Engine:
Detailed diagnostics, repair, overhaul, and specifications for all engine variants.
Lubrication System:
Oil pump, oil filter, lubrication passages, and oil change procedures.
Fuel System:
Carburetor (Mikuni/Keihin), fuel pump, fuel lines, fuel filter, and adjustments.
Exhaust System:
Exhaust pipe, muffler, heat shields, and component inspection.
Cooling System:
Radiator, fan, coolant, hoses, and thermostat operation.
Transmission:
Automatic transmission (PVT - Polaris Variable Transmission) operation, maintenance, and repair.
Drivetrain:
Shaft drive, U-joints, differentials (front and rear), and AWD system (on applicable models).
Suspension Front:
A-arms, shocks, springs, wheel bearings, and steering components.
Suspension Rear:
Swingarm, shocks, springs, linkages, and wheel bearings.
Brakes:
Hydraulic disc brake systems (front and rear), brake calipers, master cylinders, hoses, and fluid specifications.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, ignition system (CDI), lighting, and switches.
Wiring Diagrams:
Comprehensive color-coded wiring diagrams for all electrical systems.
Frame And Body:
Frame inspection, body panel removal/installation, plastics, and fenders.
Controls:
Handlebar controls, throttle, brake lever, gear selector (if applicable), and ignition switch operation.
Lighting Meters Switches:
Headlights, taillights, brake lights, neutral indicator, reverse indicator, AWD indicator, and switch functions.
Maintenance:
Routine maintenance checks, lubrication points, filter replacements, and fluid changes.
Troubleshooting:
Detailed diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Engine Repair:
Top-end rebuild (cylinder head, valves, piston), bottom-end rebuild (crankshaft, connecting rod, bearings), and full engine disassembly/assembly.
Transmission Repair:
PVT belt inspection and replacement, drive clutch and driven clutch service, and gearcase maintenance.
Brake Service:
Brake pad replacement, caliper service, bleeding procedures, and master cylinder rebuild.
Suspension Adjustment:
Shock preload adjustments, alignment procedures, and bearing service.
Electrical Diagnostics:
Testing of charging system components, ignition system, starter, and lighting circuits.
Carburetor Adjustment:
Idle speed, mixture adjustments, and jetting recommendations.
Engine Removal Installation:
Step-by-step procedures for removing and reinstalling the engine.
Electric Starter:
Operation, testing, and troubleshooting of the electric starter motor and associated circuitry.
Charging System:
Stator testing, regulator/rectifier diagnosis, and battery charging procedures.
Ignition System Testing:
Spark plug analysis, CDI module testing, and ignition coil diagnosis.
Electric Shift Program:
Diagnosis and repair of any electronic shift systems if equipped.
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and advanced DIY enthusiasts.
Diagnostic Charts:
Includes detailed charts correlating symptoms to potential causes and troubleshooting steps.
Torque Specifications:
Essential torque values for all critical fasteners and components.
Clearances And Tolerances:
Precise measurements for engine components, bearing play, and suspension alignments.
Oil Change Interval:
Typically every 100 hours or 6 months, check manual for specific recommendations.
Air Filter Cleaning:
Recommended every 25 hours or as needed based on operating conditions.
Spark Plug Replacement:
Refer to manual for specific mileage or hour intervals.
Engine Oil:
Specific SAE viscosity grade and API service classification (e.g., SAE 10W-40, API SG or higher) will be detailed in the manual.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid, as specified in the manual.
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Common Wear Items:
PVT belt wear, wheel bearings, suspension bushings, and electrical connections.
Carburetor Cleaning:
Periodic cleaning may be required due to fuel quality or debris.
