SELECT YOUR BRAND ATV


What is a Factory Service Manual?

Here is a Sample Preview Page of one.

(Sample page is restricted to one page only)


The service manual downloads for the above listed brands describes the service procedures for the complete vehicle. Follow the Maintenance Schedule recommendations to ensure that the all-terrain vehicle (ATV) is in peak operating condition and the emission levels are within the standards set by the your states/county Resources Board. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the ATV or utility vehicle.
 
All chapters in the Honda, Polaris, Yamaha, Can Am, Kawasaki, Arctic Cat, KTM and Suzuki service manuals apply to the whole vehicle and illustrates procedures for removal/installation of components that are in detailed step-by-step fashion.
 
Most all service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem.

RELATED ATV SERVICE MANUAL SEARCHES:

FRAME/BODY PANELS/EXHAUST SYSTEM TROUBLESHOOTING

Excessive exhaust noise

  • Deformed exhaust system
  • Exhaust gas leaks

Poor performance

  • Clogged muffler
  • Broken exhaust system
  • Exhaust gas leaks

LUBRICATION SYSTEM TROUBLESHOOTING

Oil level too low - high oil consumption

  • Oil consumption
  • External oil leak
  • Worn piston rings or incorrect piston ring installation
  • Worn cylinder
  • Worn valve guide or stem seals
  • Oil pump worn or damaged

Oil contamination

  • Oil or filter not changed often enough
  • Worn piston rings or incorrect piston ring installation
  • Worn valve guide or stem seals

FUEL SYSTEM TROUBLESHOOTING

Engine cranks but won’t start

  • No fuel in tank
  • No fuel to carburetor
  • Clogged fuel strainer
  • Clogged fuel line
  • Clogged fuel tank breather tube
  • Misadjusted fuel level
  • Too much fuel getting to the engine
  • Clogged air cleaner
  • Flooded carburetor
  • Intake air leak
  • Contaminated/deteriorated fuel
  • Clogged jets
  • Clogged starting enrichment valve circuit
  • Improper starting enrichment valve operation
  • Improper throttle operation
  • No spark at plug (faulty ignition system)

Lean mixture

  • Clogged fuel jets
  • Faulty float valve
  • Float level too low
  • Restricted fuel line
  • Clogged carburetor air vent tube
  • Restricted fuel tank breather tube
  • Intake air leak
  • Faulty vacuum piston
  • Faulty throttle valve

Rich mixture

  • Starting enrichment valve open (ON)
  • Clogged air jets
  • Faulty float valve
  • Float level too high
  • Dirty air cleaner
  • Worn jet needle or needle jet
  • Faulty vacuum piston

Engine stalls, hard to start, rough idling

  • Restricted fuel line
  • Fuel mixture too lean/rich
  • Contaminated/deteriorated fuel
  • Clogged jets
  • Intake air leak
  • Misadjusted idle speed
  • Misadjusted pilot screw
  • Misadjusted float level
  • Restricted fuel tank breather tube
  • Clogged air cleaner
  • Clogged slow circuit
  • Clogged starting enrichment valve circuit
  • Faulty ignition system

Afterburn when engine braking is used

  • Leanmixture in slow circuit
  • Faulty air cut-off valve
  • Faulty ignition system

Backfiring or misfiring during acceleration

  • Leanmixture
  • Faulty ignition system

Poor performance (driveability) and poor fuel economy

  • Clogged fuel system
  • Faulty ignition system

CYLINDER HEAD/VALVE TROUBLESHOOTING

Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. If the performance is poor at low speeds, check for a white smoke in the crankcase breather tube. If the tube is smoky, check for seized piston ring

Compression too low, hard starting or poor performance at low speed

Valves

Incorrect valve adjustment
Burned or bent valves
Incorrect valve timing
Broken valve spring
Uneven valve seating
Valve stuck open

Cylinder head

Leaking or damaged cylinder head gasket
Warped or cracked cylinder head
Loose spark plug

Compression too high

Excessive carbon build-up on piston head or
combustion chamber
Worn or damaged decompressor system

Excessive smoke

Worn valve stem or valve guide
Damaged stemseal
Cylinder/piston problem

Excessive noise

Incorrect valve clearance
Sticking valve or broken valve spring
Excessive worn valve seat
Worn or damaged camshaft
Worn rocker arm and/or shaft
Worn rocker arm follower or valve stem end
Worn or damaged push rod and/or cam follower
Worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Cylinder/piston problem

Rough idle

Low cylinder compression

CYLINDER/PISTON TROUBLESHOOTING

Compression too low, hard starting or poor performance at low speed

  • Leaking cylinder head gasket
  • Worn, stuck or broken piston ring
  • Worn or damaged cylinder and piston
  • Bent connecting rod

Compression too high, overheating or knocking

  • Excessive carbon built-up on piston head or combustion chamber

Excessive smoke

  • Worn cylinder, piston or piston rings
  • Improper installation of piston rings
  • Scored or scratched piston or cylinder wall

Abnormal noise

  • Worn piston pin or piston pin hole
  • Worn connecting rod small end
  • Worn cylinder, piston or piston rings

CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING

Clutch slips when accelerating

  • Incorrect clutch adjustment
  • Worn clutch discs
  • Weak clutch springs
  • Faulty clutch lifter
  • Improper oil viscosity or oil additive used

Clutch will not disengage

  • Faulty clutch lifter
  • Warped clutch plates

The vehicle creeps

  • Faulty centrifugal clutch

Clutch operating feels rough

  • Worn clutch outer and center grooves
  • Warped clutch plates
  • Loose clutch lock nut
  • Faulty clutch lifter
  • Improper oil viscosity or oil level

Hard to shift

  • Incorrect clutch adjustment
  • Worn or damaged gearshift cam and stopper arm
  • Faulty clutch lifter
  • Improper engine oil viscosity
  • Bent fork shaft and gearshift spindle or damaged shift forks and shift drum

Transmission jumps out of gear

  • Broken shift drum stopper arm
  • Weak or broken shift linkage return springs
  • Worn or damaged gearshift cam
  • Bent fork shaft or worn shift forks and shift drum
  • Worn gear dogs or slots

ALTERNATOR/STARTER CLUTCH TROUBLESHOOTING

Starter motor turns, but engine does not turn

  • Faulty starter clutch
  • Damaged starter reduction gear

CRANKCASE/TRANSMISSION/CRANKSHAFT TROUBLESHOOTING

Excessive engine noise

  • Worn, seized or chipped transmission gears
  • Worn transmission bearings
  • Worn or damaged connecting rod bearing
  • Worn crankshaftmain journal bearing
  • Worn connecting rod small end
  • Worn balancer bearing
  • Improper balancer installation

Transmission jumps out of gear

  • Worn gear dogs or dog holes
  • Worn shift drum guide groove
  • Worn shift fork guide pin
  • Worn gear shifter groove
  • Worn shift fork
  • Bent shift fork shaft

Hard to shift

  • Damaged shift fork
  • Bent shift fork shaft
  • Damaged shift fork guide pin
  • Damaged shift drum guide groove

Abnormal vibration

  • Improper balancer timing

FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING

Hard steering

  • Steering shaft holder too tight
  • Damaged steering shaft bearing/bushing
  • Insufficient tire pressure

Steers one side or does not track straight

  • Incorrect wheel alignment
  • Unequal tire pressure
  • Bent tie-rod, suspension arm or frame
  • Worn or damaged knuckle bearing or brake drum bearing
  • Weak shock absorber

Front wheel wobbling

  • Bent rim
  • Worn or damaged knuckle bearing or brake drum bearing
  • Faulty tire
  • Axle nut not tightened properly

Soft suspension

  • Weak shock absorber spring
  • Faulty shock absorber damper

Hard suspension

  • Bent shock absorber damper rod
  • Improperly installed suspension arms
  • Faulty suspension arm bushings

Front suspension noise

  • Loose front suspension fasteners
  • Damaged suspension components

REAR WHEEL/SUSPENSION TROUBLESHOOTING

Rear wheel wobbling

  • Bent rim
  • Worn or damaged rear axle bearings
  • Faulty rear tire
  • Axle fastener not tightened properly
  • Faulty swingarm pivot bearings

Rear wheel turns hard

  • Faulty rear axle bearings
  • Bent rear axle
  • Rear brake drag

Soft suspension

  • Weak shock absorber spring
  • Oil leakage fromdamper unit

Hard suspension

  • Damaged rear suspension pivot bearing or bushing
  • Damaged swingarm pivot bearing
  • Improperly tightened swingarm pivot

Rear suspension noise

  • Faulty rear shock absorber
  • Loose rear suspension fasteners
  • Worn rear suspension pivot bearing or bushing

BRAKE SYSTEM TROUBLE SHOOTING

Front wheel wobbling and noise

  • Worn brake shoes

Poor brake performance

  • Brake not adjusted properly
  • Worn brake shoes and drum
  • Water in brake drum
  • Contaminated brake shoes and drum
  • Air in hydraulic system
  • Leaking hydraulic system
  • Clogged/restricted fluid passage
  • Incorrectly installed rear brake arm
  • Worn rear brake cam

FRONT DRIVING MECHANISM TROUBLE SHOOTING

Consistent noise during cruising

  • Oil level too low
  • Foreignmatter contaminating gear oil
  • Worn or damaged bearing
  • Worn or damaged ring gear and pinion gear
  • Deformed ring gear or differential case
  • Improper tooth contact between ring gear and pinion gear

Gear noises while running

  • Oil level too low
  • Foreignmatter contaminating gear oil
  • Chipped or damaged gears
  • Improper tooth contact between ring gear and pinion gear

Gear noises while coasting

  • Damage or chipped gears

Abnormal noises when turning

  • Worn or damaged ring gear bearing
  • Worn or damaged face cam and cam follower
  • Worn or damaged differential housing groove
  • Worn cone spring or shim

Abnormal noises at start or during acceleration

  • Excessive backlash between ring gear and pinion gear
  • Worn differential splines
  • Loose fasteners
  • Worn cone spring or shim

Oil leak

  • Oil level too high
  • Clogged breather
  • Damaged seals
  • Loose case cover bolt

Over heating

  • Oil level too low
  • Insufficient backlash between ring gear and pinion gear

REAR DRIVING MECHANISM TROUBLE SHOOTING

Excessive noise

  • Worn or scored ring gear shaft and axle
  • Worn or scored pinion and splines
  • Worn pinion and ring gears
  • Excessive backlash between pinion and ring gears
  • Oil level too low

Wobble or vibration in vehicle

  • Axle not tightened properly
  • Bent axle

Oil leak

  • Oil level too high
  • Clogged breather
  • Damaged seals
  • Loose case cover bolt

Current List of Service Manuals Available:

Honda TRX Model Service Manuals

1986-1987 TRX 70, TRX70
1993-2005 TRX 90, TRX90
2006-2009 TRX 90, TRX 90EX, TRX 90X
1985-1986 TRX 125, TRX 125
1987-1988 TRX 125, TRX125
1984 TRX 200, TRX200
1986-1988 TRX 200SX, TRX200 SX
1990-1991 TRX 200 91-97 TRX 200D Type II
1985-1987 FourTrax (Four Trax) 250, TRX250
1987-1988 TRX 250X, TRX250X, TRX250 X
1986-1989 TRX 250R, TRX250R, TRX250 R
1991-1992 TRX 250X, TRX250 X
1997-2004 Recon TRX250 TM, TRX250 TE
2001-2005 TRX 250EX, TRX250 EX
2005-2011 Recon TRX250, TRX250TM, TRX250TE
2006-2009 TRX 250 EX, TRX 250X
1988-1994 FourTrax 300 (TRX 300, TRX 300 FW 4x4)
1993-2000 TRX 300EX
1995-2000 Honda TRX300 (TRX 300), TRX300FW (TRX 300 FW) Fourtrax ATV
2001-2006 TRX 300EX, TRX300 EX
2007-2009 TRX 300EX, TRX 300X
1986-1987 FourTrax TRX350 4x4
1987-1989 Foreman TRX 350D, TRX350D, TRX350 D
2000-2003 Rancher TRX350FM, TRX350TM, TRX350FE, and TRX350TE
2004-2006 Rancher TRX350TE, TRX350TM, TRX350FE, TRX350FM
1995-2003 Foreman TRX400FW
1999-2004 TRX 400EX, TRX400 EX
2004-2007 Rancher TRX400FA, TRX400FGA, TRX400
2005-2009 TRX 400EX, TRX 400X
2007-2010 Rancher TRX420, TRX420FE, TRX420FM, TRX420TE, TRX420TM, TRX420FPE, FPM
2009-2010 Rancher AT TRX420FA, TRX420FPA, TRX420
1998-2004 Foreman TRX450S, TRX450FM, TRX450ES, TRX450FE
2004-2009 TRX 450R, TRX 450ER, TRX450 E
2001-2004 Foreman Rubicon 500 TRX500FA, TRX500 FA
2005-2009 Foreman Rubicon TRX500 FA, TRX500 FGA
2005-2011 Foreman TRX500, TRX500FE, TRX500FM, TRX500TM, TRX500FPE, TRX500FPM
2003-2005 Rincon TRX650FA
2006-2011 Rincon TRX680FA,  TRX680FGA, FA/FGA
2008-2009 Honda TRX700 X X (TRX 700 XX)


Polaris Service Manuals

2005-2007 Polaris Ranger 700 XP Service Manual
2008 Polaris Ranger 800 RZR Service Repair Manual
2008 Polaris Ranger 500 Service Manual
2009 Polaris Ranger 500 4x4 EFI Service Manual
2009 Polaris Ranger 2X4 500 Carb Service Repair Manual
2009-2010 Polaris RZR RZRS 800 Service Manual
2009 Polaris Ranger Service Manual XP700 (XP-700) HD
2009 Polaris Ranger RZR 170 Service Repair Manual
2009 Polaris Ranger 4x4 6X6 700 EFI Crew Service Manual
2002-2003 Polaris Sportsman 600 Sportsman 700 Service Manual
2005 Polaris Sportsman 700, Sportsman 800 Service Manual
2008 Polaris Sportsman 800 Sportsman 700 Touring 800 Service Manual
2007 Polaris Sportsman 700 & Sportsman 800 Service Manual
2005 Polaris Sportsman 400 & Sportsman 500 Service Manual
1996-2003 Polaris Sportsman, Xplorer, Worker Service Manual
2003 Polaris Service Manual Scrambler / Sportsman / Predator
2007 Polaris Sportsman 450 & 2007 Sportsman 500 Service Manual
2010 Polaris Sportsman XP 850 & Touring 850 Service Manual
2009 Polaris Sportsman XP550 (XP 550) EPS Service Manual
2009 330 Trailboss & Blazer Service Manual
2009 Polaris Scrambler 500 Service Manual
2003 Polaris Trail Boss 330 Service Manual
2004-2006 Polaris 250 Trailblazer Service Manual
2003 2007 Polaris Predator 500 Service Repair Manual & Troy Lee

 


Yamaha Service Manuals Available:

Yamaha Badger 80 Service Manual Repair 1992-2001 Yfm80
Yamaha Badger 80 Service Manual Repair 1985-1988 Yfm80
Yamaha Raptor 80 Service Manual Repair 2002-2008 Yfm80
2009-2010 Yamaha Raptor 90 YFM90RY YFM 90R RY 90RY Service Manual
2003-2005 Yamaha Yfm450 (yfm 450) Kodiak Service Manual
2006-2009 Yamaha Raptor Yfm700rv Service Manual (yfm700, Yfm 700 Rv)
2004-2006 Bruin 350, 400 Service Manual (yfm350Fa, Yfm 350 A, Yfm400Fa, Yfm 400)
1995-1999 Yamaha Yfm350 Service Repair Manual Big Bear (yfm 350)
1998-2001 Yamaha Yfm600 Grizzly Service Manual Yfm600 Grizzly
2002-2006 Yamaha Yfm660 (yfm 660) Grizzly Service Repair Manual
2000-2005 Yamaha Yfm400 (yfm 400) Kodiak Service Repair Manual
1999-2004 Yamaha Yfm250 (yfm 250) Xl Bear Tracker Service Manual Beartracker
2001-2005 Yamaha Yfm660 (yfm 660 R) Raptor Service Manual
2003-2005 Yamaha Yfm400 (yfm 400) Yfm4 Kodiak Service Manual
Yamaha Wolverine 350 Service Manual Repair 1995-2009 Yfm350
Yamaha Warrior Service Manual Repair 1987-2004 Yfm350
Yamaha Grizzly 125 Service Manual Repair Yfm125
Yamaha Raptor 50 Service Manual Repair 2004-2008 Yfm50
Yamaha Big Bear 400 Service Manual Repair 2007-2010 Yfm40fb
Yamaha Big Bear 400 Service Manual Repair 2000-2003 Yfm400
Yamaha Grizzly 450 Service Manual Repair 2007-2009 Yfm45fg
Yamaha Raptor 350 Service Manual Repair Yfm350
Yamaha Raptor 250 Service Manual Repair 2008 Yfm250
Yamaha Wolverine 450 Service Manual Repair 2006-2010 Yfm450
Yamaha Grizzly 550 700 Service Manual Repair 2009-2010
Yamaha Breeze 125 Service Manual Repair 1989-2004 Yfa1
Yamaha Grizzly 700 Service Manual Repair 2007-2008 Yfm7fg
Yamaha Blaster YSF200 YSF-200 Service Manual 1988 2005


Can-Am Service manuals & Owner's Manuals Available:

2006 Bombardier Outlander 400 800 service manual & covers the following models: 2006 Bombardier Outlander 400 and 800 series, Max Series, 2006 Bombardier Rotax 400 & 2006 Bombardier Rotax V810

2008 Can-Am Outlander Renegade service manual & covers the following models: Outlander 500, Outlander 500 XT, Outlander Max 500, Outlander Max 500 XT, Outlander 650, Outlander 650 XT, Outlander Max 650, Outlander Max 650 XT, Outlander 800, Outlander 800 XT, Outlander Max 800, Outlander Max 800 XT, Outlander Max 800 LTD, Renegage 600 and Renegade 800

2008-2009 Can-Am Outlander 400 EFI ATV Service Manual & covers the following models: COVERS ALL MODELS.

2009 Can-Am Outlander Renegade Service Manual & covers the following models: Outlander 500, Outlander 500 XT, Outlander 500 Max 2-Seater, Outlander 500 Max XT 2-Seater, Outlander 650, Outlander650 XT, Outlander 650 Max 2-Seater, Outlander 650 Max XT 2-Seater, Outlander 800, Outlander 800 XT, Outlander 800 Max 2-Seater, Outlander 800 Max XT 2-Seater, Outlander 800 Max XT LTD 2-Seater, Renegade 500, Renegade 800

2008 Can-Am DS450 owners manual & covers the following models: 2008 DS450 and DS450 X.

2009 Can-Am DS450 owners manual & covers the following models: 2009 DS450, DS450X mx and DS450X xc.

 


Suzuki Onwer's Manuals & Factory Service Manuals Available:

1985-1990 Suzuki LT230S LT230GE LT250S service manual
1987-2006 Suzuki LT80 service manual repair LT 80
1988-1992 Suzuki LT250R service manual
2002-2007 Suzuki Vinson 500 service manual repair LT-A500F
2002-2007 Suzuki Eiger 400 service manual LT-F400
2002-2009 Suzuki Ozark service manual repair LT-F250
2003-2008 Suzuki Z400 service manual repair LT-Z400 LTZ400
2004-2009 Suzuki LTZ250 service manual repair Z250 LT-Z250
2005-2007 Suzuki King Quad 700 service manual LT-A700X
2006-2009 Suzuki LT-R450 service manual
2006-2009 Suzuki LT-Z50 service manual repair Z50
2007-2009 Suzuki LTZ90 service manual repair Z90 LT-Z90
2007-2010 Suzuki King Quad 450AXi service manual LT-A450X
2008-2009 Suzuki King Quad 750axi Service Manual
2008-2010 Suzuki King Quad 400 service manual
2009 Suzuki King Quad 500AXi service manual LT-A500XP
2009 Suzuki Z400 service manual repair LTZ400 LT-Z400


Arctic Cat ATV & Utility Service Manuals Available:

2000 Arctic Cat ATV service manual ALL MODELS
2001 Arctic Cat ATV service manual ALL MODELS
2002 Arctic Cat 250 to 500 ATV service manual
2003 Arctic Cat 250 to 500 ATV service manual repair
2004-2008 Arctic Cat DVX 400 service manual DVX400
2004 Arctic Cat 650 V-TWIN service manual repair
2004 Arctic Cat 250 to 500 ATV service manual repair
2005 Arctic Cat 250 to 650 ATV service manual repair
2006-2007 Arctic Cat DVX 90 service manual DVX90
2006 Arctic Cat DVX 50 90 service manual DVX50 DVX90
2006 Arctic Cat 400 to 650 4x4 ATV service manual
2006-2008 Arctic Cat DVX 250 service manual DVX250
2007 Arctic Cat 400 to 700 4x4 ATV service manual
2007 Arctic Cat Prowler 650 service manual XT 650
2008 Arctic Cat 700 Diesel service manual repair
2008 Arctic Cat 400 to 700 4x4 ATV service manual repair
2008 Arctic Cat Thundercat 1000 H2 service manual repair
2008-2010 Arctic Cat DVX 90 service manual DVX90
2008 Arctic Cat Prowler 650 700 service manual XT XTX
2008-2010 Arctic Cat 366 4x4 ATV service manual
2009 Arctic Cat 400 to 1000 4x4 ATV service manual
2009-2010 Arctic Cat DVX 300 service manual DVX300
2009 Arctic Cat Prowler XT XTX H1 service manual repair
2009 Arctic Cat Prowler XTZ 1000 H2 service manual repair
2009-2010 Arctic Cat 150 2x4 ATV service manual
2010 Arctic Cat Prowler service manual XT XTX XTZ
2010 Arctic Cat 400 to 1000 4x4 ATV service manual repair
2010 Arctic Cat 450 4x4 ATV service manual repair
2010 Arctic Cat 700 Diesel service manual repair
2011 Arctic Cat 450 to 1000 4x4 ATV service manual


85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, 07, 08, 09, 10, Service Manual, Shop Manual, Instructions Manual, WorkShop Manual, Owner's Manual, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, Owners Service Manual, Repair Manual, Repair Guide, Handbook, Book Text Book, Learning Book