This manual is a valuable resource for both professional technicians and first-time owners or amateurs. It provides easy-to-read instructions and all the necessary information to perform procedures correctly.
Keep this shop manual handy and use it regularly to perform routine and preventive maintenance. This will save you time and money by preventing premature failure and unnecessary repairs.
Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization
Service hints
Torque specifications
Safety first
Service hints
Special tips
Expendable supplies
Parts replacement
Serial numbers
Basic hand tools
Tune-up and troubleshooting tools
Mechanic's tips
Off road rules
Riding safely
CHAPTER TWO / TROUBLESHOOTING
Operating requirements
Emergency troubleshooting
Engine starting
Engine performance
Engine noises
Excessive vibration
Front suspension and steering
Brake problems
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist
Service intervals schedule
Periodic lubrication
Engine oil and filter change
Control cable lubrication
Non-scheduled lubrication
Periodic maintenance
Non-scheduled maintenance
Reverse cable adjustment
Tune-up
Valve clearance
Compression test check
Spark plug
Air filter
Specifications
CHAPTER FOUR / ENGINE
Engine principles
Engine cooling
Serving engine in frame
Engine removal and installation
Cylinder head cover and rocker arm assembly
Cylinder head and camshaft
Valves and valve seats
Cylinder
Piston, piston pin and piston rings
Oil pump
Cam chain tensioner
Kickstarter (chain-driven models)
Recoil starter (shaft-driven models)
Starter gears (shaft-driven models)
Secondary bevel gear and drive gear set (shaft-driven models)
Crankcase and crankshaft
Break-in procedure
Specifications
CHAPTER FIVE / CLUTCH AND TRANSMISSION
Clutch operation
Centrifugal clutch
Manual clutch
Manual clutch inspection
Clutch lifting mechanism (shaft-driven models)
Clutch release mechanism (chain-driven models)
Clutch cable (chain-driven models)
External shift mechanism
Drive sprocket (chain-driven)
Transmission and internal shift mechanism
Dual-range subtransmission (shaft-driven LT-F230)
Specifications
CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
Carburetor operation
Carburetor service
Throttle cable
Choke cable (shaft-driven models)
Fuel shutoff valve
Fuel tank
Fuel pump (shaft-driven models)
Exhaust system
Specifications
CHAPTER SEVEN / ELECTRICAL SYSTEM
Charging system (models so equipped)
Voltage regulator (shaft-driven models)
Alternator (shaft-driven models)
Magneto (chain-driven models)
Capacitor discharge ignition
Ignition coil
Starting system (models so equipped)
Starter
Starter solenoid
Lighting system
Switches
Odometer housing (shaft-driven models)
Fuse
Specifications
CHAPTER EIGHT / FRONT SUSPENSION AND STEERING
Front wheel
Front hub
Steering system
Tires
Specifications
CHAPTER NINE / REAR AXLE, SUSPENSION AND FINAL DRIVE
Rear wheel
Rear axle (shaft-driven models)
Rear axle and driven sprocket (chain-driven models)
Driven sprocket (chain-driven models)
Rear axle inspection (all models)
Final drive unit (shaft-driven models)
Drive sprocket and chain (chain-driven models)
Rear axle bearing and oil seal replacement (shaft-driven models)
Rear axle bearing housing (chain-driven models)
Shock absorber (chain-driven models)
Swing arm (chain-driven model)
Specifications
CHAPTER TEN / BRAKES
Drum brakes
Front drum brakes
Rear drum brake
Drum brake inspection (front hub and rear)
Disc brakes
Front brake pad replacement
Rear brake pad replacement
Front master cylinder (drum and disc brake models)
Rear master cylinder (disc brake models)
Front caliper
Rear caliper
Front brake disc
Rear brake disc
Front brake hose replacement (drum and disc brake models)
