Engine:
Detailed coverage of engine disassembly, inspection, repair, and reassembly, including top-end, bottom-end, cooling system, and lubrication.
Fuel System:
Carburetor adjustment, cleaning, and rebuilding; fuel pump testing; fuel tank and line maintenance.
Pvt System:
Primary and secondary clutch service, belt inspection and replacement, variable transmission system diagnostics.
Transmission:
Gearbox inspection, repair, and maintenance; driveshaft and U-joint service.
Final Drive:
Hub and wheel assembly, axle maintenance, differential inspection and service.
Brakes:
Brake caliper service, pad replacement, fluid bleeding, master cylinder inspection, rotor and drum servicing.
Electrical:
Ignition system diagnostics, starter motor and charging system testing, lighting and accessory circuits, wiring diagrams.
Body Suspension:
Front and rear suspension component inspection, replacement, and adjustment; steering system maintenance; body panel removal and installation.
General:
General information, safety precautions, torque specifications, special tools, troubleshooting guides.
Maintenance:
Scheduled maintenance tasks, fluid level checks, filter replacements, lubrication points, tire pressure recommendations.
Repair:
Comprehensive step-by-step repair instructions for all major systems, including engine rebuilds and driveline overhauls.
Troubleshooting:
Diagnostic charts and procedures to identify and resolve common and uncommon issues.
Depth:
Comprehensive, covering from basic routine maintenance to advanced engine and transmission rebuilding.
Engine Type 400:
4-stroke, SOHC, 2-valve, single-cylinder, liquid-cooled
Engine Type 500:
4-stroke, SOHC, 2-valve, single-cylinder, liquid-cooled
Displacement 400:
Approx. 375cc (specifics detailed in manual)
Displacement 500:
Approx. 499cc (specifics detailed in manual)
Horsepower Torque:
Specific horsepower and torque figures for each model variant are detailed within the manual.
Carburetor Type:
Mikuni BSR carburetor (specific models and tuning details provided).
Oil Change:
Recommended every 100 hours or annually, whichever comes first (specific fluid type and capacity detailed in manual).
Spark Plug:
Inspection/replacement intervals are provided, typically every 100-200 hours of operation.
Air Filter:
Service intervals based on operating conditions (frequent cleaning/replacement recommended for dusty environments).
Engine Oil Type:
SAE 5W-50 Synthetic or Polaris Synthetic 2W-50 (specific API service classification will be noted in manual).
Coolant Type:
Ethylene Glycol based antifreeze/coolant, pre-mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (refer to manual for precise specification).
Common Wear Items:
PVT belt wear, starter solenoid issues, and occasional carburetor jetting sensitivity are common wear items for this era.
Cooling System:
Regular inspection of hoses, radiator, and coolant level is crucial to prevent overheating.
