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. You can go here to download a sportsman repair manual. |
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
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
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
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
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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 Repair Manual 700, Sportsman 800 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.
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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 |
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