I
SECTION SUBSECTION PAGE
SAFETY NOTICE .................................................................................................................................. III
WHAT’S NEW ....................................................................................................................................... IV
INTRODUCTION .................................................................................................................................. V
01
SERVICE TOOLS AND
SERVICE PRODUCTS
01 – Service tools............................................................................. 01-01-1
02 – Service products....................................................................... 01-02-1
02
LUBRICATION
AND MAINTENANCE
01 – Lubrication and maintenance chart .......................................... 02-01-1
03
TROUBLESHOOTING
01 – Table of contents...................................................................... 03-01-1
02 – Engine ...................................................................................... 03-02-1
03 – Fuel and oil systems................................................................. 03-03-1
04 – Transmission and brake systems............................................. 03-04-1
05 – Electrical system ...................................................................... 03-05-1
06 – Suspension system and track .................................................. 03-06-1
04
ENGINE
01 – Table of contents...................................................................... 04-01-1
02 – 443 and 503 engine types........................................................ 04-02-1
03 – 494, 583 and 670 engine types................................................ 04-03-1
04 – Leak test and engine dimension measurement....................... 04-04-1
05 – CDI system............................................................................... 04-05-1
06 – Oil injection system.................................................................. 04-06-1
07 – Axial fan cooling system........................................................... 04-07-1
08 – Liquid cooling system............................................................... 04-08-1
09 – Rotary valve, coolant pump and reservoir ................................ 04-09-1
10 – Rewind starter.......................................................................... 04-10-1
11 – Carburetor and fuel pump ........................................................ 04-11-1
12 – Fuel tank and throttle cable...................................................... 04-12-1
05
TRANSMISSION
01 – Table of contents...................................................................... 05-01-1
02 – Drive belt.................................................................................. 05-02-1
03 – Drive pulley............................................................................... 05-03-1
04 – Driven pulley............................................................................. 05-04-1
05 – Pulley distance and alignment.................................................. 05-05-1
06 – Brake ........................................................................................ 05-06-1
07 – Chaincase................................................................................. 05-07-1
08 – Gearbox.................................................................................... 05-08-1
09 – Drive chain................................................................................ 05-09-1
06
ELECTRICAL
01 – Table of contents...................................................................... 06-01-1
02 – Ignition timing........................................................................... 06-02-1
03 – Spark plugs............................................................................... 06-03-1
04 – Battery...................................................................................... 06-04-1
05 – Electric starter .......................................................................... 06-05-1
06 – Testing procedure .................................................................... 06-06-1
TABLE OF CONTENTS