Primary Focus:
Repair, Maintenance, and Diagnostics
Included Sections:
General Information, Specifications, Troubleshooting, Maintenance, Engine, Transmission, Drive System, Suspension, Steering, Frame, Fuel System, Cooling System, Electrical System, Brakes, Body Panels
Type:
OEM Factory Service Manual
File Format:
PDF Download
Engine:
Liquid Cooling System, Oil Pump Pressure Testing, Engine Compression Testing, Spark Plug, Ignition Coil, Muffler/Spark Arrester, Ignition Timing, ECU, Stator Coil, RPM Limiter, Valve/Tappet Clearance
Transmission:
Engine/Transmission Oil & Filter, Front Differential/Rear Drive Lubrication, Separating Crankcase Halves, Disassembling Crankcase Half, Servicing Center Crankcase Components, Assembling Crankcase Half, Joining Crankcase Halves
Drive System:
Front Drive Selector Switch, Front Drive Selector Actuator, Front Differential, Drive Axles, Rear Gear Case, Hub, Driveshaft/Coupling, Troubleshooting Drive System
Brakes:
Hydraulic Brake Systems, Burnishing Brake Pads, Brakelight Switch (Pressure), Hydraulic Brake Caliper, Hand Brake Lever/Master Cylinder Assembly, Troubleshooting Brake System
Electrical System:
Electric Fuel Pump/Fuel Level Sensor, Battery, Testing Electrical Components, Accessory Receptacle/Connector, Power Distribution Module (PDM), Speed Sensor, Ignition Switch, Handlebar Control Switches, Starter Relay, Starter Motor, Regulator/Rectifier, Lights, Tilt Sensor, Throttle Position Sensor (TPS)
Suspension Steering:
Shock Absorbers, Front A-Arms, Rear A-Arms, Steering Post/Tie Rods, Steering Knuckles, Measuring/Adjusting Toe-Out
Fuel Cooling Lubrication:
Liquid Cooling System, Electric Fuel Injection, Throttle Body, Gas Tank, Fuel/Lubrication/Cooling Specifications, Gasoline-Oil-Lubricant Specifications
Body Frame:
Frame/Welds, Front Bumper Assembly, Front Body Panel/Fender, Rear Body Panel, Seat, Handlebar Grip, Throttle Control
Maintenance:
Periodic Maintenance, Periodic Maintenance Chart, Air Filter Service, Valve/Tappet Clearance Adjustment, Spark Plug Replacement, V-Belt Replacement, Lubrication Points, Break-In Procedure, Preparation For Storage, Preparation After Storage
Diagnostics Troubleshooting:
Troubleshooting (General), Electrical System Troubleshooting, Drive System Troubleshooting, Brake System Troubleshooting, Diagnostic Trouble Codes (DTC)
Repair Rebuild:
Engine/Transmission Removal and Installation, Top-Side Components (Removal, Servicing, Installation), Left-Side Components (Removal, Servicing, Installation), Right-Side Components (Removal, Servicing, Installation), Crankcase Halves Separation and Assembly, Drive Axle Service, Hub Service, Steering Knuckle Service
Adjustments:
Throttle Cable Adjustment, Engine RPM (Idle) Adjustment, Toe-Out Adjustment
Depth:
Comprehensive OEM Factory Level (suitable for dealership technicians and advanced DIY users)
Detail Level:
Includes detailed diagrams, photos, step-by-step instructions, and torque specifications for all major components and systems.
Oil Change:
Refer to manual for specific interval (typically every 100-200 hours or annually, whichever comes first).
Air Filter:
Refer to manual for specific interval (inspect more frequently based on operating conditions).
Valve Adjustment:
Refer to manual for specific interval (critical for engine performance and longevity).
Engine Oil:
Refer to manual for exact API and viscosity specification (e.g., API SG or higher, SAE 10W-40 or 20W-50).
Coolant Type:
Refer to manual for specific coolant type and mixture (typically a 50/50 mix of ethylene glycol based coolant and distilled water).
Brake Fluid:
Refer to manual for specific brake fluid specification (likely DOT 3 or DOT 4).
Common Wear Items:
V-belt, brake pads, tires, wheel bearings, and suspension components are common wear items on ATVs.
Potential Electrical:
As with many ATVs of this era, electrical connections and charging system components (stator, regulator/rectifier) are areas to monitor for corrosion or failure.