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May 15, 2015
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Table of Contents
General Service Manual
General Information
Abbreviations
Bearings
Fasteners
Conversion Tables
Measuring Systems
General Torque Specifications
United States Year Designations
VIN Location
Gaskets and Seals
Failed/Broken Components
Special Fasteners and Tightening Procedures
Orientation – Left Side, Right Side
Tools
Special Tools
Using Valve Adjustment Tools
Making Tools
Basic Tools
Electrical Components
Starter Motors
ECM – Black Boxes
Closed Throttle Detection System
Charging System
Ignition System – No Spark
Spark Plugs
Spark Plug
Spark Plug Codes
Spark Plug Sizes
Spark Plug Parts
Batteries
Battery Size Codes
Battery Maintenance and Replacement
Maintenance Free Battery Preparation
Engine
Counter shaft Seal
Valve Guide Replacement
Four Stroke Oil and Filter Change
Compression Test
Troubleshooting
Coolant Replacement and Bleeding
Valve Lapping
Engine Break-In
Water Pump
Engine Decompression Systems
2 Stroke Engine Inspection
Starter Clutch Removal
Crankcase Separation Tips
Rocker Arm Shaft Removal
Fuel System
Introduction to Fuel Injection
Gravity and Vacuum Fuel Delivery
Carburetor Theory
Carburetor Jetting
Air Filter
Float Valve
Carburetor Cleaning Tips
Final Drive
Drive Chain Sizes
Drive Chain Inspection and Maintenance
Shaft Drive
Belt Drive
“Endless Chain” Removal and Installation
CV Axles
Safety
Brakes
Clutch / Brake Cable End Removal
Drum Brakes
Hydraulic Brake Fluid
Brake System Bleeding
Suspension
Suspension Inspection
General Suspension Adjustment
Steering
ATV Front End Alignment
Handlebars
Ball Joints
Steering Stem
Wheels
Wheel Lacing and Truing
Tires
Motorcycle Tire Sizes
Tire Removal and Installation
ATV Tire Sizes
Damaged Fastener Removal
Broken Bolt Removal
Using Thread Inserts
Phillips Head Screw Removal
Stud Removal and Installation
Inspecting Dirt Bikes for Wear
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