- содержание:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers /Model identification (2004 models) / Fasteners / Shop supplies / Tools /Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Water damage / Starting the engine / Engine does not start / Poor Engine performance / Electronic throttle control (ETC) / Fuel system / Engine / Engine lubrication / цилиндр leakdown test / Clutch system / Gearshift linkage /Transmission / Electrical testing / Electrical troubleshooting / Meter assembly / Front gearcase / Final drive / Front suspension and steering / Brake system / specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Engine oil level check / Engine oil and filter change / Oil Pump priming / Oil Pressure test / Transmission Oil level check / Transmission oil change / Front gearcase Oil level change / Front gearcase oil change / Front hub (1996-early 2004 models) Oil level check / Front hub (1996-early 2004 models) oil change / Clutch draining and Drying / Clutch belt inspection / Air Filter Service / Fuel tank Vent Hose / Fuel Hose Inspection / Fuel Filter Service / Brake System / Control Cable lubrication Throttle Cable/Electronic Throttle Control (etc) Adjustment / Throttle Cable Adjustment / Choke Cable inspection / cooling system inspection / coolant Level Check / exhaust System / suspension / tires and Wheels / toe-in adjustment alignment / lubrication Service: Front Suspension Arms , Front Struts, lower end of the steering Shaft, front Drive Axle Inner U-Joints, Front Propeller Shaft, Front U-joints, Rear U-Joint, Upper and lower Rear Suspension Arms, and rear bar Stabilizer Assembly / Fastener inspection / Valve Clearance / Compression test / Spark Plug / Ignition timing / idle speed / specifications
CHAPTER FOUR / ENGINE TOP END
Engine service / engine cooling / Engine lubrication / Servicing the engine in the frame / Exhaust system / Cylinder Head cover / Rocker arm assembly / Camshaft / Cylinder head / Valves and Valve components / Cylinder block / Piston and piston rings / Camshaft chain and sprockets / Break-in procedure / Specifications
CHAPTER FIVE / Engine LOWER END
Flywheel and stator plate / Recoil starter / Crankcase / Oil pump / Oil system one-way check valve / Break-in procedure / Specifications
CHAPTER SIX / CARBURETOR AND FUEL SYSTEM
Carburetor operation / Carburetor / carburetor tests and adjustments / Throttle Cable replacement / Starting enrichment (choke) cable / Fuel tank / Fuel shutoff valve / Fuel level sending unit (2004-on models) / Air filter air box / Fuel pump/Specifications
CHAPTER SEVEN / FUEL INJECTION SYSTEM
Fuel system initialization and starting procedure / Depressurizing the fuel system / Fuel line fittings / Throttle body / Fuel rail and Fuel injector / Fuel pump / Fuel sender / регулятор давления / Fuel tank / Crankshaft position sensor (CPS) / Manifold air pressure (MAP) sensor / Intake air temperature (IAT) sensor / Idle air control (IAC) / Throttle position Sensor (TPS) / Engine coolant temperature (ECT) Sensor / Electronic Control Module (ECM) / Self Diagnosis / Throttle Cable Replacement / Air Filter Air Box / specifications
CHAPTER EIGHT / COOLING SYSTEM
Air cooling system / Liquid cooling system / Hoses and Hose clamps / радиатор / Cooling fan / Coolant pump / Thermostat / Specifications
CHAPTER NINE / CLUTCH AND DRIVE BELT
Clutch System operation / Clutch tools / Clutch drying / Drive belt / Belt alignment / Drive clutch / Driven clutch / Specifications
CHAPTER TEN / TRANSMISSION (1996-early 2004 models)
Transmission / Transmission inspection / Shift shafts / Front output shaft / Transmission gearcase Oil Seal inspection and replacement / Shift selector linkage / Specifications
CHAPTER ELEVEN / TRANSMISSION (LATE 2004-on MODELS)
Transmission / Transmission shafts / Differential gear assembly / (X2 and Touring models) / Snorkel shaft / Shift selector linkage / Specifications
Chapter TWELVE / FRONT DRIVE SYSTEM
Front hub and Hilliard clutch / (1996-early 2004 models) / Front hub (late 2004-on, X2 and Touring models) / Front Drive axle, boots and constant velocity (CV) / joints / Front drive shaft / Front gearcase / Front gearcase-Deluxe models with active decent / control (2007-on Sportsman 500, X2 and Touring models) / specifications
CHAPTER THIRTEEN / ELECTRICAL SYSTEM
Electrical basics / Electrical component replacement / Electrical connectors / Battery / Battery negative terminal / Charging system / генератор статора / регулятор напряжения/выпрямитель / (1996-early 2004 carbureted models) / Logic box (late 2004-2006 carbureted models) / Capacitor discharge ignition (carbureted models) / DC/Ignition system (Fuel injected Models) / Ignition Coil / Electric starting system / Starter Drive Gears / Starter Solenoid / Headlight system / Taillight and Work Light / Indicator Lamp (1996-2002 models) / speed sensor / Transmission Switch / Resistor Module (2004-on models) / Shift indicator Circuit (late 2004-on Models) / differential solenoid (X2 and Touring models) / switches / Electronic Throttle Control (etc) Switch / All Wheel Drive (AWD) Coil / Active Descent Control (ADC) Coil / (2007-on X2 and Touring Models) / cooling system Switch and sensor / Fuses and circuit breaker (2008 Models) / Speedometer / on-board Diagnostics / Winch (models so equipped) / Winch contactor (Models so equipped) / specifications
CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING
Front wheel / Front strut / Front STRUT cartridge and spring / Control arm / Handlebar / tie rods / Steering post / Tires and wheels / Specifications
CHAPTER FIFTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Rear hub and bearing carrier / Rear drive axle / Rear drive axle boot replacement / (1996-1998 models) / Rear drive axle CV joint and boots / (1999-on models) / Upper control arm (all models except X2 and Touring) / Lower control arm (all models except X2 and / Touring) / Upper control arm (X2 and Touring models) / lower Control ARM (X2 and Touring models) / Upper and lower Control ARM Inspection / Stabilizer linkage (all Models except X2 and / Touring) / Stabilizer Support (all models except X2 and / Touring) / Stabilizer support and Bar (X2 and Touring models) / specifications
CHAPTER SIXTEEN / BRAKES
тормозная служба / передняя тормозная колодка замена / передний суппорт / output shaft brake pad замена / (1996-1997 models) / Output shaft Brake caliper (1996-1997 models) / Output shaft brake pad замена / (1998-2002 models) / Output shaft brake caliper (1998-2002 models) / rear Brake Pad Replacement (2003-on Models / except X2 and Touring) / Rear Caliper (2003-on models except X2 and / Touring) / Rear Brake Pad replacement (X2 and / Touring models) / rear Caliper (X2 and Touring Models) / передний главный цилиндр / задний главный цилиндр / Brake Hose replacement / Brake Bleeding Tips / brake bleeding / Brake Fluid draining / Rear brake Pedal / Brake Disc / specifications
CHAPTER SEVENTEEN / BODY AND FRAME
Plastic inserts / Seat / Side panel / Fender cover / Front fender / Front rack, Rail and grille (1996-2004 models) / Front rack and storage box (2005-on models) / Front bumper / Heatsink guard (1996-2003 models) / Heatsink brush guard (2004-on models) / Brush guard grill and Heatsink side shield / (2004-on models) / rear Rack, Rail and bumper (1996-2002 Models) / Rear Rack and Rail (2003-on except X2 and / Touring) / rear rack and handle (Touring models) / Rear Fender / Rear quarter Panel (X2 models) / footwell / footwell Support Bracket (X2 and Touring Models) / rear storage Box (all models except X2 and Touring) / Cargo box (X2 models) / specifications
INDEX
COLOR WIRING DIAGRAMS