Product Details

Clymer repair manuals are written specifically for the do-it-yourselfer.

For routine maintenance or more extensive repairs involving engine and transmission disassembly, it has all the information you need.

Step-by-step procedures, detailed photography and extensive use of exploded views based on the complete disassembly of the machine.

Clymer shop manuals are perfect for everyone, from the first-time user to the seasoned professional.

CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

CHAPTER Three / Lubrication, Maintenance and Tune-Up

Pre-ride inspection / Engine break-in / Battery / Engine oil and filter / Final drive / Front differential / Air filter / Front drive shaft lubrication / Rear suspension pivot lubrication / Control cable lubrication / Fastener inspection / Speed limiter adjustment / Axle boot inspection / Drain inspection / Cooling system / Exhaust system / Fuel system / Drive belt inspection / Control cable adjustment / Brake system / Tire inspection / Tune-up / Valve clearance / Carburetor adjustment / Ignition timing / Compression test / Spark plug / Specifications

CHAPTER Four / Engine Top End

Exhaust system / Cylinder head cover / Camshaft and cam chain tensioner / Cylinder head / Valves / Cylinder / Piston and rings / Specifications

CHAPTER Five / Engine Lower End

Removal / Installation / Recoil starter / Balancer and oil pump gears / Cam chain and rear guide / Crankcase / Crankcase seal replacement / Crankcase bearing / Engine balancer / Oil pump / Crankshaft / Middle gear assembly / Middle gear assembly shim and lash adjustment / Specifications

CHAPTER Six / Clutch and Sheaves

Drive belt cover / Outer bearing housing / Drive belt / Primary and secondary sheaves / Right crankcase cover / Clutch / Specifications

CHAPTER Seven / Transmission and Shift Mechanisms

Select lever assembly / Select lever cable / External shift mechanism / Transmission / Shift drum and forks / Specifications

CHAPTER Eight / Fuel System

Carburetor / Fuel valve / Throttle cable / Specification

CHAPTER Nine / Electrical System

Electrical component / Ignition and charging system operation / Alternator cover / Stator and pickup coil / Rotor, starter clutch and starter gears / Starter / Starting system switches / Ignition system / Charging system / Fan system / Coolant temperature warning system / 4 Four-wheel drive relays and gear motor / Indicator circuits / Switches / Headlights / Taillight / Specifications

CHAPTER Ten / Cooling System

Cooling system safety / Radiator and fan / Fan sending unit / Coolant temperature sending unit / Thermostat / Water pump / Specifications

CHAPTER Eleven / Front Suspension and Steering

Front wheel / Front hub / Tie rods / Steering knuckle / Control arms / Shock absorbers / Steering shaft / Handlebar / Wheel run out / Specifications

CHAPTER Twelve / Front Axles and Differential

Front axles / Differential / Front drive shaft / Specifications

CHAPTER Thirteen / Rear Suspension

Rear wheel / Rear hub / Rear knuckle / Stabilizer / Control arms / Shock absorbers / Specifications

CHAPTER Fourteen / Rear Axles and Final Drive

Rear axles / Final drive unit / Specifications

CHAPTER Fifteen / Brakes

Front brake pads / Front brake caliper / Front master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Left hand brake cable replacement / Brake system draining / Brake system bleeding / Brake disc / Specifications

CHAPTER Sixteen / Body

Body panel fasteners / Seat / Fuel tank side panels / Fuel tank cover and fuel tank / Engine side cover and side panel / Front carrier / Front fender hood / Front bumper and skid plate / Front grille and lights / Front fender assembly / Rear carrier and fender panel / Rear fender / Footrest panels / Center and rear skid plates / Specifications

INDEX

WIRING DIAGRAMS