POWERSPORTS INDUSTRY FLAT RATE MANUAL

POWERSPORTS INDUSTRY FLAT RATE MANUAL

VERSION

2016

Contents

Acknowledgments .....................................................................................................7

Introduction .............................................................................................................9

ATV ........................................................................................................................11

ATV General

11

Can-Am ATV

20

Accessories

11

Accessories

20

Body/Frame

12

Body/Frame

23

Brakes

13

Brakes

31

Electrical

13

Electrical

37

Engines

14

Engines

41

Fuel/Oil

14

Fuel/Oil

55

Service

15

Ignition

62

Setup

15

Rear Drive

63

Starters

15

Service

66

Suspension

15

Setup

68

Trade In Evaluation

16

Starters

68

Arctic Cat ATV

17

Steering

70

Body/Accessories

17

Suspension

75

Brakes

18

Transmissions

76

Electrical

18

Engines

18

Fuel/Oil

19

Service

19

Setup

19

Steering

19

Suspension

19

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1

Honda ATV Accessories Body/Frame Brakes Electrical Engines Fuel/Oil Ignition Service Setup Starters Steering Suspension

Kawasaki ATV Accessories Body/Frame Brakes Electrical Engines Fuel/Oil Ignition Service Suspension

Polaris ATV Accessories Body/Frame Brakes Electrical Engines

80

Polaris ATV cont.

80

Fuel/Oil

110

80

Ignition

110

81

Service

111

83

Setup

111

84

Starters

111

92

Suspension

112

92

Suzuki ATV

114

93

Accessories

114

97

Body/Frame

114

97

Brakes

114

98

Engines

115

99

Fuel/Oil

115

100

Service

115

100

Setup

116

100

Suspension

116

100

Yamaha ATV

117

100

Accessories

117

101

Body/Frame

117

101

Brakes

118

102

Electrical

118

102

Engines

119

103

Fuel/Oil

119

104

Ignition

120

104

Service

120

104

Setup

121

105

Starters

121

106

Steering

121

107

Suspension

122

Jet Boats .................................................................................................................125

Jet Boats General

125

Engines

125

Propulsion

125

Seasonal

125

Service

125

Trade In Evaluation

126

Mercury Jet Boats

127

Electrical

127

Engines

127

Fuel/Oil

128

Ignition

129

Propulsion

129

Seasonal

130

Service

130

Starters

130

Steering

131

OMC Jet Boats

132

Engines

132

Fuel/Oil

132

Propulsion

132

Steering

132

Sea-Doo Jet Boats

133

Body/Frame

133

Electrical

134

Engines

135

Fuel/Oil

136

Ignition

137

Propulsion

138

Seasonal

138

Service

139

Setup

140

Starters

142

Steering

142

Trade In Evaluation

142

2

2001-2016 Spader Business Management, Inc. All rights reserved.

Motorcycle ..............................................................................................................145

Motorcycle General

145

Accessories

145

Body/Frame

146

Brakes

146

Electrical

147

Engines

147

Fuel/Oil

148

Seasonal

148

Service

149

Setup

149

Suspension

150

Trade In Evaluation

150

Bigdog Motorcycle

151

Service

151

BMW Motorcycle

152

Service

152

Can-Am Motorcycle

153

Accessories

153

Body/Frame

154

Brakes

154

Electrical

155

Engines

155

Fuel/Oil

155

Ignition

156

Service

156

Setup

156

Steering

156

Suspension

156

Honda Motorcycle

157

Accessories

157

Body/Frame

159

Brakes

160

Electrical

162

Engines

162

Fuel/Oil

164

Ignition

165

Service

165

Setup

173

Starters

174

Steering

174

Scooter Service

174

Scooter Setup

176

Scooter Starters

176

Kawasaki Motorcycle

177

Accessories

177

Body/Frame

177

Brakes

178

Electrical

178

Engines

178

Fuel/Oil

180

Service

180

Starters

182

Steering

182

Suspension

182

Transmission

182

KTM Motorcycle

183

Accessories

183

Body/Frame

183

Service

183

Piaggio Motorcycle

184

Service

184

Suzuki Motorcycle

186

Accessories

186

Body/Frame

186

Brakes

186

Electrical

186

Engines

187

Fuel/Oil

187

Service

187

Setup

192

Transmission

192

Triumph Motorcycle

193

Service

193

Yamaha Motorcycle

194

Accessories

194

Body/Frame

194

Brakes

200

Electrical

203

Engines

207

Fuel/Oil

222

Ignition

225

Seasonal

226

Service

226

Starters

228

Steering

229

Suspension

229

Transmission

231

2001-2016 Spader Business Management, Inc. All rights reserved.

3

Personal Water Craft ................................................................................................235

PWC General

235

Accessories

235

Body/Frame

235

Detail

235

Electrical

235

Engines

236

Fuel/Oil

237

Ignition

237

Propulsion

237

Seasonal

238

Service

239

Setup

239

Starters

239

Steering

239

Trade In Evaluation

240

Honda PWC

241

Propulsion

241

Seasonal

241

Service

241

Starters

241

Kawasaki PWC

242

Body/Frame

242

Electrical

242

Engines

242

Fuel/Oil

242

Ignition

243

Propulsion

243

Starters

243

Steering

243

Polaris PWC

244

Electrical

244

Engines

244

Fuel/Oil

245

Ignition

246

Propulsion

246

Starters

246

Sea-Doo PWC

247

Accessories

247

Body/Frame

248

Detail

264

Electrical

264

Engines

272

Fuel/Oil

289

Ignition

307

Propulsion

311

Seasonal

321

Service

322

Setup

324

Starters

326

Steering

328

Suspension

334

Trade In Evaluation

335

Yamaha PWC

336

Body/Frame

336

Electrical

336

Engines

336

Fuel/Oil

336

Propulsion

337

Seasonal

337

Service

337

Starters

337

Power Equipment .....................................................................................................341

General Power Equipment 341

General Generator

341

General Snowblower

341

Alpina Power Equipment 342

Snow Groomer

342

Honda Power Equipment 343

Generator

343

Lawn Mower

343

Snowblower

345

Tiller

346

4

2001-2016 Spader Business Management, Inc. All rights reserved.

Snowmobile .............................................................................................................349

Snowmobile General

349

Accessories

349

Body/Frame

349

Electrical

350

Engines

350

Fuel/Oil

350

Seasonal

351

Service

351

Setup

351

Suspension

352

Trade In Evaluation

352

Arctic Cat Snowmobile

353

Body/Accessories

353

Electrical

353

Engines

353

Fuel/Oil

353

Service

353

Suspension

353

Polaris Snowmobile

354

Accessories

354

Body/Frame

354

Electrical

355

Engines

355

Fuel/Oil

356

Ignition

357

Suspension

357

Ski-Doo Snowmobile

358

Accessories

358

Body/Frame

360

Brakes

376

Electrical

379

Engines

388

Fuel/Oil

412

Ignition

427

Service

430

Setup

431

Starters

432

Steering

434

Suspension

446

Trade In Evaluation

473

Transmission

473

Yamaha Snowmobile

481

Accessories

481

Body/Frame

481

Electrical

482

Engines

482

Fuel/Oil

483

Ignition

483

Service

484

Setup

484

Starters

484

Steering

484

Suspension

484

Trailer .....................................................................................................................489

Trailer General

489

Trailer Accessories

489

Trailer Hitches

489

Trailer Jacks

489

Trailer Service

489

Trailer Setup

490

Trailer Suspension

490

Trailer Tires

490

2001-2016 Spader Business Management, Inc. All rights reserved.

5

Utility Vehicle ..........................................................................................................493

Can-Am Utility Vehicle

493

Accessories

493

Body/Frame

494

Brakes

497

Electrical

497

Engines

498

Fuel/Oil

499

Ignition

499

Rear Drive

499

Service

499

Setup

499

Starters

500

Steering

500

Suspension

500

Transmissions

501

Honda Utility Vehicle

502

Accessories

502

Body/Frame

503

Brakes

504

Electrical

504

Engines

504

Service

504

Setup

505

Starters

505

Steering

505

Kawasaki Utility Vehicle

506

Accessories

506

Body/Frame

506

Brakes

506

Electrical

506

Engines

507

Fuel/Oil

507

Service

507

Setup

508

Polaris Utility Vehicle

509

Accessories

509

Body/Frame

511

Brakes

513

Electrical

514

Engines

514

Fuel/Oil

515

Service

515

Setup

516

Starters

516

Suspension

516

Transmission

517

Yamaha Utility Vehicle

518

Accessories

518

Setup

518

Flat Rate Updates ....................................................................................................523

6

2001-2016 Spader Business Management, Inc. All rights reserved.

ATV

SUGG FLAT RATE TIME

COMPUTER CODE

OPERATION

POLARIS ATV ACCESSORIES

0.5 764880 A-ARM GUARDS INSTALL (4) 0.8 761130 BRUSH GUARD INSTALL 0.5 737430 GUN SCABER INSTALL 1.5 737490 HAND & THUMB WARMER KIT INSTALL

0.5 764850 HAND GUARDS INSTALL 1.1 736510 HEATED GRIPS INSTALL 2.0 737480 LIFT KIT INSTALL 1.0 764840 LIGHTS INSTALL PIAA (FRONT)

DEALER FLAT RATE TIME

LABOR RATE

MATERIALS

TOTAL

NEW!

2.5 737470 PLOW INSTALL W/ELECTRIC LIFT 2.0 767200 PLOW INSTALL W/MANUAL LIFT W/O WINCH 2.9 736500 PLOW INSTALL W/WINCH 2.2 400850 WINCH INSTALL 1.6 400850 WINCH INSTALL 0.8 736520 WINCH INSTALL TO CURRENT PRE-WIRED 05

SPORTSMAN

POLARIS ATV BODY/FRAME

0.8 400860 ARM R&R INCL TOE ALIGNMENT 0.2 400870 ARM BUSHING R&R (EACH ADDL) 0.6 761140 BUMPER INSTALL 0.5 400880 BUMPER R&R 2.0 400890 CAB R&R (FRONT) 1.3 400900 CAB R&R (REAR) 0.3 737500 CARGO BOX INSTALL

1.5 400910 FAN BLADE R&R 1.5 400920 FAN MOTOR R&R 1.3 400930 FAN SENSOR SWITCH R&R 1.0 764870 FENDER FLARE KIT INSTALL 0.5 400940 FOOTREST R&R (EACH) 20.0 400950 FRAME R&R MAIN 18.5 764020 FRAME SWAP

POLARIS ATV BODY/FRAME continued on next page...

SPORTSMAN 850

104

? 2001-2016 Spader Business Management, Inc. All rights reserved.

NEW! Identifies jobs added in this edition - most new jobs are contributed by fewer than 3 dealers.

POLARIS

MOTORCYCLE

SUGG FLAT RATE TIME

COMPUTER CODE

OPERATION

KAWASAKI MOTORCYCLE BRAKES

2.0 760540 ABS UNIT R&R 0.5 759850 BRAKE BLEED (REAR) 0.2 754890 BRAKE LEVER R&R 0.5 662680 BRAKE PADS R&R (REAR)

0.4 732150 BRAKE PEDAL & SHIFTER STRAIGHTEN (REAR) 0.2 760550 BRAKE SWITCH ADJUST

NINJA 250 ZX7 ZX1000 11 GPZ1100 KLX110 VN900

DEALER FLAT RATE TIME

LABOR RATE

MATERIALS

TOTAL

KAWASAKI MOTORCYCLE ELECTRICAL

0.6 760440 ECU R&R 0.7 760430 METER ASSEMBLY R&R 0.5 760460 NEUTRAL SWITCH R&R 4.0 760450 WIRE HARNESS R&R 4.0 760420 WIRE HARNESS R&R

NINJA 250 NINJA 650 NINJA 250 VN1700 ZX14

KAWASAKI

KAWASAKI MOTORCYCLE ENGINES

2.5 759840 CAM CHAIN & SPROCKETS R&R 5.5 737810 CAMSHAFT R&R 3.0 759860 CLUTCH PLATES R&R 0.5 732050 COMPRESSION TEST 1.0 732050 COMPRESSION TEST 2.0 760510 CRANKCASE COVER R&R (RH)

VN800 ZG1200 VOYAGER VN1500 VN1500 ZX600R KLR650

NEW!

1.0 760530 EXHAUST INSTALL SLIP-ON 1.0 732090 EXHAUST GASKET R&R INCL MISSING HARDWARE 0.5 760520 EXHAUST HEAT SHIELD R&R 0.8 732100 HYDRAULIC SYSTEM BLEED 0.3 732100 HYDRAULIC SYSTEM BLEED 2.0 767250 MUFFLER INSTALL (FRONT)

KAWASAKI MOTORCYCLE ENGINES continued on next page...

CONCOURS KLX110 VN1700 VN1500 ZX900 VULCAN

178

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NEW! Identifies jobs added in this edition - most new jobs are contributed by fewer than 3 dealers.

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