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INSTALLATION

Summary of Contents for PZ500C

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 ...

Page 5: ......

Page 6: ......

Page 7: ......

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 10: ...GASKETS OIL SEALS AND O RINGS LOCK WASHERS PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS LOCTITE ...

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 ...

Page 28: ......

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 ...

Page 35: ......

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 51: ......

Page 52: ...CLUTCH ...

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Page 54: ...GEAR SELECTION ...

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Page 56: ......

Page 57: ...HIGH ALTITUDE TUNING ...

Page 58: ...FRONT SUSPENSION REAR SUSPENSION ...

Page 59: ......

Page 60: ...CHAPTER 3 CHASSIS STEERING ...

Page 61: ......

Page 62: ...INSPECTION ...

Page 63: ...INSTALLATION ...

Page 64: ......

Page 65: ...SKI ...

Page 66: ...INSPECTION ...

Page 67: ...FRONT SUSPENSION ...

Page 68: ...INSPECTION ...

Page 69: ...INSTALLATION ...

Page 70: ......

Page 71: ......

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 99: ......

Page 100: ......

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 110: ......

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 125: ......

Page 126: ...INSTALLATION ...

Page 127: ......

Page 128: ...OIL PUMP GDI MAGNETO CRANKCASE AND CRANKSHAFT ...

Page 129: ...REMOVAL INSPECTION ...

Page 130: ......

Page 131: ...INSTALLATION ...

Page 132: ......

Page 133: ...ENGINE COOLING FAN ...

Page 134: ...REMOVAL INSPECTION ...

Page 135: ......

Page 136: ...INSTALLATION ...

Page 137: ...RECOIL STARTER ...

Page 138: ...REMOVAL INSPECTION ...

Page 139: ...INSTALLATION ...

Page 140: ...CHAPTER 6 CARBURETION CARBURETORS ...

Page 141: ......

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 ...

Page 172: ......

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 ...

Page 180: ......

Page 181: ...MAINTENANCE SPECIFICATIONS ENGINE ...

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Page 183: ......

Page 184: ...POWER TRAIN ...

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Page 186: ......

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 ...

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