Summary of Contents for 8DG4
Page 1: ...VX600ERG SX600G MM600G VT600G VX600ERG SX600G MM600G VT600G ...
Page 2: ...NOTICE HOW TO USE THIS MANUAL MANUAL FORMAT EXPLODED DIAGRAM ...
Page 3: ...ILLUSTRATED SYMBOLS ...
Page 4: ...INDEX ...
Page 5: ......
Page 6: ......
Page 7: ......
Page 8: ......
Page 9: ...CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER ...
Page 10: ...IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY ...
Page 12: ...SPECIAL TOOLS FORTUNE UP ...
Page 13: ...FOR ENGINE SERVICE FOR POWER TRAIN SERVICE ...
Page 14: ...FOR CARBURETION SERVICE FOR ELECTRICAL SERVICE ...
Page 15: ...CHAPTER 2 PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION PERIODIC MAINTENANCE TABLE ...
Page 16: ......
Page 17: ...ENGINE SPARK PLUGS ...
Page 18: ...OIL PUMP ...
Page 19: ......
Page 20: ...FUEL LINE INSPECTION COOLING SYSTEM ...
Page 21: ......
Page 22: ......
Page 23: ......
Page 24: ......
Page 25: ......
Page 26: ...CARBURETOR SYNCHRONIZATION ...
Page 27: ...ENGINE IDLE SPEED ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT ...
Page 28: ...THROTTLE OVERRIDE SYSTEM T O R S CHECK ...
Page 29: ...STARTER CHOKE CABLE FREE PLAY ADJUSTMENT EXHAUST SYSTEM INSPECTION ...
Page 30: ...POWER TRAIN SHEAVE DISTANCE AND OFFSET ADJUSTMENT ...
Page 31: ......
Page 32: ...DRIVE V BELT ...
Page 33: ......
Page 34: ...ENGAGEMENT SPEED CHECK PARKING BRAKE PAD INSPECTION ...
Page 35: ...PARKING BRAKE ADJUSTMENT BRAKE LEVER ADJUSTMENT VX600ER SX600 VT600 ...
Page 36: ...BRAKE FLUID LEVEL INSPECTION BRAKE PAD INSPECTION ...
Page 37: ...BRAKE HOSE INSPECTION AIR BLEEDING HYDRAULIC BRAKE SYSTEM ...
Page 38: ...DRIVE CHAIN ...
Page 39: ......
Page 40: ......
Page 41: ...TRACK TENSION ADJUSTMENT ...
Page 42: ......
Page 43: ...SLIDE RUNNER INSPECTION ...
Page 44: ...MAXIMIZING DRIVE TRACK LIFE ...
Page 45: ...CHASSIS SKI SKI RUNNER ...
Page 46: ...STEERING SYSTEM ...
Page 47: ...LUBRICATION ...
Page 48: ......
Page 49: ...ELECTRICAL HEADLIGHT BEAM ADJUSTMENT ...
Page 50: ...BATTERY INSPECTION VX600ER VT600 ...
Page 51: ......
Page 52: ...BATTERY CHARGING VX600ER VT600 ...
Page 53: ...FUSE INSPECTION VX600ER VT600 ...
Page 54: ......
Page 55: ...TUNING CARBURETOR TUNING ...
Page 56: ......
Page 57: ......
Page 58: ......
Page 59: ......
Page 60: ......
Page 61: ......
Page 62: ...CLUTCH ...
Page 63: ......
Page 64: ......
Page 65: ......
Page 66: ......
Page 67: ...GEAR SELECTION ...
Page 68: ......
Page 69: ......
Page 70: ......
Page 71: ......
Page 72: ......
Page 73: ...HIGH ALTITUDE TUNING ...
Page 74: ...FRONT SUSPENSION ...
Page 75: ...REAR SUSPENSION ...
Page 76: ......
Page 77: ......
Page 78: ......
Page 79: ...CHAPTER 3 CHASSIS STEERING VX600ER SX600 VT600 ...
Page 80: ...MM600 ...
Page 81: ......
Page 82: ...INSPECTION ...
Page 83: ...INSTALLATION ...
Page 84: ......
Page 85: ......
Page 86: ...SKI VX600ER VT600 ...
Page 87: ...SX600 MM600 ...
Page 88: ...INSPECTION INSTALLATION VX600ER VT600 ...
Page 89: ...FRONT SUSPENSION ...
Page 90: ...HANDLING NOTES SX600 INSPECTION ...
Page 91: ......
Page 92: ...INSTALLATION ...
Page 93: ......
Page 94: ......
Page 95: ......
Page 96: ......
Page 97: ......
Page 98: ...CHAPTER 4 POWER TRAIN PRIMARY SHEAVE AND DRIVE V BELT ...
Page 99: ......
Page 100: ...REMOVAL ...
Page 101: ...DISASSEMBLY ...
Page 102: ...INSPECTION ...
Page 103: ......
Page 104: ...ASSEMBLY ...
Page 105: ......
Page 106: ......
Page 107: ...INSTALLATION ...
Page 108: ...SECONDARY SHEAVE ...
Page 109: ......
Page 110: ...DISASSEMBLY INSPECTION ...
Page 111: ...ASSEMBLY ...
Page 112: ......
Page 113: ...INSTALLATION ...
Page 114: ...DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL ...
Page 115: ...INSPECTION ...
Page 116: ......
Page 117: ...INSTALLATION ...
Page 118: ...WITH REVERSE MODEL ...
Page 119: ......
Page 120: ...INSPECTION ...
Page 121: ...INSTALLATION ...
Page 122: ......
Page 123: ...JACKSHAFT ...
Page 124: ...INSPECTION ...
Page 125: ...JACKSHAFT AND DRIVE CHAIN HOUSING INSTALLATION ...
Page 126: ...BRAKE ...
Page 127: ...BRAKE PAD REPLACEMENT ...
Page 128: ......
Page 129: ......
Page 130: ......
Page 131: ...BRAKE CALIPER DISASSEMBLY BRAKE CALIPER INSPECTION AND REPAIR ...
Page 132: ...BRAKE CALIPER ASSEMBLY BRAKE CALIPER INSTALLATION ...
Page 133: ......
Page 134: ...INSPECTION BRAKE MASTER CYLINDER ASSEMBLY INSTALLATION ...
Page 135: ...SLIDE RAIL SUSPENSION VX600ER SX600 ...
Page 136: ...VT600 ...
Page 137: ......
Page 138: ......
Page 139: ......
Page 140: ......
Page 141: ...MM600 ...
Page 142: ......
Page 143: ......
Page 144: ......
Page 145: ......
Page 146: ...INSPECTION ...
Page 147: ...ASSEMBLY INSTALLATION ...
Page 148: ......
Page 149: ...FRONT AXLE AND TRACK ...
Page 150: ...INSPECTION INSTALLATION ...
Page 151: ......
Page 152: ...CHAPTER 5 ENGINE EXHAUST ASSEMBLY ...
Page 153: ...INSTALLATION ...
Page 154: ...ENGINE ASSEMBLY ...
Page 155: ...INSPECTION INSTALLATION ...
Page 156: ......
Page 157: ...CYLINDER HEAD AND CYLINDER ...
Page 158: ......
Page 159: ...REMOVAL ...
Page 160: ...INSPECTION ...
Page 161: ......
Page 162: ......
Page 163: ......
Page 164: ......
Page 165: ...INSTALLATION ...
Page 166: ......
Page 167: ......
Page 168: ...OIL PUMP CRANKCASE AND CRANKSHAFT ...
Page 169: ...INSPECTION ...
Page 170: ......
Page 171: ...INSTALLATION ...
Page 172: ......
Page 173: ......
Page 174: ...AC MAGNETO ...
Page 175: ...REMOVAL ...
Page 176: ...INSTALLATION ...
Page 177: ......
Page 178: ...RECOIL STARTER ...
Page 179: ...REMOVAL INSPECTION ...
Page 180: ...INSTALLATION ...
Page 181: ...CHAPTER 6 COOLING SYSTEM HEAT EXCHANGER VX600ER SX600 VT600 ...
Page 182: ...MM600 ...
Page 183: ...INSPECTION ...
Page 184: ...INSTALLATION ...
Page 185: ...WATER PUMP ...
Page 186: ...REMOVAL INSPECTION INSTALLATION ...
Page 187: ...CHAPTER 7 CARBURETION CARBURETORS ...
Page 188: ......
Page 189: ......
Page 190: ......
Page 191: ...INSPECTION ...
Page 192: ...ASSEMBLY ...
Page 193: ...CARBURETOR SYNCHRONIZATION ...
Page 194: ...FUEL LEVEL ADJUSTMENT ...
Page 195: ...INSTALLATION ...
Page 196: ...FUEL PUMP VX600ER VT600 ...
Page 197: ...SX600 MM600 ...
Page 198: ...INSPECTION INSTALLATION ...
Page 200: ...IGNITION SYSTEM ...
Page 201: ...CIRCUIT DIAGRAM ...
Page 202: ...TROUBLESHOOTING ...
Page 203: ......
Page 204: ...CONDENSER SX600 MM600 AC MAGNETO ...
Page 205: ...SPARK PLUG SPARK PLUG CAP IGNITION COIL ...
Page 206: ...THROTTLE OVERRIDE SYSTEM T O R S HANDLEBAR SWITCH RIGHT ...
Page 207: ...CARBURETOR SWITCH MAIN SWITCH ...
Page 208: ...LOAD CONTROL RELAY EMERGENCY ENGINE STARTING SX600 MM600 ...
Page 209: ...ELECTRICAL STARTING SYSTEM VX600ER VT600 CIRCUIT DIAGRAM ...
Page 210: ...TROUBLESHOOTING ...
Page 211: ...MAIN SWITCH ...
Page 212: ...STARTER MOTOR ...
Page 213: ......
Page 214: ......
Page 215: ......
Page 216: ...CHARGING SYSTEM VX600ER VT600 CIRCUIT DIAGRAM ...
Page 217: ...TROUBLESHOOTING ...
Page 218: ...BATTERY STATOR COIL ...
Page 219: ...LIGHTING SYSTEM CIRCUIT DIAGRAM ...
Page 220: ......
Page 221: ...TROUBLESHOOTING ...
Page 222: ......
Page 223: ...BULB S HEADLIGHT BEAM SWITCH ...
Page 224: ...HEADLIGHT RELAY ...
Page 225: ...SIGNAL SYSTEM CIRCUIT DIAGRAM ...
Page 226: ......
Page 227: ...TROUBLESHOOTING ...
Page 228: ......
Page 229: ......
Page 230: ......
Page 231: ...BRAKE LIGHT SWITCH GEAR POSITION SWITCH VX600ER VT600 DC BACK BUZZER VX600ER VT600 ...
Page 232: ...WATER TEMPERATURE SENSOR ...
Page 233: ...OIL LEVEL SWITCH FUEL SENDER ...
Page 234: ...GRIP WARMER SYSTEM CIRCUIT DIAGRAM ...
Page 235: ...TROUBLESHOOTING ...
Page 236: ......
Page 237: ......
Page 238: ...GRIP AND THUMB WARMER COIL VARIABLE RESISTOR THUMB WARMER ...
Page 239: ...VARIABLE RESISTOR GRIP WARMER PASSENGER GRIP WARMER VT600 ...
Page 240: ...PASSENGER GRIP WARMER SWITCH VT600 RESISTOR VT600 ...
Page 241: ...PASSENGER GRIP WARMER RELAY VT600 ...
Page 242: ...FAULT LOCATION TABLE ...
Page 243: ......
Page 244: ...CHAPTER 9 SPECIFICATIONS GENERAL SPECIFICATIONS ...
Page 245: ......
Page 246: ......
Page 247: ...MAINTENANCE SPECIFICATIONS ENGINE ...
Page 248: ......
Page 249: ......
Page 250: ...POWER TRAIN ...
Page 251: ......
Page 252: ......
Page 253: ......
Page 254: ...CHASSIS ...
Page 255: ...ELECTRICAL ...
Page 256: ......
Page 257: ...HIGH ALTITUDE SETTINGS ...
Page 258: ...TIGHTENING TORQUE PENGINE ...
Page 259: ...POWER TRAIN ...
Page 260: ......
Page 261: ...CHASSIS ...
Page 262: ...GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS ...
Page 263: ...CABLE ROUTING ...
Page 264: ......
Page 265: ......
Page 266: ......
Page 267: ......
Page 268: ......
Page 269: ......
Page 270: ......
Page 271: ......
Page 272: ......
Page 273: ......
Page 274: ......
Page 275: ......
Page 276: ......
Page 277: ......
Page 278: ......
Page 279: ......
Page 280: ......
Page 281: ......
Page 282: ...WIRING DIAGRAM VX600ERG SX600G MM600G VT600G ...
