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before proceeding.
8. To prevent objects or debris from falling into the engine, cover all openings.
9. Read each procedure thoroughly and compare the illustrations to the actual components before
starting the procedure. Perform the procedure in
10. Recommendations are occasionally made to refer service to a dealership or specialist. In these
cases, the work can be performed more economically by the specialist than by the home
mechanic.
11. The term replaces means to discard a defective part and replace it with a new part. Overhaul
means to remove, disassemble, inspect, measure, repair and/or replace parts as required to
recondition an assembly.
12. Some operations require using a hydraulic press. If a press is not available, have these
operations performed by a shop equipped with the necessary equipment. Do not use makeshift
equipment that may damage the motorcycle.
13. Repairs are much faster and easier if the UTV is clean before starting work. Degrease the
motorcycle with a commercial degreaser; follow the directions on the container for the best
results. Clean all parts with cleaning solvent when removing them.
14.
If special tools are required, have them available before starting the procedure. When special
tools are required, they are described at the beginning of the procedure
15.
Make diagrams of similar-appearing parts. For instance, crankcase bolts are often not the same
lengths. Do not rely on memory alone. Carefully laid out parts can become disturbed, making it
difficult to reassemble the comports correctly.
16.
Make sure all shims and washers are reinstalled in the same location and position.
17.
Whenever rotating parts contact a stationary part, look for a shim or washer.
18.
Use new gaskets if there is any doubt about the condition of old ones.
19.
If using self-locking fasteners, replace them with new ones. Do not install standard fasteners in
place of self-locking ones.
20.
Use grease to hold small parts in place if they tend to fall out during assembly. Do not apply
grease to electrical or brake components.
Removing Frozen Fasteners
If a fastener cannot be removed, several methods may be used to loosen it. First, apply a
penetrating fluid. Apply it liberally and let it penetrate for 10-15 minutes. Rap the fastener several times
with a small hammer. Do not hit it hard enough to cause damage. Reapply the penetrating fluid if
necessary.
GENERAL INFORMATION
CAUTION
Do not direct high-pressure water at steering
bearings,
fuel
hoses,
suspension and electrical components. Water
may force grease out of the bearings and
possibly damage the seals
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wheel
bearings,
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Table of Contents
Troubleshooting
