SECTION 6 - DRIVE SYSTEM
TABLE OF
CONTENTS
Drive System........................................................... 6-2
General Information................................................. 6-2
Front Drive Actuator ................................................ 6-2
Front Differential ...................................................... 6-3
Drive Axles ............................................................ 6-16
Rear Gear Case .................................................... 6-21
Hub........................................................................ 6-21
Hydraulic Brake Caliper......................................... 6-22
Troubleshooting Drive System............................... 6-26
Troubleshooting Brake System.............................. 6-26
SECTION 7 - SUSPENSION
TABLE OF
CONTENTS
Suspension ............................................................. 7-2
Shock Absorbers ..................................................... 7-2
Front A-Arms ........................................................... 7-3
Rear A-Arms ........................................................... 7-5
Wheels and Tires .................................................... 7-7
SECTION 8 - STEERING/FRAME
TABLE OF
CONTENTS
Steering/Frame........................................................ 8-2
Steering Post/Tie Rods ........................................... 8-2
Handlebar Grip ........................................................ 8-4
Steering Knuckles ................................................... 8-4
Measuring/Adjusting Toe-In..................................... 8-6
Front Rack ............................................................... 8-8
Front Bumper Assembly .......................................... 8-8
Front Body Panel/Side Panels ................................ 8-8
Footrests ............................................................... 8-11
Belly Panel ............................................................ 8-11
Exhaust System .................................................... 8-11
Rear Body Panel/Rack .......................................... 8-12
Adjusting Headlight ............................................... 8-13
Taillight Assembly.................................................. 8-13
Seat ....................................................................... 8-13
Troubleshooting ..................................................... 8-14
SECTION 9 - CONTROLS/INDICATORS
TABLE OF
CONTENTS
Hand Brake Lever/Master Cylinder Assembly ......... 9-2
Throttle Control ....................................................... 9-3
Shift Lever ............................................................... 9-4
Speedometer/Tachometer/LCD............................... 9
SAMPLE TEXT / PAGE FROM THE MANUAL:
=========================
Shift Lever
REMOVING
1. Remove the E-clip securing the shift rod to the
engine shift arm.
2. Remove two cap screws, two self-tapping screws,
and three nylon ties securing the left-side splash
panel and remove the panel.
3. Remove the axle and nut securing the shift lever to
the upper shift arm; then remove the shift lever.
Account for a spring and two O-rings.
4. Using two open-end wrenches, remove the lock
nut securing the shift rod to the upper shift arm.
Remove the shift rod and discard the lock nut.
NOTE: Never reuse a lock nut. Once a lock nut
has been removed, it must be replaced with a new
lock nut.
Speedometer/
Tachometer/LCD
REPLACING
To replace the speedometer, use the following procedure.
1. Remove the two reinstallable rivets securing the
instrument pod; then remove the ignition switch
retaining ring.
2. Remove the two nuts securing the mounting studs;
then remove the speedometer from the instrument
pod and disconnect the multi-pin connector.
3. Mount the speedometer in the instrument pod and
secure with the two nuts; then connect the
multi-pin connector.
4. Install the instrument pod and secure with the reinstallable
rivets.
5. Secure the ignition switch with the retaining ring.
THIS IS NOT SOME GENERIC REPAIR INFORMATION. IT IS A VEHICLE SPECIFIC SERVICE MANUAL! THIS HIGHLY DETAILED SERVICE REPAIR MANUAL CONTAINS EVERYTHING YOU WILL EVER NEED TO SERVICE, REPAIR, RESTORE, MAINTAIN, REFURBISH OR EVEN REBUILD YOUR VEHICLE.
COMPLETE & EASY TO USE STEP-BY-STEP INSTRUCTIONS, ILLUSTRATIONS, DIAGRAMS, SPECIFICATIONS & WIRING SCHEMATICS WILL HELP ASSIST YOU TO PERFORM RIGHT FROM VERY SIMPLE REPAIRS TO COMPLEX ONES !!.
CLEAR PICTURES AND ZOOMABLE ILLUSTRATIONS HELP YOU PERFORM YOUR SERVICE REPAIR WITH UTMOST EASE! NO TECHNICAL EXPERTISE REQUIRED. YOU SEE IT AND YOU DO IT (DO-IT-YOURSELF MANUAL)
THIS IS THE SAME MANUAL THAT TECHNICIANS AND MECHANICS IN DEALERSHIPS & ELSEWHERE USE TO SERVICE & REPAIR YOUR VEHICLE! YOU CAN REFER THIS MANUAL RIGHT FROM YOUR PC/LAPTOP OR ONLY PRINT OFF THE PAGES THAT YOU REQUIRE FOR THE MOMENT.