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TABLE OF CONTENTS
General Information ...................................................... 2
General Specifications................................................ 2
Torque Specifications ................................................. 2
Torque Conversions (ft-lb/N-m)................................... 3
Fuel - Oil - Lubricant ................................................... 3
Genuine Parts............................................................. 4
Preparation For Storage ............................................. 4
Preparation After Storage........................................... 5
Periodic Maintenance/Tune-Up .................................... 6
Air Filter ...................................................................... 6
Valve Clearance ......................................................... 7
Muffler/Spark Arrester ................................................ 7
Adjusting Throttle Cable ............................................. 7
Engine RPM (Idle) ...................................................... 8
Engine Oil - Filter........................................................ 8
Transmission Lubricant............................................... 9
Front Differential/Rear Drive Lubricant ....................... 9
Tires ......................................................................... 10
Driveshaft/Coupling .................................................. 10
Injector Timing .......................................................... 10
Shift Lever ................................................................ 10
Frame/Welds/Racks ................................................. 11
Hydraulic Brake Systems ......................................... 11
Burnishing Brake Pads ............................................. 13
Coolant ..................................................................... 13
Checking/Replacing V-Belt ....................................... 13
Fuel Filter.................................................................. 15
Steering Post/Tie Rods............................................... 19
Front Body Panel/Side Panels .................................. 16
Rear Body Panel/Rack ............................................. 18
Handlebar Grip ......................................................... 21
Hand Brake Lever/Master Cylinder Assembly .......... 21
Throttle Control......................................................... 23
Shift Lever ................................................................ 23
LCD Gauge .............................................................. 24
Steering Knuckles..................................................... 24
Measuring/Adjusting Toe-Out ................................... 25
Front Rack ................................................................ 26
Front Bumper Assembly ........................................... 26
Footrests................................................................... 27
Belly Panel................................................................ 27
Exhaust System........................................................ 27
Taillight Assembly ..................................................... 28
Seat .......................................................................... 28
Lights ........................................................................ 28
Troubleshooting ........................................................ 30
Engine/Transmission .................................................. 31
Removing Engine/Transmission ............................... 32
Top-Side Components .............................................. 36
Left-Side Components.............................................. 64
Right-Side Components ........................................... 70
Center Components ................................................. 85
Installing Engine/Transmission ................................. 98
Troubleshooting ...................................................... 104
Fuel/Lubrication/Cooling.......................................... 106
Diesel Fuel Injection System.................................. 106
Lift Pump ................................................................ 106
Unit Injectors .......................................................... 107
Injector Timing ....................................................... 107
Fuel Filter ............................................................... 107
Fuel Solenoid Assembly......................................... 107
Fuel Tank ............................................................... 108
Fuel/Vent Hoses..................................................... 108
Oil Filter/Oil Pump .................................................. 108
Testing Oil Pump Pressure..................................... 109
Liquid Cooling System ........................................... 109
Radiator ................................................................. 109
Hoses/Thermostat.................................................. 110
Fan ......................................................................... 110
Water Pump ........................................................... 111
Troubleshooting...................................................... 111
Electrical System ...................................................... 112
Battery.................................................................... 112
Switches................................................................. 113
Accessory Receptacle/Connector.......................... 113
Brakelight Switch (Auxiliary)................................... 113
Brakelight Switch (Handlebar Control) ................... 114
Cooling Fan Switch ................................................ 114
Engine Coolant Temperature (ECT) Switch/
Thermistor ........................................................... 115
Glow Plug Controller/Relay .................................... 115
Fan Motor ............................................................... 116
Fuse Block/Power Distribution Module................... 116
Speed Sensor ........................................................ 116
Ignition Switch ........................................................ 117
Handlebar Control Switches .................................. 117
Drive Select Switch ................................................ 118
Front Drive/Differential Lock Actuator .................... 118
Starter/Starter Solenoid ......................................... 119
Starter Relay .......................................................... 119
Alternator/Regulator............................................... 120
Headlights .............................................................. 121
Taillight - Brakelight ................................................ 121
Fuel Solenoid ......................................................... 122
Troubleshooting...................................................... 122
Drive System/Brake System..................................... 123
Front Drive Actuator ............................................... 123
Front Differential..................................................... 124
Drive Axles ............................................................. 136
Rear Gear Case ..................................................... 139
Hub ........................................................................ 140
Hydraulic Brake Caliper ......................................... 141
Troubleshooting Drive System ............................... 144
Troubleshooting Brake System .............................. 144
Suspension................................................................ 145
Shock Absorbers.................................................... 145
Front A-Arms.......................................................... 146
Rear A-Arms .......................................................... 148
Wheels and Tires ................................................... 149
Troubleshooting...................................................... 151
