CAUTION: Avoid injury! Cargo box is heavy. Use a safe lifting device or get an assistant to help lift, install or remove cargo box.


MX31393

1. Position cargo box onto vehicle frame so hinges (A) are positioned inside pivot brackets (B).

2. Secure cargo box using M12x90 capscrews and flange locknuts (C). Install capscrew with threads to the outside of vehicle.

3. Tighten capscrews until pivot brackets contact ends of hinge.

4. Apply a spray lubricant to the pivot hardware, hinges, and pivot brackets.


MX35811


MX31392

5. To install cargo box support rod, have a second person raise and hold cargo box securely.

6. Install 90? end (D) of support rod into hole (E) in cargo box channel, as shown. To secure top end of rod, install push-on nut (F) to a depth of 20 mm (0.79 in.).

7. Lower opposite end of support rod, and push inward on rod forcing it over sill (G).

8. Route end (H) of support rod into slot (I).

9. To lower cargo box, raise cargo box slightly using lift handle on side of cargo box.

10. Release support rod from latch slot (I) by pulling up on lower end of rod.

11. Lower the cargo box, and push down on cargo box handle until support rod latches into cargo box with an audible snap.

Install Load Guard

1. Raise and secure cargo box.


M78495

2. Install load guard (A) to cargo box so bottom lip (B) is positioned on underside of box and square tube frame (C) is to the inside of box.

3. Secure bottom of load guard with six M8x20 carriage bolts, flat washers, and flange locknuts (D). Tighten locknuts to 25 N•m (18 lb-ft).

4. Attach both sides of load guard using two self-tapping screws (E) retained from shipping brackets on cargo box.

Remove Protective Film

Open Hood


MX35576a, MX31042

1. Stand in front of machine and grasp hood lift handle (A).

2. Pull up on hood release handle to unlock latch (B).

3. When the hood latch is released, pull upward on the hood to pivot to full open position.

Remove Protective Film

• Remove white protective film from around fenders and hood.

Closing Hood

1. Grasp hood lift handle (A).

2. Pivot hood downward to closed position.

3. Press down on hood to latch hood in closed position.

Clean and Polish Plastic Hood and Fenders

IMPORTANT: Avoid damage! Improper care of machine plastic surfaces can damage the surface:

• Do not wipe plastic surfaces when they are dry. Dry wiping will result in surface scratches.

• Use only cheesecloth for wiping surfaces.

• Do not use abrasive materials, such as polishing compounds, on plastic surfaces.

• Do not spray insect repellent near machine.


1. Remove any dust or dirt with water.

2. Dry thoroughly to avoid water spots.

3. Spray PLEDGE®1 onto plastic surfaces and leave on for 30 to 60 seconds.

4. Use a dry soft cloth to wipe off to bring out lustre.

Check Fluid Levels

• Check all fluid levels.

Check Machine Safety System

Perform safety system check to make sure the electronic safety interlock circuit is functioning properly. Perform all tests. (See Testing Safety System in the OPERATING section.)

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PLEDGE® is a Registered Trademark of S.C. Johnson, Co.