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Manual Details
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Coverage Areas
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Covered Models:
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GSX Limited 600 HO SDI, GSX Limited 800R Power TEK, GSX Limited Touring 600 HO SDI, GSX Sport 500SS, MX Z Adrenaline 600 HO SDI, MX Z Adrenaline 800R Power TEK, MX Z Renegade 600 HO SDI, MX Z Renegade 800R Power TEK, MX Z Renegade X 600 HO SDI, MX Z Renegade X 800R Power TEK, MX Z TNT 500SS, MX Z TRAIL 500SS, MX Z X 600 HO SDI, MX Z X 800R Power TEK, SUMMIT EVEREST 800R Power TEK, SUMMIT X 800R Power TEK
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Page Count
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Page Count:
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551
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Manual Type
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Manual Type:
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Service Repair Manual
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Language
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Language:
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English
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Format
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File Format:
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PDF
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Delivery
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Delivery Method:
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Instant Download
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Manual Coverage
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Systems Covered
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Engine Systems:
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Engine removal/installation, cylinder head, valve train, cylinder block, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (carburetion/injection), ignition system, exhaust system.
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Drivetrain Systems:
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CVTech primary and secondary clutches, drive chain case, final drive, driven axle, drive track.
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Suspension Systems:
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Front suspension (A-arms, shocks, springs), rear suspension (SC-5, SC-4 variants depending on model, shocks, springs, idler wheels, sliders).
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Electrical Systems:
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Lighting, ignition switch, starter motor, battery, stator, regulator/rectifier, wiring diagrams, sensors.
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Chassis Systems:
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Frame, handlebars, steering system, brake system, skis, snow flaps, seat, body panels.
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Procedures Included
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Maintenance Procedures:
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Routine inspections, lubrication points, belt inspection/replacement, spark plug replacement, coolant checks/flushes, chain case oil changes, track tension adjustment.
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Repair Procedures:
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Engine component overhauls, clutch servicing and adjustment, suspension shock rebuilding/replacement, brake caliper servicing, track drive system repairs, electrical component troubleshooting and replacement.
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Troubleshooting:
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Diagnostic charts for common starting issues, performance problems, electrical faults, and drive system anomalies.
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Illustrations Diagrams:
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Detailed illustrations, exploded diagrams, drawings, and photos for all service procedures.
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Technical Depth
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Technical Depth:
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Comprehensive, covering from basic maintenance to complete engine rebuilds and advanced electrical diagnostics.
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Notes Cautions Warnings:
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Inclusion of notes, cautions, and warnings throughout each chapter to highlight critical service information.
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Engine Specifications
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Primary Engine 600
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Engine Type 600:
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Rotax 600 HO (High Output) SDI (Selectable Ignition Delay)
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Engine Configuration 600:
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Liquid-cooled, 2-stroke, parallel-twin
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Displacement 600:
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597.1 cc
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Bore X Stroke 600:
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72 mm x 73 mm
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Fuel System 600:
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Electronic Fuel Injection (EFI) with Throttle Body Injection (TBI)
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Primary Engine 800
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Engine Type 800:
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Rotax 800R Power TEK
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Engine Configuration 800:
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Liquid-cooled, 2-stroke, parallel-twin
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Displacement 800:
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799.4 cc
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Bore X Stroke 800:
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82 mm x 75.7 mm
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Fuel System 800:
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Electronic Fuel Injection (EFI) with Throttle Body Injection (TBI)
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Primary Engine 500
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Engine Type 500:
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Rotax 500SS
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Engine Configuration 500:
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Liquid-cooled, 2-stroke, parallel-twin
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Displacement 500:
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499.3 cc
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Bore X Stroke 500:
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70 mm x 64 mm
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Fuel System 500:
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Carbureted (2 x Mikuni TM40)
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Performance
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Horsepower 600 Ho Sdi:
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~120 hp (estimated)
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Horsepower 800R Powertek:
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~151 hp (estimated)
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Horsepower 500Ss:
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~107 hp (estimated)
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Maintenance
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Service Intervals
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Initial Break In:
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Specific break-in procedure recommended for new engines (typically involves varying RPMs and avoiding prolonged high RPMs).
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Track Tension Check:
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Check and adjust track tension every 500 miles or annually.
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Chaincase Oil Change:
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Every 1,000 miles or annually.
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Clutch Inspection:
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Inspect clutches annually for wear, damage, and proper operation. Service as needed.
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Fluid Specifications
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Coolant Type:
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Ethylene glycol-based antifreeze (e.g., XPS Antifreeze/Coolant)
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Coolant Ratio:
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50/50 mix of antifreeze and distilled water.
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2-Stroke Oil:
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Premium 2-stroke synthetic oil (e.g., XPS Synthetic Blend Oil).
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Known Issues
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Carburetor Icing:
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Potential for icing on carbureted models (500SS) in very cold, humid conditions. Manual likely details countermeasures.
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Electrical Connections:
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As with many vehicles of this era, checking for corrosion and secure connections in electrical components is good practice.
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