Product Information
Table of Contents
Chapter One: General Information
- Manual organization
- Notes, cautions and warnings
- Safety first!
- Serial numbers
- Fasteners
- Buying parts
- Maintenance techniques
- Vehicle storage
- Chemicals and lubricants
- RTV gasket sealant
- Threadlock
- Case hardener
- Jacking
- Towing
- Cleaning
Chapter Two: Troubleshooting
- Troubleshooting
- Engine troubleshooting
- Electrical troubleshooting
- Drive train troubleshooting
- Fuel system troubleshooting
- Cooling system troubleshooting
- Suspension and steering troubleshooting
- Brake system troubleshooting
Chapter Three: Lubrication, Maintenance and Tune-Up
- Pre-checks
- Service intervals
- Tires and wheels
- New battery installation
- Battery electrical cable connections
- Periodic lubrication
- Periodic maintenance
- Engine tune-up
Chapter Four: Engine Top End
- Engine operation
- Cylinder head components
- Valve guide and valve seat
- Piston, piston pin and piston rings
- Cylinder and camshaft
- Camshaft chain tensioner adjuster
Chapter Five: Engine Lower End
- Engine removal and installation
- Servicing engine in frame
- Oil cooler (LT-F4WDX [280 cc] models)
- Oil pump and oil strainer
- Crankshaft and bearings
- Piston and crankshaft
- Transmission and gears
- Kick starter
- Recoil starter
- Shift shaft and shift cam
- Cam chain guide and cam chain
- Balance weight and balance shaft
- Oil seal replacement
- Engine removal and installation
- Brake components
- Brake pad
Chapter Six: Clutch
- Clutch removal
- Clutch installation
- Clutch adjustment
- Clutch hydraulic system
Chapter Seven: Transmission and Shift Mechanism
- Transmission removal
- Transmission installation
- Gearshift and footrest
Chapter Eight: Fuel and Exhaust Systems
- Carburetor removal
- Carburetor installation
- Carburetor adjustment
- Fuel tank
- Fuel lines
- Fuel system troubleshooting
- Exhaust system removal
- Exhaust system installation
- Exhaust system inspection
Chapter Nine: Electrical System
- Electrical components
- Electrical system troubleshooting
- Charging system
- Charging system inspection
- Ignition system
- Ignition system troubleshooting
- Lighting system
- Lighting system troubleshooting
- Starting system
- Starting system troubleshooting
- Switches
- Wiring diagrams
Chapter Ten: Front Suspension and Steering
- Front suspension
- Front suspension inspection
- Front suspension maintenance
- Front wheel
- Front wheel hub
- Steering system
Chapter Eleven: Front Drive Mechanism (Four-Wheel Drive)
- Front drive mechanism
- Front drive mechanism inspection
- Front drive mechanism maintenance
- Front differential
Chapter Twelve: Rear Suspension, Rear Axle and Final Drive
- Rear suspension
- Rear suspension inspection
- Rear suspension maintenance
- Rear wheel
- Rear wheel hub
- Rear differential
Chapter Thirteen: Brakes
- Brake system
- Brake components
- Brake troubleshooting
- Front brake master cylinder
- Front brake hydraulic lines
- Front brake caliper
- Rear brake master cylinder
- Rear brake hydraulic lines
- Rear brake caliper
- Brake pad replacement
- Brake fluid replacement
- Brake bleeding
Chapter Fourteen: Body
- Body components
- Body panel removal and installation
- Seat removal and installation
- Footrest removal and installation
Index
Wiring Diagrams
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