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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
Warning light system / Starting the engine / Engine will not start / Starting difficulties / Poor Engine performance / Fuel system / Engine / Engine lubrication / цилиндр leakdown test / система сцепления / Electrical testing / Electrical troubleshooting / Meter assembly / Front gearcase / Steering / Brake system / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE and TUNE-UP
maintenance schedule / pre-Ride inspection / Tune-up / Engine compression test / Engine oil and filter / Oil Pressure test / Clutch / Transmission oil / Shift linkage / Air filter / Inline breather filter / Air intake ducts / Idle speed (carbureted models) / Control cables / Fuel system / Exhaust system / Ignition timing (2002-2004 carbureted models) / Spark plugs / Cooling System / front Gearcase Oil / Rear gearcase Oil (all Models except X2 and Touring Models) / Tires and Wheels / Steering System / Suspension / Brake System / Lighting System / Recoil Starter / lubrication Service / fasteners / wires, hoses and Control cables / specifications
CHAPTER FOUR / ENGINE TOP END
Component identification /Rocker cover / Rocker arms and pushrods / цилиндрическая головка / цилиндрический блок и поршни / Valve lifter / Specifications
CHAPTER FIVE / Engine LOWER END
Engine service / Oil system priming / Engine removal / Engine installation / Recoil starter (MV7 models) / Alternator covers (all models except MV7) / Flywheel, bendix and stator / Water pump cover / stator housing / Timing gears/Water / oil pump / Camshaft thrust plate / Crankcase / Engine break-in / Specifications
CHAPTER SIX / CLUTCH AND DRIVE BELT
Clutch System operation / Clutch tools / Clutch drying / Drive belt / Clutch outer cover / Clutch inner cover / Drive clutch / Driven clutch / Specifications
CHAPTER SEVEN / TRANSMISSION AND SHIFT MECHANISM (ALL MODELS EXCEPT X2 AND TOURING MODELS)
gearshift selector / Transmission case / Transmission / Specifications
EIGHT / TRANSMISSION AND SHIFT MECHANISM (X2 AND TOURING MODELS)
gearshift selector / Transmission Case / Transmission shafts / Differential gear assembly / snorkel shaft / Specifications
CHAPTER NINE / AIR / FUEL AND EXHAUST SYSTEMS (CARBURETED MODELS)
Air box / Exhaust system / Intake manifold / Carburetor / carburetor tests and adjustments / Pilot screw / Throttle cable / Throttle lever housing / Choke (starter) cable / Fuel draining / Fuel valve / Fuel tank / Rear tank (2005-on MV7 models) / Fuel sender (late 2004-on 600 and 700 models, 2005-on mv7 models) / Fuel Pump / Specifications
CHAPTER this/AIR / FUEL SYSTEM (FUEL INJECTED MODELS)
Air box / Exhaust system / Exhaust manifold / Intake manifold / Priming the fuel system / Depressurizing the fuel system / Fuel tank / Fuel pump / Fuel sender / регулятор давления / Throttle lever housing / Throttle cable / Throttle body / Fuel injectors / Crankshaft position (CKP) sensor / Temperature and barometric air pressure / (T-BAP) sensor / Throttle position sensor (TPS) / Electronic Control Unit (ECU) / self diagnosis / Specifications
Chapter ELEVEN / ELECTRICAL SYSTEM
Electrical component replacement / Electrical connectors / Battery / Charging system / Stator / Voltage Controller/rectifier / Logic box (2005-on carbureted models) / Relays / Ignition system identification / CDI unit / Trigger coil / Ignition coil / Electronic control unit (ECU) / Starting system / Starter / Starter solenoid / Electronic throttle control (ETC) switch / headlight pod / Headlight / Taillight Assembly / Work Light (Models so equipped) / switches / All Wheel Drive (AWD) Coil / Active Descent Control (ADC) Coil / Speed Sensor / transmission Switch / Resistor module (2004-on Models) / Shift Indicator Circuit / Differential Solenoid (X2 and Touring Models) / Differential Controller Relay (X2 and Touring Models) / Meter Assembly / on-board Diagnostics / Fuses / Wiring and connectors / Wiring Diagrams / specifications
Chapter TWELVE / COOLING SYSTEM
Hoses and Hose clamps / cooling system inspection / Coolant reservoir / радиатор / радиатор fan / Fan switch (2002-2004 600 and 700 models) / Coolant temperature sensor / Coolant temperature sensor (carbureted models) / Thermostat / Water pump / Specifications
CHAPTER THIRTEEN / WHEELS, TIRES AND HUBS
Wheels / Front hub / Front bearing carrier / Rear hub / Rear bearing carrier / Tires / Specifications
CHAPTER FOURTEEN / FRONT SUSPENSION, STEERING AND FRONT DRIVE SYSTEM
Hubstrut / Front strut / a-arm / tie rod / Steering post / Handlebar / Handlebar grip / Front Drive axle / Front Drive shaft / Universal joint / Front gearcase / Specifications
CHAPTER FIFTEEN / REAR SUSPENSION AND REAR DRIVE SYSTEM
амортизатор / верхний рычаг управления / нижний рычаг управления / контроль рычага управления / стабилизатор linkage assembly /стабилизатор support / задний приводной мост / задний редуктор (все модели except X2 and Touring / models) / задний приводной вал (Все модели except X2 and / Touring models) / Specifications
CHAPTER SIXTEEN / BRAKES
Brake operation / Brake service notes / Brake bleeding / Brake fluid draining / Brake Pad inspection / Front Brake caliper / Rear brake caliper / Front brake master цилиндр / Rear brake master цилиндр / Brake pedal / Brake disc / brake hoses / Specifications
CHAPTER SEVENTEEN / BODY AND FRAME
Quick release inserts / Rider?s seat / Rider?s backrest and passenger seat (X2 models) / Passenger seat (Touring models) / Side panel / Fender cover / Front fender / Front rack / Front bumper (all models except MV7) / Front brush guard / Grill and Heatsink shield (all models except / mv7 models) / Rear rack (all models except MV7, X2 and Touring models) / Rear rack (Touring models) / Rear rack and brush guard assembly / (mv7 Models) / Rear Fender (all models except X2 and mv7 models) / Rear quarter Panel (X2 Models) / footwell / Rear Storage box (all models except X2 models) / Cargo Box (X2 Models) / Winch / Winch contactor / specifications
INDEX
COLOR WIRING DIAGRAMS