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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 / испытание на утечку цилиндров / система сцепления / электрические испытания / электрические проблемы / 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 передышку filter / Air intake products / Idle speed (carbureted models) / Control cables / Fuel system / Exhaust system / Ignition timing (2002-2004 carbureted models) / Spark свечи / 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 / цилиндр block and pistons / Valve lifter / Specifications
CHAPTER FIVE / ENGINE LOWER END
Engine service / Oil system priming / Engine removal / Engine installation / Recoil starter (MV7 models) / Генератор covers (all models except MV7) / Flywheel, bendix and статор / Water pump cover / Статор housing / Timing gears / Water/oil pump / Camshaft упорный 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 редактирование / 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- $ 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 / Pressure regulator / 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 / Статор / Voltage regulator/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 под / Фара / задняя фара 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 соленоид (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 клешни / Cooling system inspection / Coolant водохранилища / Радиатор / Radiator 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 / передний приводной мост / передний приводной вал / универсальный шарнир / передний редуктор / Specifications
CHAPTER FIFTEEN / REAR SUSPENSION AND REAR DRIVE SYSTEM
Shock амортизатор / Upper control arm / Lower control arm / Control arm inspection / Stabilizer linkage assembly / Stabilizer support / Rear drive axle / Rear gearcase (all models except X2 and Touring / models) / Rear drive shaft (all models except X2 and / Touring models) / Specifications
CHAPTER SIXTEEN / BRAKES
Brake operation / Brake service notes / Brake bleeding / Brake Fluid draining / Brake Pad inspection / передний тормозной суппорт / задний тормозной суппорт / передний тормозной главный цилиндр / задний тормозной главный цилиндр / тормозная педаль / тормозной диск / тормозные шланги / 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 radiator 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) / Лебедка / Winch contactor / Specifications
INDEX
COLOR WIRING DIAGRAMS