
MMR2004-101_00_02A.FM I
SECTION SUBSECTION PAGE
SAFETY NOTICE .................................................................................................................................... III
INTRODUCTION .................................................................................................................................... IV
01 SERVICE TOOLS AND
SERVICE PRODUCTS
01 – Service tools .................................................................................. 01-01-1
02 – Service products ............................................................................ 01-02-1
02 MAINTENANCE 01 – Table of contents ........................................................................... 02-01-1
02 – Maintenance chart ......................................................................... 02-02-1
03 – Storage .......................................................................................... 02-03-1
04 – Preseason preparation ................................................................... 02-04-1
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 and track..................................................................... 03-06-1
04 ENGINE 01 – Table of contents........................................................................... 04-01-1
02 – 277 engine type ............................................................................. 04-02-1
03 – 443 and 552 engine types ............................................................. 04-03-1
04 – 593 engine type ............................................................................ 04-04-1
05 – Leak test and engine dimension measurement ............................ 04-05-1
06 – CDI system .................................................................................... 04-06-1
07 – Oil injection system ....................................................................... 04-07-1
08 – Axial fan cooling system ................................................................ 04-08-1
09 – Liquid cooling system.................................................................... 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