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General| Ignition | CDI |
|---|---|
| Starting System | Electric with auxiliary recoil |
| Drive System | Shaft drive |
| Front Suspension | Independent double-wishbone |
| Rear Suspension | Swingarm with single shock |
| Front Brakes | Dual hydraulic discs |
| Rear Brakes | Sealed mechanical drum |
| Ground Clearance | 6.3 inches |
| Transmission | 5-speed with reverse |
| Rear Tires | 25 x 12-9 |
Safety precautions and warnings for operating and maintaining the vehicle.
Guidelines and procedures for performing service and repairs on the vehicle.
Information to identify the specific vehicle models covered by the manual.
Technical data and measurements for various vehicle components.
Specified torque settings for fasteners and components during assembly/disassembly.
List of special and common tools required for maintenance and repair procedures.
Guidelines for properly routing electrical cables and wiring harnesses.
General information and specifications related to lubrication systems and fluids.
Specified torque settings for lubrication system components like drain plugs and filter caps.
Common problems and solutions related to engine oil level, leaks, and contamination.
Procedures for draining, filling, and replacing engine oil and filters.
Instructions for checking and changing oil in the front and rear differentials.
Identification and maintenance of lubrication points on the vehicle chassis and components.
Recommended service intervals for various vehicle components based on usage.
Procedures for maintaining the fuel line, filter, throttle, and air cleaner elements.
Maintenance tasks for spark plugs, valve clearance, and cylinder compression.
Procedures for checking and servicing brake fluid, shoes, and drums.
Maintenance for clutch, suspension, steering system, and wheels/tires.
Overview of fuel system components, specifications, and required tools.
Diagnosing and resolving common fuel system performance issues like no start or poor running.
Procedures for removing, installing, and inspecting the fuel tank and fuel pump.
Maintenance and disassembly/assembly of the air cleaner case and carburetor.
Adjusting float level, throttle synchronization, pilot screw, and high altitude settings.
Details on engine removal/installation, specifications, and torque values.
Step-by-step instructions for safely removing the engine from the vehicle frame.
Step-by-step instructions for installing the engine back into the vehicle frame.
Overview of cooling system components, oil cooler, and fan specifications.
Procedures for inspecting, removing, and installing the oil cooler and associated hoses.
Instructions for removing, disassembling, and assembling the cooling fan.
Technical details and specifications for cylinder head and valve components.
Diagnosing issues like low compression, noise, and leaks in the cylinder head assembly.
Procedures for inspecting, refacing, and replacing valve seats for optimal performance.
Instructions for installing the camshaft and reassembling the cylinder head.
Details on cylinder and piston measurements, tolerances, and torque values.
Diagnosing issues like low compression, overheating, and excessive wear in the cylinder/piston assembly.
Procedures for inspecting cylinder bore, wear, and measuring for warpage.
Inspecting piston ring-to-groove clearance and piston wear.
Overview of clutch, oil pump, and kick starter components, specs, and torque values.
Diagnosing issues like clutch slip, hard shifting, and starter motor problems.
Procedures for removing, inspecting, and installing the centrifugal clutch components.
Maintenance and assembly of the oil pump and kick starter mechanisms.
Overview of alternator, starter clutch, and gearshift linkage systems and their troubleshooting.
Procedures for removing, inspecting, and installing the starter reduction gear assembly.
Maintenance and installation of the alternator and starter clutch components.
Procedures for removing, disassembling, and installing the gearshift linkage components.
Details on crankcase, crankshaft, and transmission components, specs, and torque values.
Diagnosing crankcase noise, shifts issues, and gear problems.
Procedures for separating the crankcase and servicing the crankshaft.
Maintenance and inspection of transmission gears and output shaft components.
Overview of front wheel, suspension, and steering components, specs, and torque values.
Diagnosing steering stiffness, wheel wobble, and suspension issues.
Procedures for removing/installing handlebars and servicing the front wheel.
Maintenance for tie rods, steering stem, and pivot bearings.
Maintenance for front shock absorbers and swingarm pivot bearing replacement.
Overview of brake system components, specifications, and torque values.
Diagnosing brake performance issues like noise, fluid leaks, and lever play.
Procedures for bleeding, filling, and inspecting the front brake system.
Maintenance for the rear brake assembly and master cylinder disassembly/assembly.
Overview of rear wheel, suspension, and drive components, specs, and torque values.
Diagnosing rear wheel wobble, suspension noise, and hard/soft suspension issues.
Procedures for removing, inspecting, and replacing rear wheels and axle bearings.
Maintenance for rear shock absorbers and swingarm pivot bearing replacement.
Overview of front differential and final drive systems, specifications, and torque values.
Diagnosing issues with differential noise, leaks, and gear wear.
Procedures for removing, disassembling, and inspecting the front differential assembly.
Final drive assembly, gear tooth contact pattern checks, and related procedures.
Procedures for removing and installing the front and rear bumper assemblies.
Instructions for removing and installing the front and rear fender components.
Procedures for removing and installing front and rear carriers on Foreman models.
Wiring diagrams and specifications for the ignition system components.
Diagnosing no-start, weak spark, and component issues in the ignition system.
Procedures for inspecting the CDI unit and ignition coil for proper function.
Checking and adjusting the ignition timing for optimal engine performance.
Wiring diagram and specifications for the battery and charging system components.
Diagnosing battery overcharged or undercharged conditions and related issues.
Procedures for inspecting, removing, and charging the vehicle battery.
Overview of starter system components, specifications, and troubleshooting guidance.
Diagnosing starter motor not turning, slow cranking, or engine not starting issues.
Procedures for removing, inspecting, and installing the starter motor and relay switch.
Overview of lights, switches, and indicators, including specifications and torque values.
Diagnosing issues with headlights, indicators, and cooling fan warnings.
Procedures for servicing neutral/reverse switches and ignition/handlebar switches.
Maintenance for the oil temperature sensor and fuel unit/meter systems.
Electrical wiring diagram for the 1986 Fourtrax model.
Electrical wiring diagram for the 1987 Fourtrax model.
Electrical wiring diagram for the 1987 Foreman model.
Electrical wiring diagram for Foreman models after 1987.
Explanation of the Full Time 4 Wheel Drive system and its differential components.
Description of how the cooling system, fan control, and temperature sensing operate.
Explanation of the DC-CDI system's role in improving low-speed engine performance.
Diagnosing poor performance at low/idle and high speeds, including engine start problems.
Troubleshooting poor handling, steering issues, and loss of engine power.
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