Powertrain:
Engine (carburetor, intake, heads, camshaft, valve train, block, pistons, rings, rods, crankshaft, oil pump, pan, ignition, timing, muffler, exhaust), Transmission (clutch, flywheel, seals, transfer case)
Chassis:
Brakes (pads, shoes, rotor, lines, hoses), Suspension (shocks, struts), Steering System, Axles, CV boots, hubs, bearings, wheels, tires (rotation, alignment)
Electrical:
Ignition system, spark plugs, spark plug wires, wiring harness, sensors (oil, pressure), volt meter, battery, starter motor, alternator, lighting (headlights, taillights, fog lights, interior lights, turn signals), switches, relays
Fuel System:
Fuel pump, fuel filter, fuel lines, carburetor assembly, air filter, fuel tank cap, fuel filler neck
Cooling System:
Radiator, radiator fan, oil radiator, coolant hoses, fan shroud
Body And Trim:
Body panels, doors, door hinges, door handles, hood, hood latch, hood hinge, bumpers, grilles, fenders, trim replacement, interior lighting, dashboard, dash replacement, glovebox, center console, door panels, emblems, mud guards, mud flaps
Routine Maintenance:
Oil change, transmission fluid change, fluid changes, tire rotation, air filter replacement, spark plug replacement, brake fluid flush, coolant flush, battery maintenance, fuel filter replacement, PCV system service
Diagnostics And Troubleshooting:
Engine performance issues, starting problems, electrical system faults, brake system diagnosis, suspension noise, transmission issues, cooling system leaks
Major Repairs:
Engine rebuild (top and bottom end), cylinder head service, piston and ring replacement, crankshaft and connecting rod service, valve train overhaul, carburetor overhaul and adjustment, transmission overhaul, brake caliper and rotor replacement, suspension component replacement, electrical component replacement, exhaust system repair and replacement
Component Replacement:
Starter motor, alternator, fuel pump, ignition coil, spark plug wires, water pump, radiator, brake pads, brake rotors, brake calipers, wheel bearings, CV joints, suspension arms, tie rods, exhaust system components, battery, light bulbs, wiper blades
Special Tools:
Lists required special tools for specific repair procedures, such as pullers, presses, and calibration tools.
Depth:
Comprehensive; covers everything from routine maintenance to complete engine and transmission rebuilds. Includes detailed diagrams, torque specifications, and diagnostic procedures.
Torque Specs:
Includes detailed torque specifications for all critical fasteners, essential for proper assembly and preventing damage.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for troubleshooting and repair of all electrical systems.
Diagnostic Codes:
Details on any diagnostic trouble codes (DTCs) and their interpretation, if applicable to the vehicle's electronic systems.
Oil Change Interval:
Typically every 20-40 operating hours or annually, whichever comes first. Specific recommendation in the manual.
Spark Plug Replacement:
Recommended every 100-200 operating hours or as needed based on inspection. Manual will specify plug type and gap.
Cv Belt Inspection:
Regular inspection for wear and damage, typically recommended at every oil change.
Engine Oil Type:
SAE 0W-40 or 10W-40 Synthetic Motorcycle/ATV Oil meeting JASO MA/MA2 specifications. Manual will provide exact viscosity and API rating.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify the exact type and capacity.
Gearcase Oil Type:
Polaris specific gearcase lubricant or equivalent. Manual will detail the type and capacity for final drive/gearcase.
Coolant Type:
Antifreeze/coolant mixture. Manual will specify the type (e.g., ethylene glycol based) and mixture ratio.
Common Wear Items:
CV boots, brake pads, wheel bearings, battery, drive belt (CVT). The manual will detail inspection and replacement procedures for these and other components.
Carburetor Tuning:
Carburetors can sometimes require adjustments due to altitude or fuel changes, detailed in the manual.
