Summary of Contents for VT500A
Page 2: ...NOTICE ...
Page 3: ...HOW TO USE THIS MANUAL MANUAL FORMAT EXPLODED DIAGRAM ...
Page 4: ...ILLUSTRATED SYMBOLS ...
Page 5: ...INDEX ...
Page 6: ...CHAPTER 1 GENERAL INFORMATION ...
Page 7: ...MACHINE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER ...
Page 8: ...IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY ...
Page 10: ...CIRCLIPS SPECIAL TOOLS FOR TUNE UP ...
Page 11: ...FOR ENGINE SERVICE ...
Page 12: ...FOR POWER TRAIN SERVICE ...
Page 13: ...FOR ELECTRICAL SERVICE ...
Page 14: ...CHAPTER 2 PERIODIC INSPECTIONS AND ADJUSTMENTS ...
Page 15: ......
Page 16: ...INTRODUCTION PERIODIC MAINTENANCE TABLE ...
Page 17: ......
Page 18: ...ENGINE SPARK PLUGS ...
Page 19: ...OIL PUMP ...
Page 20: ......
Page 21: ...FUEL LINE INSPECTION COOLING SYSTEM ...
Page 22: ......
Page 23: ......
Page 24: ......
Page 25: ......
Page 26: ......
Page 27: ...CARBURETOR SYNCHRONIZATION ...
Page 28: ...ENGINE IDLE SPEED ADJUSTMENT THROTTLE CABLE ADJUSTMENT ...
Page 29: ...THROTTLE OVERRIDE SYSTEM T O R S CHECK STARTER CHOKE CABLE ADJUSTMENT ...
Page 30: ...EXHAUST SYSTEM INSPECTION ...
Page 31: ...POWER TRAIN DRIVE V BELT ...
Page 32: ......
Page 33: ...ENGAGEMENT SPEED CHECK PARKING BRAKE PAD INSPECTION PARKING BRAKE ADJUSTMENT ...
Page 34: ...BRAKE FLUID LEVEL INSPECTION BRAKE PAD INSPECTION ...
Page 35: ...BRAKE HOSE INSPECTION AIR BLEEDING HYDRAULIC BRAKE SYSTEM ...
Page 36: ...DRIVE CHAIN ...
Page 37: ......
Page 38: ...TRACK TENSION ADJUSTMENT ...
Page 39: ...SLIDE RUNNER INSPECTION ...
Page 40: ...CHASSIS SKI SKI RUNNER STEERING SYSTEM ...
Page 41: ...LUBRICATION ...
Page 42: ......
Page 43: ...ELECTRICAL HEADLIGHT BEAM ADJUSTMENT ...
Page 44: ...TUNING CARBURETOR TUNING Except for VT600 MM600 ...
Page 45: ......
Page 46: ......
Page 47: ......
Page 48: ......
Page 49: ......
Page 50: ......
Page 51: ......
Page 52: ......
Page 53: ......
Page 54: ...CLUTCH TUNING ...
Page 55: ......
Page 56: ......
Page 57: ......
Page 58: ...GEAR SELECTION ...
Page 59: ......
Page 60: ......
Page 61: ...HIGH ALTITUDE TUNING ...
Page 62: ...FRONT SUSPENSION ...
Page 63: ...REAR SUSPENSION ...
Page 64: ......
Page 65: ......
Page 66: ...CHAPTER 3 CHASSIS ...
Page 67: ...STEERING ...
Page 68: ......
Page 69: ...INSPECTION ...
Page 70: ...INSTALLATION ...
Page 71: ......
Page 72: ...SKI ...
Page 73: ...INSPECTION ...
Page 74: ...FRONT SUSPENSION ...
Page 75: ...HANDLING NOTES VX500XTC XTCE XTCR VX600XTC XTCE XTCR SX VX700SX INSPECTION ...
Page 76: ...INSTALLATION ...
Page 77: ......
Page 78: ......
Page 79: ...CHAPTER 4 POWER TRAIN ...
Page 80: ...PRIMARY SHEAVE AND DRIVE V BELT ...
Page 81: ......
Page 82: ...REMOVAL DISASSEMBLY ...
Page 83: ...INSPECTION ...
Page 84: ......
Page 85: ...ASSEMBLY ...
Page 86: ......
Page 87: ...INSTALLATION ...
Page 88: ...SECONDARY SHEAVE ...
Page 89: ......
Page 90: ...DISASSEMBLY INSPECTION ...
Page 91: ...ASSEMBLY ...
Page 92: ...INSTALLATION ...
Page 93: ...DRIVE CHAIN HOUSING WITH OUT REVERSE MODEL ...
Page 94: ...INSPECTION ...
Page 95: ...WITH REVERSE MODEL ...
Page 96: ......
Page 97: ...INSPECTION ...
Page 98: ...JACKSHAFT ...
Page 99: ......
Page 100: ...BRAKE ...
Page 101: ...BRAKE PAD REPLPLACEMENT ...
Page 102: ......
Page 103: ......
Page 104: ......
Page 105: ...CALIPER DISASSEMBLY CALIPER INSPECTION AND REPAIR ...
Page 106: ...CALIPER ASSEMBLY ...
Page 107: ......
Page 108: ...MASTER CYLINDER INSPECTION MASTER CYLINDER ASSEMBLY ...
Page 109: ...SLIDE RAIL SUSPENSION VX500 600 700 ...
Page 110: ...VT500 600 MM600 700 ...
Page 111: ......
Page 112: ......
Page 113: ......
Page 114: ......
Page 115: ...INSPECTION ...
Page 116: ...FRONT AXLE AND TRACK ...
Page 117: ...INSPECTION INSTALLATION ...
Page 118: ......
Page 119: ...CHAPTER 5 ENGINE ...
Page 120: ...ENGINE ASSEMBLY 500 600 ...
Page 121: ...700 ...
Page 122: ...CYLINDER HEAD AND CYLINDER 500 600 ...
Page 123: ...700 ...
Page 124: ...REMOVAL ...
Page 125: ...INSPECTION ...
Page 126: ......
Page 127: ......
Page 128: ......
Page 129: ......
Page 130: ...INSTALLATION ...
Page 131: ......
Page 132: ...OIL PUMP CRANKCASE AND CRANKSHAFT 500 600 ...
Page 133: ...700 ...
Page 134: ...INSPECTION ...
Page 135: ......
Page 136: ...INSTALLATION 500 600 ...
Page 137: ...INSTALLATION 700 ...
Page 138: ......
Page 139: ...CDI MAGNETO 500 600 ...
Page 140: ...700 ...
Page 141: ...REMOVAL 500 600 REMOVAL 700 ...
Page 142: ...INSTALLATION 500 600 ...
Page 143: ...INSTALLATION 700 ...
Page 144: ...RECOIL STARTER 500 600 ...
Page 145: ...700 ...
Page 146: ...REMOVAL ...
Page 147: ...INSPECTION ...
Page 148: ...INSTALLATION 500 600 ...
Page 149: ...INSTALLATION 700 ...
Page 150: ...CHAPTER 6 COOLING SYSTEM ...
Page 151: ...HEAT EXCHANGER 500 600 ...
Page 152: ...700 ...
Page 153: ......
Page 154: ...WATER PUMP 500 600 ...
Page 155: ...REMOVAL INSPECTION ...
Page 156: ...INSTALLATION ...
Page 157: ...700 ...
Page 158: ...REMOVAL INSPECTION INSTALLATION ...
Page 159: ...CHAPTER 7 CARBURETION ...
Page 160: ...CARBURETORS 500 600 ...
Page 161: ......
Page 162: ......
Page 163: ......
Page 164: ......
Page 165: ...700 ...
Page 166: ......
Page 167: ......
Page 168: ......
Page 169: ...INSPECTION ...
Page 170: ...ASSEMBLY ...
Page 171: ...FUEL LEVEL ADJUSTMENT ...
Page 172: ...THROTTLE POSITION SENSOR TPS INSPECTION AND ADJUSTMENT ...
Page 173: ......
Page 174: ...FUEL PUMP 500 600 ...
Page 175: ...700 ...
Page 176: ...INSPECTION ...
Page 177: ...CHAPTER 8 ELECTRICAL ...
Page 178: ......
Page 179: ......
Page 180: ...SWITCH INSPECTION SWITCH INSPECTION INSPECTING A SWITCH SHOWN IN THE MANUAL ...
Page 182: ...CIRCUIT DIAGRAM VT600 MM600 ...
Page 183: ...TROUBLESHOOTING ...
Page 184: ...MAIN SWITCH FOR ELECTRIC MODEL ...
Page 185: ...STARTER MOTOR ...
Page 186: ......
Page 187: ......
Page 188: ...CHARGING SYSTEM CIRCUIT DIAGRAM VX500XT XTC XTCE XTCR VT500 VX600XT XTC XTCE XTCR SX ...
Page 189: ...CIRCUIT DIAGRAM VT600 MM600 ...
Page 190: ...TROUBLESHOOTING ...
Page 191: ...BATTERY CHARGING COIL ...
Page 192: ...IGNITION SYSTEM CIRCUIT DIAGRAM VX500XT XTC XTCE XTCR VT500 VX600XT XTC XTCE XTCR SX ...
Page 193: ...CIRCUIT DIAGRAM VT600 MM600 ...
Page 194: ...CIRCUIT DIAGRAM VX700SX MM700 ...
Page 195: ...TROUBLESHOOTING ...
Page 196: ...SPARK PLUG CAP IGNITION COIL ...
Page 197: ...SOURCE COIL SPARK PLUG ...
Page 198: ...THROTTLE OVERRIDE SYSTEM T O R S ...
Page 199: ...HANDLEBAR SWITCH RIGHT ...
Page 200: ...CARBURETOR SWITCH MAIN SWITCH ...
Page 201: ...LIGHTING SYSTEM CIRCUIT DIAGRAM VX500XT XTC XTCE XTCR VT500 VX600XT XTC XTCE XTCR SX ...
Page 202: ...CIRCUIT DIAGRAM VT600 MM600 ...
Page 203: ...CIRCUIT DIAGRAM VX700SX MM700 ...
Page 204: ...TROUBLESHOOTING ...
Page 205: ...BULB S HEADLIGHT BEAM SWITCH ...
Page 206: ...C D I MAGNETO ...
Page 207: ...SIGNAL SYSTEM CIRCUIT DIAGRAM VX500XT XTC XTCE XTCR VT500 VX600XT XTC XTCE XTCR SX ...
Page 208: ...CIRCUIT DIAGRAM VT600 MM600 ...
Page 209: ...CIRCUIT DIAGRAM VX700SX MM700 ...
Page 210: ...TROUBLESHOOTING ...
Page 211: ......
Page 212: ......
Page 213: ......
Page 214: ...TAIL BRAKE LIGHT BULB BRAKE LIGHT SWITCH GEAR POSITION SWITCH BACK BUZZER ...
Page 215: ...THERMO SENSOR ...
Page 216: ...OIL LEVEL SWITCH ...
Page 217: ...FUEL SENDER CONDENSER NON ELECTRIC MODEL ...
Page 218: ...GRIP WARMER SYSTEM CIRCUIT DIAGRAM VX500XT XTC XTCE XTCR VT500 VX600XT XTC XTCE XTCR SX ...
Page 219: ...CIRCUIT DIAGRAM VT600 MM600 ...
Page 220: ...CIRCUIT DIAGRAM VX700SX MM700 ...
Page 221: ...TROUBLESHOOTING ...
Page 222: ......
Page 223: ...GRIP AND THUMB WARMER COIL VARIABLE RESISTOR PASSENGER GRIP WARMER VT500 VT600 ...
Page 224: ...PASSENGER GRIP WARMER SWITCH VT500 VT600 C D I MAGNETO ...
Page 225: ...ELECTRONICALLY CONTROLLED CARBURETOR E C C VT600 MM600 CIRCUIT DIAGRAM ...
Page 226: ...E C C TEST LEAD VT600 MM600 ...
Page 227: ...NAMES OF COMPONENTS VT600 MM600 ...
Page 228: ...FUNCTION OF COMPONENTS VT600 MM600 ...
Page 229: ...MAINTENANCE PROCEDURE VT600 MM600 ...
Page 230: ...FAULT LOCATION TABLE VT600 MM600 ...
Page 231: ......
Page 232: ...ATMOSPHERIC PRESSURE SENSOR INSPECTION VT600 MM600 ...
Page 233: ...AIR TEMPERATURE SENSOR INSPECTION VT600 MM600 ...
Page 234: ...WATER TEMPERATURE SENSOR INSPECTION VT600 MM600 ...
Page 235: ...FUEL SELECT SWITCH INSPECTION VT600 MM600 SOLENOID VALVE INSPECTION VT600 MM600 ...
Page 236: ...CHAPTER 9 SPECIFICATIONS ...
Page 237: ...GENERAL SPECIFICATIONS ...
Page 238: ......
Page 239: ...MAINTENANCE SPECIFICATIONS ENGINE ...
Page 240: ......
Page 241: ......
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Page 245: ......
Page 246: ......
Page 247: ...POWER TRAIN ...
Page 248: ......
Page 249: ......
Page 250: ......
Page 251: ......
Page 252: ...CHASSIS ...
Page 253: ......
Page 254: ...ELECTRICAL ...
Page 255: ...E C C VT600 MM600 ...
Page 256: ...GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS ...
Page 257: ...CABLE ROUTING 500 600 ...
Page 258: ......
Page 259: ......
Page 260: ...CABLE ROUTING 700 ...
Page 261: ......
Page 262: ......
Page 263: ...CHAPTER 10 OPTIONAL KIT ...
Page 264: ...REVERSE GEAR KIT ...
Page 265: ......
Page 266: ......
Page 267: ......
Page 268: ...INSTALLATION ...
Page 269: ......
Page 270: ...STARTER MOTOR KIT ...
Page 271: ......
Page 272: ...INSTALLATION ...
Page 273: ......
Page 274: ...WIRING DIAGRAM VT600 MM600 WIRING DIAGRAM VT600 MM600 ...
Page 275: ...COLOR CODE ...
Page 276: ...WIRING DIAGRAM VX700SX MM700 WIRING DIAGRAM VX700SX MM700 ...
Page 277: ...COLOR CODE ...
Page 279: ...COLOR CODE ...
