Summary of Contents for 8DJ
Page 1: ...PZ500C VT500XLC PZ500C VT500XLC ...
Page 2: ...NOTICE HOW TO USE THIS MANUAL MANUAL FORMAT EXPLODED DIAGRAM ...
Page 3: ...ILLUSTRATED SYMBOLS ...
Page 4: ...INDEX ...
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Page 8: ...CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER ...
Page 9: ...IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY ALL REPLACEMENT PARTS ...
Page 11: ...SPECIAL TOOLS FOR TUNE UP FOR ENGINE SERVICE ...
Page 12: ...FOR POWER TRAIN SERVICE ...
Page 13: ...FOR CARBURETION SERVICE FOR ELECTRICAL SERVICE ...
Page 14: ...CHAPTER 2 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION PERIODIC MAINTENANCE TABLE ...
Page 15: ......
Page 16: ...ENGINE SPARKPLUGS ...
Page 17: ...OILPUMP ...
Page 18: ...FUEL LINE INSPECTION ...
Page 19: ...COOLING FAN BELT INSPECTION ...
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Page 21: ......
Page 22: ...CARBURETOR SYNCHRONIZATION ...
Page 23: ...ENGINE IDLE SPEED ADJUSTMENT ...
Page 24: ...THROTTLE CABLE FREEPLAY ADJUSTMENT ...
Page 25: ...THROTTLE OVERRIDE SYSTEM TO R S CHECK ...
Page 26: ...STARTER CHOKE CABLE FREEPLAY ADJUSTMENT EXHAUST SYSTEM INSPECTION ...
Page 27: ...POWER TRAIN SHEAVE DISTANCE AND OFFSET ADJUSTMENT ...
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Page 29: ...DRIVE V BELT ...
Page 30: ......
Page 31: ...ENGAGEMENT SPEED CHECK PARKING BRAKE PAD INSPECTION PARKING BRAKE ADJUSTMENT ...
Page 32: ...BRAKE FLUID LEVEL INSPECTION BRAKE PAD INSPECTION ...
Page 33: ...BRAKE HOSE INSPECTION AIR BLEEDING HYDRAULIC BRAKE SYSTEM ...
Page 34: ...DRIVE CHAIN ...
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Page 36: ...TRACK TENSION ADJUSTMENT ...
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Page 38: ...SLIDE RUNNER INSPECTION ...
Page 39: ...CHASSIS SKI SKI RUNNER STEERING SYSTEM ...
Page 40: ...LUBRICATION ...
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Page 42: ...ELECTRICAL HEADLIGHT BEAM ADJUSTMENT ...
Page 43: ...BATTERY INSPECTION ...
Page 44: ......
Page 45: ...BATTERY CHARGING ...
Page 46: ...TUNING CARBURETOR TUNING ...
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Page 52: ...CLUTCH ...
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Page 54: ...GEAR SELECTION ...
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Page 57: ...HIGH ALTITUDE TUNING ...
Page 58: ...FRONT SUSPENSION REAR SUSPENSION ...
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Page 60: ...CHAPTER 3 CHASSIS STEERING ...
Page 61: ......
Page 62: ...INSPECTION ...
Page 63: ...INSTALLATION ...
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Page 65: ...SKI ...
Page 66: ...INSPECTION ...
Page 67: ...FRONT SUSPENSION ...
Page 68: ...INSPECTION ...
Page 69: ...INSTALLATION ...
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Page 72: ...CHAPTER 4 POWER TRAIN PRIMARY SHEAVE AND DRIVE V BELT ...
Page 73: ......
Page 74: ...REMOVAL DISASSEMBLY ...
Page 75: ...INSPECTION ...
Page 76: ......
Page 77: ...ASSEMBLY ...
Page 78: ......
Page 79: ...INSTALLATION ...
Page 80: ...SECONDARY SHEAVE ...
Page 81: ......
Page 82: ...DISASSEMBLY INSPECTION ...
Page 83: ...ASSEMBLY ...
Page 84: ......
Page 85: ...INSTALLATION ...
Page 86: ...DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL ...
Page 87: ...INSPECTION ...
Page 88: ...INSTALLATION ...
Page 89: ...WITH REVERSE MODEL ...
Page 90: ......
Page 91: ...INSPECTION ...
Page 92: ...INSTALLATION ...
Page 93: ...JACKSHAFT ...
Page 94: ...INSPECTION ...
Page 95: ...JACKSHAFT AND DRIVE CHAIN HOUSING INSTALLATION ...
Page 96: ...BRAKE ...
Page 97: ...BRAKE PAD REPLACEMENT ...
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Page 101: ...BRAKE CALIPER DISASSEMBLY BRAKE CALIPER INSPECTION AND REPAIR ...
Page 102: ...BRAKE CALIPER ASSEMBLY BRAKE CALIPER INSTALLATION ...
Page 103: ......
Page 104: ...INSPECTION BRAKE MASTER CYLINDER ASSEMBLY ...
Page 105: ...SLIDE RAIL SUSPENSION PZ500 ...
Page 106: ...VT500XL ...
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Page 111: ...INSPECTION ...
Page 112: ...FRONT AXLE AND TRACK ...
Page 113: ...INSPECTION INSTALLATION ...
Page 114: ...CHAPTER 5 ENGINE EXHAUST ASSEMBLY ...
Page 115: ...INSPECTION INSTALLATION ...
Page 116: ...ENGINE ASSEMBLY ...
Page 117: ...INSTALLATION ...
Page 118: ...CYLINDER HEAD AND CYLINDER ...
Page 119: ......
Page 120: ...REMOVAL ...
Page 121: ...INSPECTION ...
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Page 126: ...INSTALLATION ...
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Page 128: ...OIL PUMP GDI MAGNETO CRANKCASE AND CRANKSHAFT ...
Page 129: ...REMOVAL INSPECTION ...
Page 130: ......
Page 131: ...INSTALLATION ...
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Page 133: ...ENGINE COOLING FAN ...
Page 134: ...REMOVAL INSPECTION ...
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Page 136: ...INSTALLATION ...
Page 137: ...RECOIL STARTER ...
Page 138: ...REMOVAL INSPECTION ...
Page 139: ...INSTALLATION ...
Page 140: ...CHAPTER 6 CARBURETION CARBURETORS ...
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Page 142: ......
Page 143: ...REMOVAL DISASSEMBLY ...
Page 144: ...INSPECTION ...
Page 145: ...ASSEMBLY ...
Page 146: ...INSTALLATION ...
Page 147: ......
Page 148: ...FUEL PUMP ...
Page 149: ...INSPECTION INSTALLATION ...
Page 150: ...CHAPTER 7 ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION ...
Page 151: ...ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM VT500XL ...
Page 152: ...TROUBLESHOOTING VT500XL ...
Page 153: ...MAIN SWITCH VT500XL ...
Page 154: ...STARTER MOTOR VT500XL ...
Page 155: ...INSPECTION VT500XL ...
Page 156: ...ASSEMBLY VT500XL ...
Page 157: ...CHARGING SYSTEM CIRCUIT DIAGRAM VT500XL ...
Page 158: ...TROUBLESHOOTING VT500XL ...
Page 159: ...BATTERY VT500XL CHARGING COIL VT500XL ...
Page 160: ...IGNITION SYSTEM CIRCUIT DIAGRAM ...
Page 161: ...TROUBLESHOOTING ...
Page 162: ...SPARK PLUG CAP IGNITION COIL CDI MAGNETO ...
Page 163: ...SPARKPLUG THROTTLE OVERRIDE SYSTEM T O R S ...
Page 164: ...HANDLEBAR SWITCH RIGHT CARBURETOR SWITCH ...
Page 165: ...MAIN SWITCH ...
Page 166: ...LIGHTING SYSTEM CIRCUIT DIAGRAM ...
Page 167: ...TROUBLESHOOTING ...
Page 168: ...BULB S HEADLIGHT BEAM SWITCH ...
Page 169: ...CDI MAGNETO ...
Page 170: ...SIGNAL SYSTEM CIRCUIT DIAGRAM ...
Page 171: ...TROUBLESHOOTING ...
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Page 173: ...TAIL BRAKE LIGHT BULB BRAKE LIGHT SWITCH GEAR POSITION SWITCH VT500XL AC BACK BUZZER ...
Page 174: ...DC BACK BUZZER VT500XL OIL LEVEL SWITCH ...
Page 175: ...GRIP WARMER SYSTEM CIRCUIT DIAGRAM ...
Page 176: ...TROUBLESHOOTING ...
Page 177: ...GRIP AND THUMB WARMER COIL VARIABLE RESISTOR VT500XL PASSENGER GRIP WARMER VT500XL ...
Page 178: ...PASSENGER GRIP WARMER SWITCH VT500XL CDI MAGNETO ...
Page 179: ...CHAPTER 8 SPECIFICATIONS GENERAL SPECIFICATIONS ...
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Page 181: ...MAINTENANCE SPECIFICATIONS ENGINE ...
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Page 184: ...POWER TRAIN ...
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Page 187: ...CHASSIS ...
Page 188: ...ELECTRICAL ...
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Page 190: ...HIGH ALTITUDE SETTINGS PZ500 VT500XL ...
Page 191: ...TIGHTENING TORQUE ...
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Page 194: ...CABLE ROUTING ...
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Page 208: ...WIRING DIAGRAM PZ500 VT500XL ...
Page 209: ...COLOR CODE ...
