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 checks / Service maintenance intervals schedule / Fluid checks / Break-in / Periodic lubrication / Engine oil and filter change / Control cable lubrication / Engine counter balancer / Transmission oil change / Rear axle housing lubrication / Periodic maintenance / Drive belt chain adjustment check / Oil injection pump adjustment / General inspection and maintenance / Toe-in adjustment / Tune-up / Cylinder head blot torque / Cylinder compression check / Spark plug / Ignition timing / Cam chain adjustment / Valve clearance / Carburetor adjustment / Idle speed / Storage / Specifications

CHAPTER FOUR / ENGINE (2-STROKE MODELS)

Removal installation / Liquid cooling / Cylinder head / Cylinder / Reed valve assembly / Piston, piston pin and rings / Recoil starter / Coolant pump / Engine balancer / Crankcase / Crankshaft, bearings and shim / Oil injection system / Break-in / Specifications

CHAPTER FIVE / ENGINE (4-STROKE MODELS)

Engine cooling / Engine lubrication / Removal installation / Cylinder head cover and rocker arm assembly / Camshaft / Cylinder head / Cylinder / Piston, pin and rings / Cam chain, sprockets and tensioner / Recoil starter / Flywheel and stator plate / Coolant pump / Crankcase / Crankshaft, balance shaft, bearings and seals / Oil pump / One way check valve / Break-in procedure / Specifications

CHAPTER SIX / FUEL AND EXHAUST SYSTEMS

Carburetor operation / Carburetor / Throttle cable / Choke cable / Fuel tank / Fuel shutoff valve / Air box / Fuel pump / Exhaust system / Specifications

CHAPTER SEVEN / COOLING SYSTEM

Polaris variable transmission PVT cooling system / Engine cooling air cooled models / Engine cooling liquid cooled models / Specifications

CHAPTER EIGHT / CLUTCH/DRIVE BELT SYSTEM

Drive unit / Drive pulley assembly / Driven pulley / Drive belt / Clutch inner cover / Specifications

CHAPTER NINE / TRANSMISSION SYSTEM

Type I transmission / Type II transmission / Type III transmission / Specifications

CHAPTER TEN / FRONT DRIVE SYSTEM

Front hubs / Front drive shaft boots and CV joints / Center chain and sprockets / Front chain and sprockets / Specifications

CHAPTER ELEVEN / ELECTRICAL SYSTEM

Charging system / Alternator stator / Voltage regulator/rectifier / Capacitor discharge ignition / Ignition high tension coil /Ignition stator coils exciter and pulser / Electric starting system / Starter drive gears / Starter solenoid / Lighting system / Switches / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING

Front wheel / Front hub / Front fork tubes / Front suspension / Steering shaft / Tires and wheels / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION

Rear wheels / Rear tires / Rear axle / Drive chain / Drive and driven sprockets / Tire changing and tire repairs / Shock absorber / Rear swing arm / Specifications

CHAPTER FOURTEEN / BRAKES

Front brakes / Hydraulic brakes / Front brake caliper / Mechanical rear brake caliper / Hydraulic rear caliper / Master cylinder / Brake hose / Brake disc / Brake bleeding / Specifications

CHAPTER FIFTEEN / BODY

Seat / Fuel tank cover / Front panel / Front fender / Rear fender / Side panels / Specifications

INDEX

WIRING DIAGRAMS

NOTE: This manual is not exclusive to the model specified in this listing and contains information on a variety of makes and models.