Covered Models:
Summit (Freeride, X E-TEC 800R 163, X E-TEC 800R 154, X E-TEC 800R 146, Everest E-TEC 800R, Everest 800R Power T.E.K. 163, SP, Everest 800R Power T.E.K. 154, X E-TEC 600 H.O., Everest 800R Power T.E.K. 146, Everest E-TEC 600 H.O., Sport), Expedition (SE E-TEC 600 H.O., LE E-TEC 600 H.O.), GSX (LE E-TEC 600 H.O., SE), Grand Touring (LE E-TEC 600 H.O., Sport 600), MX Z (X-RS E-TEC 800R, X E-TEC 800R, TNT E-TEC 800R, X-RS E-TEC 600 H.O., X E-TEC 600 H.O., TNT 800R Power T.E.K., TNT E-TEC 600 H.O., TNT 600, Sport 600), Renegade (Backcountry X E-TEC 800R, Backcountry E-TEC 800R, Backcountry X E-TEC 600 H.O., Backcountry 800R Power T.E.K., X E-TEC 600 H.O., X E-TEC 800R, Adrenaline 800R Power T.E.K., Adrenaline E-TEC 800R, Backcountry E-TEC 600 H.O., Adrenaline E-TEC 600 H.O.)
Engine Variants Covered:
Rotax 800R E-TEC, Rotax 600 H.O. E-TEC, Rotax 800R Power T.E.K., Rotax 600
Estimated Pages:
N/A (Electronic format, interactive)
Type:
Electronic Repair Manual (Interactive Program)
Primary Format:
Proprietary Executable Program (self-running)
Secondary Format Option:
PDF (generatable)
Engine:
Complete Overhaul, Tuning, Diagnosis, Internal Components (pistons, rings, valves, crankshaft, connecting rods), Cylinder Head, Block, Timing
Fuel System:
Fuel pump, injectors, fuel lines, fuel tank, carburetor (if applicable to specific models), fuel filter replacement, fuel pressure testing
Lubrication:
Oil pump, oil passages, oil filter, oil type and capacity specifications, lubrication points
Cooling System:
Radiator, coolant type and capacity, water pump, thermostat, cooling fan, hoses, pressure testing
Combustion System:
Spark plugs, ignition system, timing, combustion chamber analysis, emissions control
Steering System:
Handlebars, steering post, tie rods, ski alignment, steering linkage, bushings
Transmission Drivetrain:
Primary clutch, secondary clutch, drive belt inspection and replacement, chaincase, gears, bearings, lubrication
Power Train:
Engine to transmission interface, drive axle, track system components, suspension linkages
Body:
Body panels, fairings, seat, storage compartments, decals, mounting hardware
Brakes:
Brake calipers, master cylinder, brake lines, brake fluid, brake pads, rotor inspection and replacement, parking brake
Exhaust System:
Exhaust manifold, muffler, exhaust pipe, gaskets, mounting hardware
Electrical System:
Battery, charging system (stator, rectifier/regulator), starter motor, lighting (headlight, taillight, brake light), ignition switch, wiring harnesses, fuses, relays, ECUs, diagnostic connectors
Suspension:
Front ski suspension (shocks, springs, control arms), Rear suspension (shocks, springs, trailing arms, skid frame), bearings, lubrication points
Track System:
Track inspection, tension adjustment, drive sprockets, idler wheels, bogie wheels, lubrication
Maintenance:
Routine checks, lubrication schedules, filter replacements (air, oil, fuel), spark plug replacement, battery maintenance, track tension adjustment, brake pad replacement, drive belt inspection and replacement
Troubleshooting:
Diagnostic procedures for common issues, fault code interpretation (for E-TEC models), step-by-step guides for identifying and resolving problems across all systems
Repair Disassembly Assembly:
Detailed instructions for engine removal and installation, transmission disassembly and reassembly, clutch servicing, suspension component replacement, brake caliper rebuild, electrical component replacement
Tuning Adjustment:
Clutch calibration, suspension adjustments, engine tuning parameters (where applicable), idle speed adjustment
Inspections:
Pre-ride inspections, seasonal maintenance checks, wear component inspections (bearings, bushings, control arms)
Depth:
Comprehensive (from basic maintenance to complete engine and drivetrain rebuilds)
Diagnostic Capabilities:
Advanced diagnostic procedures, including electrical system troubleshooting and component testing
Visual Aids:
High-definition text, images, exploded parts views, and electrical diagrams
Interactivity:
Fully interactive page flipping, zoom functionality, and powerful search feature
Break In Period:
Specific break-in procedures for new engines and clutches are detailed.
Annual Service:
Recommended annual service includes checking all fluids, inspecting drive belt, clutch service, checking suspension components, and battery maintenance.
Clutch Service:
Clutch inspection and cleaning recommended every 1000 miles or annually. Roller and bushing lubrication is critical.
Coolant:
Proprietary blend of antifreeze and water, specific capacity listed per model. Typically a 50/50 mix.
Chaincase Oil:
Specific synthetic gear lubricant, capacity approx. 150 ml (0.16 US qt).
Brake Fluid:
DOT 4 brake fluid.
E-Tec Oil Consumption:
E-TEC models can consume oil as part of their operation; the manual details normal consumption rates and troubleshooting for excessive use.
Clutch Wear:
Regular inspection of clutch buttons, rollers, and springs is essential to prevent premature wear or failure.
Suspension Bushings:
Wear on suspension bushings can lead to alignment issues and imprecise handling; manual provides inspection and replacement procedures.