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Table of Contents
General Information/Foreword.......................................2
Specifications ............................................................... 2
Torque Specifications 3Torque Conversions (ft-lb/N-m)5
Gasoline — Oil — Lubricant......................................... 5
Preparation for Storage ................................................ 6
Preparation after Storage ............................................. 6
Periodic Maintenance/Tune-up ......................................7
CVT Air Inlet ................................................................. 7
Air Filter ........................................................................ 7
Testing Engine Compression........................................ 9
Spark Plug.................................................................... 9
Muffler/Spark Arrester................................................... 9
Engine/Transmission Oil — Filter............................... 10
Front Differential/Transaxle Lubricant......................... 11
Shift Lever/Shift Cable................................................ 13
Hydraulic Brake Systems............................................ 14
Burnishing Brake Pads............................................... 15
Checking/Replacing V-Belt......................................... 16
Steering/Body/Controls ................................................17
Racks.......................................................................... 17
Seat ............................................................................ 17
Side and Rear Body Panels ....................................... 17
Front Body Panels...................................................... 19
LCD Gauge................................................................. 20
Steering Post/Tie Rods............................................... 20
Handlebar Grip ........................................................... 22
Throttle Control........................................................... 22
Steering Knuckles....................................................... 23
Measuring/Adjusting Toe-Out..................................... 25
Shift Lever .................................................................. 26
Shift Cable.................................................................. 27
Front Bumper --- Inner................................................ 28
Skid Plate ................................................................... 28
Muffler......................................................................... 28
Headlights — Taillight................................................. 29
Troubleshooting.......................................................... 31
Engine/Transmission ....................................................32
Removing Engine ....................................................... 32
Servicing Engine......................................................... 35
Disassembling Engine................................................ 36
Servicing Engine Components ................................... 41
Assembling Engine..................................................... 49
Assembly Schematic .................................................. 57
Installing Engine ......................................................... 59
Troubleshooting Engine.............................................. 62
Removing Drive and Driven Clutch............................. 64
Installing Drive and Driven Clutch............................... 64
Servicing Clutch Components .................................... 65
Fuel/Lubrication/Cooling..............................................69
Throttle Body .............................................................. 69
Throttle Cable Free-Play............................................. 70
Gas Tank.................................................................... 71
Oil Pump..................................................................... 71
Liquid Cooling System................................................ 72
Troubleshooting.......................................................... 76
Electrical System .......................................................... 77
Battery.........................................................................77
Electronic Power Steering (EPS) ................................79
Ignition Switch.............................................................81
Ignition Coil .................................................................81
Ignition Timing.............................................................82
Accessory Receptacle/Connector ...............................82
Switches......................................................................82
Fan Motor....................................................................84
Lights...........................................................................84
Power Distribution Module (PDM)...............................85
EFI Sensors/Components ...........................................85
RPM Limiter ................................................................90
Stator Coil ...................................................................91
Regulator/Rectifier ......................................................91
Starter Motor ...............................................................91
Starter Relay ...............................................................92
Electronic Control Module (ECM)................................93
EFI Diagnostic System................................................93
Troubleshooting ..........................................................98
Drive System/Brake System ........................................ 99
Hub Assembly.............................................................99
Drive Axles................................................................101
Front Drive Actuator..................................................103
Front Differential........................................................105
Driveshaft..................................................................112
Transaxle ..................................................................113
Hand Brake Lever/Master Cylinder Assembly...........127
Hydraulic Brake Caliper.............................................128
Troubleshooting Drive System..................................131
Troubleshooting Brake System.................................131
Suspension.................................................................. 132
Shock Absorbers.......................................................132
Front A-Arms.............................................................133
Rear A-Arms .............................................................135
Wheels and Tires ......................................................137
Troubleshooting ........................................................138
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