Part of the John Deere Repair Manuals.
All 312 pages of this John Deere Trail Buck Technical Manual (OEM #TM2160) focus on one machine family: the Trail Buck Utility ATV in 500, 650, 650EX, and 650EXT configurations. Inside, you get the Trail Buck Main Schematic for full electrical circuit tracing, a complete troubleshooting section covering cooling, magneto, lubrication, and cylinder diagnostics, plus page after page of torque tables spanning engine, CVT, drivetrain, brakes, and body fasteners. Exploded views walk you through every assembly from crankshaft and balancer to front differential backlash adjustment. Torque the cooling fan mount screw to 4.5 N·m (40 lb-in.) and confirm your headlights pull exactly 2 x 30 W before chasing an electrical fault with a multimeter and a prayer. Your machine is down. Get factory numbers, not forum guesses. Bookmarked by section and keyword-searchable; pull it up on your tablet, walk to the ATV, and start wrenching.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 3-4 | Table of Contents, Specifications and Information, Identification Numbers, Tools and Materials, Component Location, Schematics and Harnesses, Theory of Operation |
| Safety | 5-10 | Recognize Safety Information, Understand Signal Words, Replace Safety Signs, Handle Fluids Safely - Avoid Fires, Be Prepared for Emergencies |
| Technical Data | 11-30 | Fastener Torques (Metric Fastener Torque Values, Inch Fastener Torque Values, Gasoline, Gasoline Storage, - Cycle Gasoline Engine Oil, Break-In Engine Oil - 4-Cycle Gasoline, Hydrostatic Transmission and Hydraulic Oil, Gear Case Oil, Gear Transmission Grease, Alternative Lubricants, Synthetic Lubricants, Lubricant Storage, Mixing of Lubricants, Oil Filters) |
| Specifications | 31-35 | Engine Specifications - 500, Engine Specifications - 650, Engine Specifications - 500 and 650, Required Tools |
| Diagnostics | 36-47 | Cooling System, Magneto System, Lubrication, Cylinder and Head |
| Tests and Adjustments | 48-50 | Leak Test |
| Repair | 51-58 | Component Location, Engine Removal, Engine Installation, Anti-Vibration System |
| Fuel Circuit | 59-64 | Fuel System Components, General, Fuel Lines, Fuel System Pressurization |
| Carburetor | 65-73 | Carburetor Components, Throttle Cable, Choke Cable |
| Fuel Circuit | 74-76 | Air Intake Components, Air Filter, Air Filter Cleaning/Draining, Air Filter Box |
| Cooling System | 77-88 | Engine Side Components, Vehicle Side Components, General, Coolant Level |
| Ignition and Charging System | 89-93 | Charging Components, General, Magneto Housing Cover, Seal |
| Oil System | 94-103 | Oil System Components, General, Engine Oil Pressure Test, Oil Change |
| Cylinder and Head | 104-194 | Cylinder Head Components, Piston and Rings Components, General, Spark Plug |
| Electrical | 195-236 | Specifications (Electrical Specifications, Required Tools, Recommended Tools), Schematics and Harnesses (Component Location, Trail Buck Main Schematic) |
| Drive Train | 237-260 | Required Tools (Special or Required Tools), Recommended Tools (Special or Required Tools), Repair, Front Drive Shaft (Removal, Inspection, Installation, Drive Shaft Boot Removal) |
| Steering | 261-268 | Specifications (Steering Control Specifications, Recommended Tools), Component Location (Steering System) |
| Suspension | 269-276 | Specifications (Suspension Specifications, Recommended Tools), Component Location (Swing Arm), Repair (General, Rear Shock, Swing Arm) |
| Brakes | 277-294 | Specifications (Brakes Specifications, Recommended Tools), Component Location (Front Brakes, Rear Brake) |
| Body / Frame | 295-312 | Repair, Body Parts (Trail Buck Series), Seat (Trail Buck Series), General, Steering Cover (Removal, Storage Cover), Console (Removal, Installation) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fan Mount Screw/Nut Torque | 4.5 N•m (40 lb-in.) | p. 26 |
| Pilot Lamp Cluster LED Voltage | 0.7 V approximately (each) | p. 198 |
| SAE Wire Size (Gauge) | 20, 18, 16, 14, 12, 10 | p. 197 |
| Metric Wire Size (mm) | 0.5, 0.8, 1.0, 2.0, 3.0, 5.0 | p. 197 |
| Headlight Power Rating | 2 x 30 W | p. 198 |
| Fan Thermostat Switch ON Temperature | 95° C (203° F) | p. 23 |
| Fan Thermostat Switch OFF Temperature | 90° C (194° F) | p. 23 |
| Engine/Transmission Oil Capacity | 3 L (3.17 qt) | p. 25 |
| Fuel Tank Capacity | 21.8 L (5.8 U.S. gal) | p. 25 |
| Cooling System Capacity | 2.5 L (2.65 qt) | p. 25 |
| Spark Plug Torque | 18 N•m (159 lb-in.) | p. 26 |
| Engine Drain Plug Torque | 39 N•m (29 lb-ft) | p. 26 |
