Engine:
Complete engine servicing, including top-side components, left-side components, right-side components, center crankcase components, fuel/lubrication/cooling systems (EFI, gas tank, oil filter/pump, oil cooler, liquid cooling, radiator, thermostat, fans, water pump, fuel pump).
Transmission:
Engine/Transmission oil, filter, removal, installation, and servicing.
Drive System:
Front differential, rear drive lubricant, driveshaft/coupling, front drive actuator, drive axles, rear gear case, hub, hydraulic brake caliper, troubleshooting.
Electrical System:
Battery, RPM limiter, testing electrical components, accessory receptacle, brakelight switch, ECT sensor, fan motor, PDM, ignition coil, EFI sensors, speed sensor, EPS, ignition switch, headlight switch, drive select switch, reverse override switch, front drive actuator, stator coil/CKP sensor, starter motor/relay, ECM, regulator/rectifier, headlights, taillight-brakelight, ignition timing, tilt sensor, TPS, diagnostic trouble codes (DTC), troubleshooting.
Suspension:
Shock absorbers, front A-arms, rear trailing arms, wheels and tires, troubleshooting.
Steering Frame Controls:
Electronic Power Steering (EPS), rack and pinion assembly, steering wheel, steering shaft, steering knuckles, front wheel alignment, hood, rear body panel, accelerator pedal, shift lever/cable, LCD gauge, exhaust system, cargo box, seats, troubleshooting.
Brakes:
Comprehensive coverage of the hydraulic brake system, including burnishing brake pads, checking/replacing V-belt, and troubleshooting the brake system.
Maintenance:
Periodic maintenance, tune-up, lubrication points, air filter service, valve/tappet clearance adjustment, engine compression testing, spark plug service, muffler/spark arrester, fluid changes (engine oil, front differential, rear drive), V-belt inspection and replacement, brake pad burnishing.
Diagnostics:
Comprehensive troubleshooting tables for engine, brakes, drive system, suspension, steering/frame/controls, and electrical systems. Diagnostic Trouble Codes (DTCs) for EFI and ECM.
Repair Rebuild:
Detailed steps for removing, servicing, and installing major components like engine/transmission, top-side, left-side, right-side, and center crankcase components. Rebuilding of fuel system components, cooling system components, and electrical components.
Adjustments:
Valve/tappet clearance, front wheel alignment, brake adjustments (implicitly through system servicing).
Wiring Diagrams:
Specific wiring diagrams for XT, XTX, and XTZ models are provided, crucial for electrical troubleshooting and repairs.
Parts Identification:
References 'Genuine Parts' and includes detailed illustrations and diagrams within sections, aiding in part identification during maintenance and repair.
Depth:
High. Covers everything from basic maintenance and tune-ups to in-depth diagnostics, component removal/installation, rebuilding, and electrical system troubleshooting with wiring diagrams. Aims to provide the same information as expert technicians.
Torque Specifications:
Includes specific Torque Specifications and Torque Conversions (ft-lb/N-m) for critical fasteners throughout the vehicle, essential for accurate assembly and component integrity.
Troubleshooting Tables:
Extensive use of troubleshooting tables for all major vehicle systems, providing structured diagnostic approaches.
Recommended Intervals:
The manual contains a detailed Periodic Maintenance Chart outlining recommended service intervals for all components (e.g., engine oil changes, filter replacements, lubrication, belt checks, brake inspections).
Engine Oil:
Specific API service classifications, viscosity grades (e.g., 0W-40, 10W-40, 20W-50) and capacities for the engine, front differential, and rear gear case are provided in the 'Gasoline - Oil - Lubricant' and specific component sections.
Coolant:
Specifications for the liquid cooling system, including coolant type (e.g., ethylene glycol-based antifreeze) and mixture ratios, are detailed.
Brake Fluid:
Specifications for hydraulic brake fluid (e.g., DOT 3 or DOT 4) are provided in the Hydraulic Brake System section.
Lubricant Specifications:
Covers lubricants for various points including chassis grease, U-joint grease, and differential/gear case oils, as outlined in the Lubrication Points and fluid spec sections.
Common Failures:
While not explicitly stated in the product description, a comprehensive service manual like this is designed to address common issues, which for ATVs of this era might include wear on suspension components, drive belt issues, electrical connection corrosion, and fuel system component maintenance. The troubleshooting sections are key for addressing these.
Storage Procedure:
Detailed procedures for preparing the vehicle for storage and preparing it after storage are included.
Break In Procedure:
A specific 'Break-In Procedure' section is listed, crucial for new engines or after major overhauls.