Engine Mechanical:
Full coverage: disassembly, assembly, inspection, repair of engine components (pistons, rings, crankshaft, connecting rods, cylinder head, valves, etc.)
Engine Electrical:
Ignition system, starting system, charging system, CDI unit, ignition timing, wiring diagrams
Fuel System:
Carburetor tuning and adjustment, fuel pump, fuel lines, fuel filter
Cooling System:
Radiator, coolant, fan, thermostat, water pump
Exhaust System:
Exhaust pipes, mufflers, heat shields
Drivetrain Transmission:
Clutch system, drive clutch, driven clutch, chain case, gears, lubrication
Suspension Front:
IFS (Independent Front Suspension) components, shocks, springs, control arms, steering linkage
Suspension Rear:
Rear suspension components, track, shocks, springs, torque arm
Braking System:
Hydraulic disc brakes, brake calipers, master cylinder, brake lines, pads, rotors
Steering System:
Handlebars, steering post, tie rods, steering post support
Electrical System Lighting:
Headlights, taillights, brake lights, wiring harness
Body Chassis:
Chassis components, body panels, seat, decals, bumpers
Track System:
Track inspection, drive sprockets, idler wheels, suspension adjustments
Scheduled Maintenance:
Detailed maintenance schedules and procedures (e.g., lubrication, spark plug replacement, chain adjustment)
Troubleshooting:
Comprehensive diagnostic charts and procedures for common and uncommon issues
Engine Repair:
Complete engine overhaul, rebuild procedures, component replacement
Transmission Repair:
Clutch service, chain replacement, drive/driven clutch service
Suspension Repair:
Shock absorber replacement, steering linkage repair, track adjustment
Brake Service:
Brake pad replacement, caliper service, bleeding procedures
Electrical Diagnostics:
Wiring diagram interpretation, component testing, fault finding
Carburetor Adjustment:
Detailed procedures for cleaning, rebuilding, and tuning carburetors
Track Maintenance:
Track tension adjustment, inspection for damage, drive component checks
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts
Diagnostics:
Advanced diagnostic procedures and specifications
Rebuilds:
Full rebuild procedures for major components (engine, transmission)
Torque Specs:
Detailed torque specifications for all fasteners and critical components
Clearances:
Component clearances and tolerances for engine and other systems
Type:
Liquid-cooled, 2-stroke, parallel twin
Displacement:
698 cc (approximate, often marketed as 700)
Bore X Stroke:
Not explicitly stated in product info, but typically around 72mm x 68mm for this era
Horsepower:
Estimated 95-105 HP (typical for 700cc 2-strokes of this era, exact figure varies)
Torque:
Not explicitly stated in product info
Ignition:
CDI (Capacitor Discharge Ignition)
Starting System:
Recoil (pull start) and potentially electric start (depending on trim/options)
Carburetion:
Dual Mikuni VM series carburetors (common configuration, e.g., VM34 or VM38)
Fuel Type:
Unleaded gasoline (typically 87 octane or higher, with oil injection)
Oil System:
Oil injection system (auto-lube)
Initial Service:
Break-in service (e.g., 20-50 hours, check manual for specifics)
Engine Oil Change:
N/A (2-stroke, oil injected; focus on oil injection system maintenance)
Spark Plugs:
Check/replace every 50-100 operating hours (depending on use)
Clutch Inspection:
Inspect and clean secondary clutch roller/buttons annually or every 100 hours
Chain Case Lubrication:
Change chain case oil every 50-100 hours or annually
Suspension Lubrication:
Lubricate suspension zerks as per schedule (typically annually)
Engine Oil:
Polaris 2-stroke synthetic oil injection lubricant (e.g., Ves-Ex or equivalent)
Chain Case Oil:
Polaris Synthetic Chain Case Lubricant or equivalent SAE 80W-90 gear oil
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors (50/50 mix with distilled water)
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Carburetion Icing:
Common in cold, humid conditions; can be mitigated with proper venting or additives
Clutch Wear:
Wear on primary/secondary clutch components (rollers, buttons, springs) can affect performance
Track Tension:
Improper track tension can lead to premature wear of track, sliders, and bearings
Suspension Bushings:
Wear in suspension bushings can lead to sloppy handling and increased component wear
Oil Injection Pump Failure:
Though rare, failure can lead to engine seizure; regular checks are crucial
