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Yamaha MM600D, Manual

The Yamaha MM600D Service Manual is a comprehensive user manual for your MM600D model, containing detailed instructions, diagrams, and troubleshooting techniques. Easily accessible for free download at manualshive.com, this manual ensures you have all the information you need to maximize the performance of your Yamaha MM600D.

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ELECTRICAL SYSTEM 

159 

5.  Remove the right handlebar switch assembly. 

6. 

Installation  the reverse of the preceding steps. 

Main Switch 

The main switch (Figure 

34) is mounted on the center 

cover. 

1.  Remove the rear handlebar cover. 

2. 

Remove the center cover. 

3. 

Disconnect the main switch electrical connector and 

remove the main switch. 

Installation is the reverse of the preceding steps. 

Carburetor Switch 

Refer to Throttle Override System in this chapter. 

Throttle Switch 

Refer to Throttle Override 

System in this chapter. 

INSTRUMENT PANEL 

WARNING LIGHT CHECK 

The instrument panel (Figure 

35)  is equipped with a 

water temperature warning light and an oil level warning 
light. 

The  water temperature light comes on  when  coolant 

temperature reaches 

If this light comes 

on while riding, stop the engine and allow it to cool before 
restarting. 

The oil level light comes on when the oil level in the oil 

tank 

is low. Do not ride the snowmobile until the oil tank 

is filled. 

Warning Light Check 

The water temperature and oil level warning lights can 

be checked for proper operation. 

When the main switch is turned on, the warning lights 

on the instrument panel (Figure 35) should 

turn 

on. After 

a few seconds, the warning lights should turn off. Interpret 
these results as follows: 
1. 

If a warning light did not come on after the main switch 

was turned on, check the warning light bulbs 

as 

described 

in  this  chapter. If  the  bulb is good,  check  the  oil  level 
gauge or thermoswitch as described in this chapter. 
2.  If the water temperature warning light stayed on and 

the  engine  shows  no  sign  of  overheating,  check  the 
thermoswitch as described in this chapter. 

3.  If the oil level warning light stayed on and the oil 

tank 

is full, check the oil level sender as described in this chap- 
ter. 

FUEL LEVEL SENDER 

All models are equipped with an electrical fuel gauge. 

The fuel gauge is connected to a fuel level sender (A, Fig- 
ure 36) located 

in 

the fuel 

tank, 

Summary of Contents for MM600D

Page 1: ...nd Tune up Engine Fuel and Exhaust Systems Electrical System Oil Injection System Cooling System Recoil Starter Drive System Brakes Chaincase Jackshaftand Front Axle Front Suspension and Steering Track and Rear Suspension Off season Storage Index Wiring Diagrams ...

Page 2: ...s 39 Fuel system 48 Testing electrica1components 39 Engine 49 Ignition system troubleshooting 40 Two strokepressure testing 53 Battery charging system Power train 56 Models with electric start 44 Skis and steering 57 Lighting system 46 Track assembly 57 Electric starting system 46 CHAPTER THREE LUBRICATION MAINTENANCE AND TUNE UP 59 Prc ride checks 59 Unscheduledmaintenance 73 Fluid checks 59 Engi...

Page 3: ...or service 127 Exhaust system repair 141 Carburetor adjustments 136 CHAPTER SIX ELECTRICALSYSTEM Battery 144 Instrument panelwarning light check 159 Capacitordischarge ignition CDI 148 Fuel level sender 159 CDI box 150 Oil level sender testing 160 Ignition coils 151 Thermoswitchtesting 160 Voltage regulator 151 Throttle override system 161 Electric startingsystem 151 Handwarmer 162 Switches 156 Li...

Page 4: ...700 VX6OOER and Jackshaft 219 VX7OOXTCD models 215 Front axle 226 Drive chain sprockets and gears VT6OO VT7OO VX600ER and X700XTCD models 218 CHAPTER THIRTEEN FRONT SUSPENSION AND STEERING 233 Skis 233 Steering system 244 Shockabsorber 241 Steering adjustment 247 Handlebar and grips 242 CHAPTER FOURTEEN TRACK AND REAR SUSPENSION 251 Rear suspension 251 Shockabsorbers 254 Wear strips 252 Suspension...

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Page 6: ......

Page 7: ...que specifications Table 8 liststechnicalabbreviations Table 9 lists metric tap and drill sizes Table 10 lists decimaland metric equivalents MANUALORGANIZATION All dimensions and capacities are expressed in metric and U S standard units of measurement This chapter provides general information on shop safety tool use service fundamentals and shop supplies Thetablesat the endof the chapterincludegen...

Page 8: ... ble liquids such as gasoline or cleaning solvent 4 If welding or brazing on the vehicle remove the fuel tank carburetorandshocksto a safedistanceat least50 ft 15 m away 5 Use the correct type and size of tools to avoid damag ing fasteners 6 Keep tools clean and in goodcondition Replaceor re pair worn or damaged equipment 7 When loosening a tight fastener be guided by what would happen if the tool...

Page 9: ... more tedious and difficult service jobs performed in the home garage There are many types of chemical cleaners and solvents available for shop use Most are poisonousand extremely flamma ble Topreventchemicalexposure vaporbuildup fireand serious injury observe each product warning label and note the following 1 Read and observe the entire product label before using any chemical Always know what ty...

Page 10: ...cause before tightening with a wrench The length L Figure 4 diameter D and distancebe tween thread crests pitch T classify metric screws and bolts A typical bolt may be identified by the numbers 8 1 25 X 130 This indicates the bolt has diameter of 8 mm The distance between thread crests is 1 25 mm and the length is 130 mm Always measure bolt length as shown in Figure 5 to avoid purchasing replacem...

Page 11: ...rking loose Washers can be used as spacers and seals or to help distribute fastener load and to prevent the fas tener from damaging the component As with fasteners when replacing washers make sure the replacementwashers are of the same design and qual ity Cotter Pins A cotter pin is a split metal pin inserted into a hole or slot to preventa fastenerfrom loosening In certain appli cations the faste...

Page 12: ...se lubricatingthe crankshaftand lower end of the connectingrods The rest of the oil enters the combustionchamber to lubricate the piston rings and cylinder walls This oil is burned during the combustion process then expelled with the engine s exhaust Engine oil must have several special qualities to work well in a 2 stroke snowmobileengine The oil must func tion properlyin the highoperatingtempera...

Page 13: ...ids or in systems for which it was not designed Mixing DOT 5 fluid with other fluids may cause brake system failure When adding brake fluid only use the fluid recommended by the manufacturer Brake fluid will damage any plastic painted or plated surface it contacts Use extreme care when working with brake fluid and remove any spills immediatelywith soap and water Hydraulic brake systems require cle...

Page 14: ...ese holes Assemble and tighten the fasteners to the specified torque within the time frame recommended by the RTV sealant manufacturer Gasket Remover Aerosolgasket removercan help removestubborn gas kets This product can speed up the removal process and preventdamage to the mating surface that may be caused by using a scraping tool Most of these types of products are very caustic Follow the gasket...

Page 15: ...chance of the tool slipping The box end wrenchis designed with either a 6 or 12 pointopening For stubborn or damagedfasten ers the 6 point provides superior holding ability by con tactingthe fasteneracrossa widerareaatall sixedges For generaluse the 12 point works well It allows the wrench to be removed and reinstalled without moving the handle over such a wide arc Anopen endwrenchisfast and works...

Page 16: ...nd installation Impact Driver An impactdriver provides extra forcefor removingfas teners by convertingthe impact of a hammer into a turn ing motion This makes it possible to remove stubborn fasteners without damaging them Impact drivers and in terchangeable bits Figure 15 are available from most tool suppliers When using a socket with an impactdriver make sure the socket is designedfor impact use ...

Page 17: ...ft lb In this example although the torquewrench is pre set to 16 5 ft lb the actualtorque is 20 ft lb Pliers Torque Adapters Torque adapters or extensions extend or reduce the reach of a torque wrench The torque adapter shown in Figure 18 is used to tighten a fastener that cannot be reached due to the size of the torque wrench head drive and socket If a torqueadapterchanges the effectivelever leng...

Page 18: ...hem Also the snap ring plier tips may break Always wear eye pro tection when using snap ring pliers Hammers Various types of hammers Figure 23 are available to fit a number of applications A ball peen hammer is used tostrikeanothertool such as a punchor chisel Soft faced hammers are requiredwhen a metal object mustbe struck withoutdamagingit Neveruse a metal faced hammeron engineand suspensioncomp...

Page 19: ...ry according to the ex perience of the person performing the procedure Accu rate results are only possible if the mechanic possesses a feel for using the tool Heavy handed use of measuring tools produces less accurate results than if the tool is grasped gently by the fingertips so the point at which the tool contacts the object is easily felt This feel for the equipmentproducesmore accurate measur...

Page 20: ...micrometer Theoutsidemicrometeris used to measure the outside diameter of cylindrical forms and the thickness of materials A micrometer s size indicates the minimum and maxi mum size of a part that it can measure The usual sizes Figure27 are0 1 in 0 25mm 1 2in 25 50mm 2 3 in 50 75 mm and 3 4 in 75 100mm Micrometersthat cover a wider range of measurement are available These use a large frame with i...

Page 21: ...If a thimble mark doesnot align exactly with the sleeveline estimatethe amountbetween the lines For accurate readings in ten thousandthsof an inch 0 0001 in use a vernierinch micrometer 4 Add the readingsfrom Steps 1 3 Vernier inch micrometer A vernier inch micrometer is accurate to ten thousandth of an inch or 0 0001 in It has the same ...

Page 22: ...rform the followingsteps while referringto Figure 31 1 Read themicrometerinthesameway asa standardmi crometer This is the initial reading 2 If a thimble mark aligns exactly with the sleeve line reading the vernier scale is not necessary If they do not align read the vernier scale in Step 3 3 Determine which vernier scale mark aligns with one thimble mark The vernierscale number is the amount in te...

Page 23: ...Sleeve Thimble 1 Largest number visible on the sleeve line 0 100 in 2 Number on sleevemarks visible between the numbered sleeve mark and the thimble edge 0 050 in 3 Thimbleis between 0 018 and 0 019 in on the sleeve line 0 018 in Vernier line coinciding with thimble line in Total reading 0 1683 in ...

Page 24: ...ier micrometer Figure 34 is accurate to two thousandths of a millimeter 0 002 mm It has the same markings as a standard metric micrometer with the addition of a vernier scale on the sleeve The vernier scale consists of five lines marked 0 2 4 6 and 8 These lines run parallel to the thimble lines and represent 0 002 mm increments When readinga metric verniermicrometer refer to Fig ure 35 and perfor...

Page 25: ...rks do not align the micrometeris out of adjustment c Followthe manufacturer s instructionsto adjustthe micrometer 1 Store micrometersin protectivecases or separate pad ded drawers in a toolbox 2 When instorage make sure the spindleand anvilfaces do not contact each other or another object If they do temperaturechanges and corrosion may damage the con tact faces 3 Do not clean a micrometer with co...

Page 26: ...able post in position Re movethe gauge and measurethe lengthof the posts Tele scoping gauges are typically used to measure cylinder bores To use a small boregauge select the correctsize gauge for the bore Carefully insert the gauge into the bore Tighten the knurled end of the gauge to carefullyexpand the gauge fingers to the limit within the bore Do not overtighten the gauge as there is no built i...

Page 27: ...ression gauge Figure 42 measures combus tionchamber cylinder pressure usuallyinpsi orkg cm2 The gauge adapter is either inserted or screwed into the spark plug hole to obtain the reading Disable the engine so it does not start and hold the throttle in the wide open position when performing a compressiontest An engine that does not have adequate compressioncannot be prop erly tuned See Chapter Thre...

Page 28: ...rnatoroutput is an example of AC voltage This voltagemust be changed or rectifiedtodirect current to operate in a battery poweredsystem Measuring voltage Unless otherwise specified perform all voltage tests with the electricalconnectorsattached Whenmeasuringvoltage selecta meterrangeone scale higher than the expected voltage of the circuit to prevent damage to the meter To determine the actual vol...

Page 29: ...h tempera lures may indicate high resistance readings and result in the unnecessary replacementof a component Measuringresistance and continuitytesting CAUTION Only use an ohmmeter on a circuit that has no voltage present The meter will be dam aged if it is connected to a live circuit An analog meter mustbecalibrated each time it is used or the scale i s changed See Multimeter in this chapter A co...

Page 30: ...ageor cor rosion Keep gasolineandotherchemicalsoff paintedsur faces 6 Use penetratingoil on frozen or tight bolts Avoid us ing heat where possible Heat can warp melt or affect the temperof parts Heat also damages the finishof paint and plastics 7 When a part is a press fit or requires a special tool for removal the informationor typeof tool is identifiedin the text Otherwise if a part is difficult...

Page 31: ...minutes Rap the fastener several times with a small hammer Do not hit it hard enough to cause damage Reapply the penetratingoil if necessary For frozen screws apply penetrating oil as described then insert a screwdriverin the slot and rap the top of the screwdriver with a hammer This loosens the rust so the screw can be removed in the normal way If the screw head is toodamaged to use thismethod gr...

Page 32: ...on 9 Remove the stud removal tool or the two nuts Removing Hoses When removingstubbornhoses do not exert excessive force on the hose or fitting Remove the hose clamp and carefully insert a small screwdriveror pick tool between the fitting and hose Apply a spray lubricant under the hose and carefullytwist the hose off the fitting Clean the Bearing puller Spacer Shaft Bearing fitting of any corrosio...

Page 33: ...l is with a hydrau lic press Note the following when using a press a Always support the inner and outer bearing races with a suitable size wooden or aluminum spacer ring Figure 54 If only the outer race is supported pressure applied against the balls and or the inner race will damage them b Always make sure the press ram Figure 54 aligns with the center of the shaft If the ram is not cen tered it ...

Page 34: ...l temperature rises to approximately 120 C 248º F remove the bearing from the pot and quicklyinstallit If necessary placea socketon the inner bearingraceandtap thehearinginto place As the bearing chills it will tighten on the shaft so installation must be done quickly Make sure the bearing is installedcompletely 2 Follow this step when installinga bearingin a housing Bearingsare generallyinstalled...

Page 35: ...gure 58 Do not install new bear ings by driving on the inner bearingrace Install the bearing s until it seats completely Seal Replacement Seals Figure 59 are used to contain oil water grease or combustion gasses in a housing or shaft Improper re moval ofa sealcan damagethe housingor shaft Improper installation of the seal can damage the seal Note the fol lowing 1 Prying is generally the easiest an...

Page 36: ...tions Close the belt guard after inspecting the belt Make sure the belt guard mounts are not loose or damaged 11 While the engine shroud is open visually inspect all hoses fittings and parts for looseness or damage Cheek the tightnessof all bolts and nuts Tighten as required 12 Check the handlebar and steering components for loosenessor damage Do not ride the vehicleif any steer ing componentis da...

Page 37: ... If possible repair the snowmobile in order to drive to safety Conserve energy and stay warm 2 Keep handsand feet active to promote circulationand avoid frostbite while servicing the machine 3 Mentally retrace your route Where was the last point where helpcould be located Do not attemptto walk long distances in deep snow Make yourself comfortable until help arrives 4 If the right equipment is on h...

Page 38: ...000 MM600 593 VT600 593 VX600 593 VX600SX 593 MM700 698 VT700 698 VX700 698 VX700SX 698 2001 and 2002 MM600 593 SX600 593 VT600 593 VX600 593 MM700 698 SX700 2001only 698 VT700 698 VX700 698 Yamaha designates model year by including a suffix letter in the model number For instance a unit with model number VT700B would indicate it is a1998 model The mode year suffix letters are as follows A 1997 B ...

Page 39: ... 307 121 VX700SX 307 121 2000 MM600 358 141 VT600 345 136 VX600 307 121 VX600SX 307 121 MM700 VT700 345 136 VX700 307 121 VX700SX 307 121 2001and 2002 MM600 358 141 SX600 307 121 VT600 345 136 VX600 307 121 MM700 358 141 SX700 2001 only 307 121 VT700 345 136 VX700 307 121 Table 3 VEHICLE WIDTH Model cm in 1997 MM700 116 45 5 VX700SX 116 45 9 1998 MM700 116 45 5 VT700 120 47 2 VX700SX 117 46 1 VX70...

Page 40: ...X 117 46 1 2001 and 2002 MM600 111 43 8 SX600 117 46 1 VT600 120 47 2 VX600 120 47 2 MM700 111 43 8 SX700 2001 only 117 46 1 VT700 120 47 2 VX700 120 47 2 Table 4 VEHICLE HEIGHT Model cm in 1997 MM700 119 46 7 VX700SX 108 42 7 1998 MM700 119 46 7 VT700 130 51 2 VX700SX 108 42 7 VX700SXS 108 42 7 VX700XT 123 48 4 VX700XTC 123 48 4 VX700XTCD 130 51 2 VX700XTCP 123 48 4 1999 VT600 130 51 2 VX600ER 13...

Page 41: ...TION 35 Table 4 VEHICLE HEIGHT continued 1 Model cm in 2000 MM600 VT600 VX600 VX600SX MM700 VT700 VX700 VX700SX 2001 and2002 MM600 SX600 VT600 VX600 MM700 SX700 2001 only VT700 VX700 Table 5 VEHICLE WEIGHT Model kg Ib ...

Page 42: ...6 0 5625 14 28750 37 64 0 578125 14 68437 19 32 0 59375 15 08125 39 64 0 609375 15 47812 5 8 0 625 15 87500 41 64 0 640625 16 271 87 21 32 0 65625 16 66875 43 64 0 671875 17 06562 11 16 0 6875 17 46250 45 64 0 703125 17 85937 23132 0 71875 18 25625 47 64 0 734375 18 65312 3 4 0 750 19 05000 49 64 0 765625 19 44687 25 32 0 78125 19 84375 51 64 0 796875 20 24062 13116 0 81 25 20 63750 53 64 0 828125...

Page 43: ... 8 32 Fahrenheit Weight Ounces 28 3495 Grams Pounds 0 4535924 Kilograms Grams 0 035274 Ounces Kilograms 2 2046224 Pounds Pressure Pounds per square inch 0 070307 Kilograms per square centimeter Kilograms per square 14 223343 Pounds per squareinch centimeter Kilopascals 0 1450 Pounds per square inch Pounds per square inch 6 8 9 5 Kilopascals Speed Miles per hour 1 609344 Kilometersper hour Kilomete...

Page 44: ...er take off PtS Pints qt Quarts rPm Revolutionsper minute  TOR Throttle override system Table 10 METRIC TAP AND DRILL SIZES Metric tap Drill Decimal Nearest mm size equivalent fractian 3 X 0 50 NO 39 0 0995 3 32 3 x 0 6 0 3 32 0 0937 3 32 4 x 0 7 0 No 30 0 1285 1 8 4 x 0 7 5 1I 8 0 125 1 1 6 5 X 0 8 0 No 19 0 166 It 64 5 x 0 9 0 No 20 0 161 5 32 6 x 1 0 0 No 9 0 196 13 64 7 x 1 0 0 16 64 0 234 15...

Page 45: ...ever even with the best of care the snowmobile may require troubleshooting Electrical specificationsare listed in Tables 1 3 at the end of this chapter OPERATINGREQUIREMENTS An engine needs three basics to run properly correct airlfuelmixture compressionanda spark at the righttime Figure1 If one basic requirementis missing theengine will not run The ignitionsystem is the weakestlink of the three b...

Page 46: ...ementwithout solving the basic problem Precautions Certainmeasures must be taken to protect the capacitor discharge system Damage to the semiconductors in the system may occur if the followingis not observed 1 Do not attempt to start the engine or rotate the crank shaft if the CDI unit is not grounded to the engine 2 Do not touch or disconnect any ignition components when the engine is runningor w...

Page 47: ...amaged generatingcoil Dirty wiring connection Damaged ignition coil Engine misfires at high speed Check See Enginemisfiresatidle Coil breaks down Coil shorts through insulation Spark plug gap too wide Incorrect spark plug heat range Incorrect ignition timing Engine backfiresthrough exhaust Incorrect spark plug heat range Burnedspark plug electrodes Check Enginepreignition I Cracked spark plug insu...

Page 48: ...debris that has accumulated next to the spark plug base The debris could fall into thecylinder when theplugis removed caus ing serious engine damage 1 Removeall spark plugs keepingthem in order Check the condition of each plug See Chapter Three Replace fouled or damaged spark plugs as required WARiVING During this test do not hold the spark plug wireor connector by hand or a serious elec trical sh...

Page 49: ...ws a If necessary switch the ohmmeter to the R X 1 scale b Measureresistance between the two primary termi nalsusingan accurateohmmeter Refer toFigure 7 c Compare the measured resistance with the specifi cations listed in Table 1 d Disconnect the meter leads 4 Check ignition coil secondary resistanceas follows a Remove the spark plug cap from the end of each high tensioncable b If necessary switch...

Page 50: ...ace the stator assembly as describedin Chapter Six 5 Connectan ohmmeterbetween the brown redwire ter minal in the triangularconnectorand the black wiretermi nal in the rectangularconnector from the ignition pickup coil Figure10 6 Comparethe reading to the specificationin Table 1 If the reading is not within specifications replace the stator assemblyas described in ChapterSix 7 Reattachthe connecto...

Page 51: ...rminaland thepositivevoltmeterlead to the pos itive battery terminal See Figure 12 5 Start the engine Gradually increase engine speed to 3000 rpm and note the voltmeter reading The correct reading is 13 3 14 3 volts If meter reading is less than specified check the charging coil resistance as described in this chapter If the charging coil resistance is correct and chargingsystem troublesremain the...

Page 52: ...in Table3 If the reading is not within specifications perform the Lighting C o i lResistance Test in this chapter Lighting Coil Resistance Test The lightingcoil is located in the stator 1 Open the shroud 2 Disconnectthe rectangularsix wire connectorlocated near the CDI box 3 Connect an ohmmeter between the yellow and black wire terminalsfrom the lightingcoil Figure 16 4 Compare the reading to the ...

Page 53: ...rforming the following tests make sure to conned the test leads properly 1 Open the shroud 2 Locate the batteryin the enginecompartmentand iden tify the positive and negative battery cables CAUTION Do not leave the jumper cable installed in Step 3 connected more than a few seconds Excessive use of the cable may cause addi tional damage to the starting system WAR VING Because sparks may be produced...

Page 54: ...stem troubleshooting at the gas tank and work through the system reserving the carburetor as the final point Most fuel system problems result from an empty fueltank a plugged fuel filter malfunctioningfuel pump or sour fuel Figure 20 provides a series of syrnp toms and causes that can be useful in localizing fuel sys tern problems Carburetorstarting enrichment valves can also present problems A st...

Page 55: ...ature burning of fuel and is caused by hot spots in the combustion chamber Figure 21 The fuel actually ignites before it should Glowing deposits in the combustion chamber inadequate cooling or overheated spark plugs can all cause preignition This is first noticed in the form of a power loss but eventually results in extendeddamage to the internal parts of the en gine because of higher combustion c...

Page 56: ...loat level Incorrect carburetoradjustment Flooding carburetor Flooding at carburetor 1 Engine starts but stops immedeiatelv Check Excessive fuel pump pressure Damaged fuel inlet valve Dirty fuel inlet valve Check Incorrect starter valveadjustment Incorrect use of starter valve Clogged fuel filter screen Clogged or damaged fuel line Clogged or leaking pulse line Clogged vent line Damagedfuel pump D...

Page 57: ...arburetormixture Engine backfires I Check Incorrect spark plug heat range Fuel mixture too rich Incorrect carburetoradjustment Poor quality fuel Check Poor quality fuel Air fuel mixture too lean Incorrect carburetoradjustment High gas consumption I Check Incorrect carburetoradjustment Clogged exhaust system Loose inlet seat Defective inlet seat gasket Worn fuel inlet valve Leaks at fuel line conne...

Page 58: ...ursnear top of stroke rect ignition timing which can result in a power loss Preignition or detonationalso causes a power loss A galling piston or cylinder incorrect piston clearance or worn or sticky piston rings may be responsible Look for loose bolts defective gaskets or leaking mating snr faces on the cylinder head cylinder or crankcase Also check the crankshaft seals Refer to Two Stroke Pressu...

Page 59: ...on is impossible Any other source of leakage such as porous or cracked crankcase castings results in the same conditions It is possible to test for and isolate engine crankcase leaks The test issimplebut requiresspecialequipment A typical two stroke pressuretest kit is shown in Figure27 Pressure testing requires plugging all engine openings then applyingair pressure If the enginedoes not hold air ...

Page 60: ...not open fully Clogged high speed nozzle Clogged pulse line Leaking pulse line Insufficient fuel supply Faulty fuel pump Check See Ignition system trouble See Fuelsystem trouble Incorrect ignition timing Excessive carbon buildup in combustion chamber Incorrect fuelloil mixture Incorrect oil type Incorrect fuel type Incorrect carburetoradjustment Clogged or leakingcooling system water line Cloggedf...

Page 61: ...t range Execessivecarbonbuildupin combustionchamber Incorrect fuel oilmixtureratio Poor quality fuel Abnormalnoiseduringengine idle with a coldengine Check Excessivepistonclearance Excessivepistonring wear Excessive piston skirt wear Bent or damaged connecting rod Abnormal noise during suddenacceleration Check Excessive piston pin clearance Excessiveclearanceat the connecting rod upper end Excessi...

Page 62: ... speed too high 2 Incorrect sheave distance 3 Incorrect belt length Drive Belt Edge Cord Failure 1 Misaligned primary and secondary sheaves 2 Loose engine mounts Brake Not Holding Properly 1 Incorrect brake cable adjustment 2 Worn brake pads 3 Worn brake disc 4 Oil saturated brake pads 5 Sheared key on brake disc 6 Incorrect brake adjustment 7 Air in hydraulic brake lines Brake Not Releasing Prope...

Page 63: ...lfunction Loose Steering 1 Loose steering post bearing 2 Loose steering post or steeringcolumn fasteners 3 Loose tie rod ends 1 Improperlyadjusted tie rods 2 Improperlyinstalled steering arms 3 Damaged steering components Rapid Ski Wear 1 Skis misaligned 2 Worn out ski wear rods skags TRACK ASSEMBLY The followingitems providea startingpoint to trouble shoot track assembly malfunctions Also refer t...

Page 64: ...ngcoil resistance MM600 MM700 later SX600 0 31 0 37 ohms MM700 early SX700 VX7OOSX 0 32 0 40 ohms VT OO VX650 0 29 0 35 ohms VT700 0 28 0 34 ohms VX7OOmBTCBTCD XTCP SXS 0 28 0 34 ohms Table 3 LIGHTING SYSTEM TEST SPECIFICATIOHS Lighting coil voltage min Lighting coll resistance 11 volts at 3000 rpm 0 255 0 31 3 ohms ...

Page 65: ...e listed in Tables 1 3 Recom mended lubricantsand fuels are listed in Table 4 Tables 1 18 are at the end of this chapter FRE RIDE CHECKS Check the machine before each ride Refer to Chapter One FLUIDCHECKS Check vital fluids daily or before each ride to ensure proper operation and prevent excessive component dam age Refer to Table 1 BREAK IF PROCEDURE Follom7ing cylinder servicing boring honing or ...

Page 66: ... ame Do not smoke vhile mkingfuel 1 Mix the oil with the gasoline in a well ventilatedloca tion The oil temperabre should be at least 20ÂC 68O F before attempting to mix the oil and gasoline 2 Mix the oil and gasoline thoroughly in a separate dean scalable container that is larger than the quantity being mixed to allow for agitation 3 Always measure quantities exactly For a 50 lgaso line to oil mi...

Page 67: ...he pilot lamp lights Add oil as soon as possible when the low oil pilot light comes on When the oil level is low perform the following I Open the hood 2 Removethe oil tank fill cap Figure I and pourin the required amount of Yamalube 2 cycle Oil or equivalent Fill the tank until the oil level is up to the full markon the transparenttank 3 Reinstall the fill cap and close the hood Chaincase Oil Oil ...

Page 68: ...cess grease from the fitting and spindle Repeat the procedure for the spindle on the other side of the snowmobile Slide Suspension Lubricatetbe slidesuspensionseasonallyor every2000 miles with a low tempemwe grease at each of the grease fittings shown in Figure 6 If operating the sno vmobile under severe conditions or in wet snow lubricate the fit tings more ofien NOTE l f is not Recessmy to remov...

Page 69: ... reinstall the steering column Control Cable Ends Periodically lubricate the throttle and oil control cable ends and pockets in the throttle lever Figure 9 with a low temperature grease Periodically lubricate the park ing brake control cable end at the parking brake lever Figure 10 with a low temperaturegrease NOTE Yamaha does not recommend lubricating control cables to prevent possible cable maIf...

Page 70: ...the side ofthemastercylinder A Figure12 Thefluidlevel must be no lower than the mark B on the side of the master cylinder 3 If the fluid level is lower than the mark add DOT 4 brake fluid to the master cylinder as follows a Wipeoffthe master cylindercoverwith aclean rag b Remove the screws holding the cover to the master cylinder and remove the cover C Figure 12 and diaphragm c Add DOT 4 brake flu...

Page 71: ...fraying or kinking Replace the cable assembly if any inner cable strands are broken 4 Check the cables for improper routing kinking or other damage Make sure the cables enter the metal cable receptaclesproperly 5 Withthe cables connectedto the throttlelever turn the handlebar from side to side whilechecking the cables for incorrect routing or other conditions that could cause the throttle lever to...

Page 72: ...the fuel filter and if dirty or damaged installa new filter Make sure the filter is securely clamped to the intake tube 3 Reinstall the fuel tank Hose and Cable Inspection Check all hoses and cables monthly and seasonallyfor wearor damage Also check for proper routing When in stallingnewhosesorwhenreconnectinghoses makesure hoseendscan bottomcompletelyon theirfittings Thisal lows proper installati...

Page 73: ...the limiterstrap bolts for tightness Replacedamagedlimiter straps as required See Chapter Fourteen Inspect the teeth on the drive sprockets for wear and damage If thesprocketsaredamaged replacethemas de scribed in Chapter Fourteen RearSuspension Rail Wear Strip Inspection Frequently inspect the wear strips C Figure 18 mounted on the bottom of the rear suspension rails Note the following 1 Visually...

Page 74: ...djust the track tension c Tighten the axle nuts securely d Recheck the adjustment as described in Step 3 and Step4 6 Checktrack aiigmentasfollowsaftersettingthe track tension Truckalignment Track alignment is related to track tension and should be checked and adjusted when the tensionis checked and adjusted If the track is misaligned the rear idler wheels drive sprocket lugs and track lugs will we...

Page 75: ... one side or the other alignment adjustment is required 5 If the trackis offsetto the right B Figure 231 tighten the right adjuster bolt and loosen the lefione Figure 21 in equal amountsuntil the track is centered If the track is offset to the Ieft C Figure 231 tighten the left adjuster bolt a d loosen the right one in equal amounts 6 Repeat Step 3 and Step 4 and if alignment is still not correct ...

Page 76: ...against moving parts or touch hot especially exhaust parts Spark Plugs Check the spark plugs periodicallyfor firing tip condi tion and gap Refer tosparkplugservice under Tune upin this chapter Cooling System All models are equipped with a closed liquid cooling system This section describes maintenance procedures for the cooling system Coola t level Check the coolant level at the beginningof each r...

Page 77: ...your urea Cuolanfchange Completely drain and refill the cooling system once a year CAUTION Use onlya high qzdulityethyleneglycol anti freeze specz cully lubeled for use with ah minumengines Do not mean uleohol bused atzt reeze Perform the following procedure when the engine is cold CAurro w Do not spill u tfreeze on painted surfaces becaz seif will dam ge the suduce Wash immediately with soapy wat...

Page 78: ...nd the sno vmobilewith the truck ruised and the engine running 17 Run the engine at 2500 rpm so the coolant pump cir culates coolant through the cooling system If the coolant leveldrops add coolanttomaintainthecorrectlevel inthe filler neck Figure 33 When the coolant level stabilizes stop the engine and lower the track to the ground Install the coolant cap 18 Fill the reservoir tank to the full ma...

Page 79: ...ngine UNSCHEDULED MAINTENANCE Check the following service items frequently and ser vice as required Engine Mounts and Fasteners Loose engine mount bolts cause incorrect drive belt alignment Check the engine mountingbolts to make sure they are all tight Refer to Chapter Four If the engine mountsare loose checkthe clutch alignmentas described in Chapter Ten Body Inspection Repair or replace damaged ...

Page 80: ...n rings and head gasket It is a good idea to check compressionat each tune up record the compression of each cylinder then compare the current compression with test results from earlier tune ups The first step is to record the mea sured compressionof each cylinder and the date so it can be compared with tests recorded at the next tune up A gradual change may indicate normal wear or may help in spo...

Page 81: ...plug base NOTE Ifthe plug is difficultto remove applypene trating oil like WD 40 or Liquid Wrench around the base of the plug and let it soak I f the plug is still difficult to remove apply penetrating oil and let it soak into the threads again 3 Remove the spark plug with a 14 mm spark plug wrench 4 Inspect the plug carefully Look for a broken center porcelain excessively eroded electrodes and ex...

Page 82: ...76 CHAPTERTHREE 63 SPARK PLUG CONDITIONS OIL FOULED CARBON FOULED OVERHEATED GAP BRIDGED SUSTAINED PREIGNITION WORN OUT ...

Page 83: ...examina tion of the spark plug Refer to Figure35 Normal condition If the plug has a light tan or gray colored deposit and no abnormal gap wear or erosion good engine earbure tion and ignition conditionare indicated This plug is the proper heat range and may be serviced and returned to use Carbon fouled Soft dry sooty deposits covering the entire firing end of the plug are evidence of incomplete co...

Page 84: ...trodes and premature gap wear are signs of overheating along with a gray or white blistered porcelain insulator surface The most common cause for this condition is using a spark plug of the wrong heat range too hot If the plug has not been changed to a hot ter sparkplug and the plug isoverheated considerthe fol lowingcauses 1 Lean fuel mixture incorrect main jet or incorrect oil pump adjustment 2 ...

Page 85: ... b Loosen thejamnut A Figure 43 and rotatethead juster 3 to adjust the throttle valve height Retightenthe jam nut c Operatethe throttletwo or three times thenrecheck the valve height on all three carburetors d Reinstall the top covers 4 Reinstallthe carburetorsasdescribedin ChapterFive 5 Adjust engine idle speed as described in this section Throttle lever free play Refer to the previous section in...

Page 86: ...wmobile and check performance If theenginehesitatesduringaccelerationfroma stop rotate each pilot mixture screw slightly counterclockwise Re check engine performanceand readjust the pilot mixture screw setting as needed NOTE Operation in other than normal conditions i e extremely warm or cold weather or high altitude operation may require changing the pilot jet to obtain satisfactory low speed per...

Page 87: ...ication Take this information into account along with altitude and temperature conditions previouslymentioned NOTE It is importantto note that the followingjet ting guidelinesare guidelinesonly Individ ual adjustments vary because of altitude temperature and snow conditions Use spark plug condition as a guideline when changingjets and adjustingthe carburetor Low speed tuning Low speed operation le...

Page 88: ... needlegroove using two shims Figure51 The shims allow more pre cise tuning For instance the jet needle position may be 2 0 or 2 5dependingon the arrangementof the shims and clip 1 Referto ChapterFive and remove the throttlevalveas sembly Figure52 2 Unscrew the jet needle retaining plate screws Figure 53 and remove the jet needle 3 Note the position of the clip Figure49 and shims be fore removal R...

Page 89: ...hen the ambient temperatureis 20 F 29 C at an altitudeof 4000 fi 1219 m the recommended main jet size for the No 1 carburetor is 141 3 and 140 0 for the No 2 and 3 carburetors 2 Refer to Chapter Five for carburetor removal and in stallation Then replace the main jets as required 3 Reinstallthe carburetoras described in Chapter Five CAUTION Do not run the engine withoutthe air boxin stalled as engi...

Page 90: ... rather than turn and wander when running straight at steady throttle On the other hand if ski pressure is too heavy the ma chine tends to plow during cornering and the skis dig in during straight line running rather than staying on top of the snow Ski pressure for one snow condition is not necessarily good for another condition For instance if the surface is very hard andofferslittlesteeringtract...

Page 91: ...spring pressure rating Front Shock Absorber Damping VX700SXS Shock absorber damping is adjustable on the front shock absorbers used on model VX700SXS To change damping rotatethe adjustingknob Figure56 The stan dard setting is seven clicks out Turning the knob in in creases dampingpressure The minimum setting hard is oneclickout maximumsetting soft is sixteenclicksout CAUTION Position the adjusting...

Page 92: ...ng rate The holes in the bracket are marked A B and C Figure 60 Hole A provides the softest setting Standard setting is hole B To change the setting first look at the bracket slot and note if the bracketslot is knurled Figure61 If theslot is knurled then the bolt shaft is also knurled Turning the bolt head causes the bolt shaft to move in the slot to an other position Hold the bolt head so it cann...

Page 93: ...mounting bolts to 72 N rn 52 ft lb Table 1 DAILY MAINTENANCE SCHEDULE Check fuel tank level Check coolant level Check injection system oil level Check for cooling system leaks Check condition of the drive belt Check stop switch operation Check recoil starter operation Checkheadlight and taillight operation Check headlight and taillight lens Check steeringoperation Check steeringbolts for tightness...

Page 94: ...nd driven sheaves Check drive chain condition Check the fuel system for leaks9 damage or wear and repair as required Check fuel filter Check brake system Performcarbonremoval rocedure Replaceseais aRer every two years repfacebrakehoses after every four years or if cracked or damaged Table 4 RECOMMENDED LUBRICANTSAND FUEL Engine injection oil Chaincase Fuel Ski spindle rear suspension front suspens...

Page 95: ...l13 3 Steel 13 9 1 MM700 1997 1999 Aluminum 10 3 Steel13 3 1 MM700 2000 on Steei 10 3 Steel13 3 SX600 A uminum 10 3 Steel13 9 1 SX700 Steel10 3 Steel13 9 1 6 0 0 Steel 10 3 Steel 13 9 1 VT700 Steei 10 3 Steel17 2 OrangefPinWarange VX6OOER None Steel13 9 1 VX6OOSX Aluminum 10 3 Steel13 9 1 VX7OOSX Aluminum 10 3 Steel10 3 1 VX7OOSXS SteeI 30 3 Steel13 9 GreenPinWGreen VX7OOXT TC TCD Steel 10 3 Steel...

Page 96: ...UTCH SPECIFICATIONS 6500 10 000 FT Model Shift weight outer Shift weight inner Spring MM600 Aluminum 10 3 Steel 0 3 MM700 1997 1999 2 None None OrangelPinklOrange MM700 2000 on Aluminum10 3 AluminumlO 3 I 6 0 0 Aluminum 10 3 Aluminum10 3 PinklSilver Pink 7 0 0 None Steel13 9 GreenlGreenlGreen VT600 None Steel13 3 PinklGreenIPink 7 0 0 None Steel10 3 OrangelPinklOrange VX6OOER None Steel13 9 GreedG...

Page 97: ...e 15 CHAINCASE SPROCKET SPEClFlCATlOMS 4500 7000 FT 1 Model Upper lower sprocket number af teeth Chain links Use sea level standard specification Table 16 CHAINCASE SPROCKET SPEClFlCATlONS 6500 10 000 FT Model Upper lower sprocket number of teeth Chain links I Use sea level standard specification 2 Above 9000 ft number of sprocket teeth is 21 40 3 Above 9500 ft number of sprocket teeth is 20140 an...

Page 98: ...3 Clip Pilot jet 8200 9800ft No 1 No 2 and No 3 Clip Pilot jet No 1 carburetor isat PTO clutch end of engine No 3carburetor i sat recoil starter end of engine Table 18 MAIN JET CLIP POSITION AND PILOT JET 6S8 cc ENGINES Temperature Altitude 40ÂF 20 F OnF 20Â F 40Â F 0 300ft No 1 148 8 1 4 7 5 146 3 145 0 143 8 No 2and No 3 147 5 146 3 145 0 1 4 3 8 1 4 2 5 Clip 3 0 3 0 3 O 3 0 2 5 Pilot jet 45 0 4...

Page 99: ...NGINES continued Temperature Altitude 4OoF 2W F OoF 20Â 40 F 1700 3300ft No 1 No 2 and No 3 Clip Pilot jet 3300 5000ft No 1 No 2 and No 3 Clip Pilot jet 5000 6700ft No 1 No 2 and No 3 Clip Pilotj e t 6700 8300ft No 1 No 2 and No 3 Clip Pilot jet 8300 10 000 ft No I No 2 and No 3 Clip Pilot jet ...

Page 100: ...udying the text and illustra tions i n this chapter it can be less expensive to perform the preliminary operations and then taking the engine to the dealership Since dealerships have lengthy waiting lists for service especiallyduring the fall and winter sea son thispracticecan reduce the timea unit is in the shop If much ofthepreliminarywork isdone therepairscan be scheduledand performed much quic...

Page 101: ...One 3 Usespecialtoolswherenoted In somecases it maybe possible to perform the procedure with makeshift tools but this is not recommended Using makeshift tools can damage the components and may cause serious injury Where special snowmobile tools are required they may be purchasedthrough any Yamahadealership Other tools can be purchased throughthe dealership from a motorcy cle store or from an auto ...

Page 102: ...emove the shroud a Open the shroud b Disconnect any interferingwiring It may be neces sary todetachthe wiring from thehoodorspeedom eter cable c Disconnect the speedometercable d Disconnect the hood restrainingcable and have an assistantsupport the shroud c Removethe screws that attach the hood hinge then lift off the shroud f Set the shroud out of the way to prevent it from be ing damaged 2 If eq...

Page 103: ...ame Carry it to a workbench for fur ther disassembly ENGINE INSTALLATION 1 Degreasethe enginecompartmentand wash withclean water 2 Clean all the exposed electrical connectors with an electrical contact cleaner 3 Check all the coolant hoses and the hose connections for looseness or damage Make sure the hose clamps are tight 4 Examine the engine mounting bracket components Figure 11 Replace any dama...

Page 104: ...98 CHAPTER FOUR ENGINE MOUNTS ...

Page 105: ...he engine for inspection check the compression as described in Chapter Three before disassembly 1 If the engine is mounted in the frame perform the 61 lowing a Open the shroud b Drain the cooling system as described in Chapter Three c Disconnectthe coolanthose A Figure4 and cool ant temperatureconnector 3 4 d Disconnect the carburetor heater hose A Figure 13 from the engine e Disconnect the spark ...

Page 106: ...tlet 6 Washer 7 Seal 8 Coolant fitting 9 Nut 10 Coolant sensor 11 Washer 12 Spark plug 13 Cylinder head 14 Head gasket 15 Nut 16 Cylinder 17 Stud 18 Dowel 19 Gasket 20 Upper pistonring 21 Lower piston ring 22 Piston 23 Piston pin 24 Circlip 25 Needle bearing 26 Connectingrod ...

Page 107: ...einstallthe spark plug and makesure it can be threaded into the cylin der head completely 3 Use a straightedge and feeler gauge to measure the flatness of the cylinder head Small imperfections or slight warpage can be removed by resurfacing the cylin der head as follows a Tapea pieceof400 600 grit wet emery sandpaperto a piece of thick plate glass or surface plate Figure 18 b Slowly resurface the ...

Page 108: ...nder unless a new piston is installed 6 Rotatethe engine until the piston is at the bottom of its stroke then pull the cylinder straight up away from the piston and remove it 7 Repeat the procedure for the remainingcylinders 8 Remove the cylinder base gasket 9 Cover the openings in the crankcase around the con necting rods with clean rags to keep dirt and loose parts from entering the crankcase In...

Page 109: ...piece of 400 600 grit wet emery sandpaper onto a piece of thick plate glass or surface plate Figure 18 c Slowly resurface the cylinder by moving it in a fig ure eightpattern on the sandpaper d Rotatethe cylinderseveraltimesto avoid removing too much material from oneside e Reinstall the cylinder head studs as described in Chapter One 11 After servicing the cylinder wash the bore with hot soapywate...

Page 110: ...ightenthe cylinder retaining nuts in a crossingpattern to 28 N m 20 ft lb 9 Install the carburetor assembly asdescribed in Chapter Five 10 Install the exhaust manifold onto the cylinders Tighten the exhaustmanifold retaining bolts in a crossing pattern to 27 N m 20 fi lb 11 If the engine is installedinthe frame install the muf fler and exhaust pipe as described in Chapter Five 12 Install the cylin...

Page 111: ...the piston pin does not push out by hand remove it as described in Step 6 6 If the piston pin is tight use a puller as shown in Fig ure26 Thetoolcan befabricatedas shown Assemblethe toolonto thepistonand pullthepiston pin fromthepiston Makesureto installa padbetweenthe piston and thepiece of pipe to prevent scoring the side of the piston NOTE I f the pin is left partly in the piston the pin and pi...

Page 112: ...ring and pressing equipment These special tools and technicians trained and experiencedat rebuildingthe crankshaft as sembly are not available at most service shops The manufacturer recommends re placement o f the connecting rods and crankshaft if any part other than the outer sealsor the main bearings at the ends of the crankshaft require replacement Parts for the crankshaft also may not be avail...

Page 113: ...nt of the piston look for a lean fuel mixture or over advancedignition timing e If the piston has a melted pocket starting in the crown or if there is a hole in the piston crown the engine is running too lean Incorrect jetting an air leak or over advanced ignition timing may cause this A spark plug that is too hot can also cause this type of piston damage f If the piston is seized around the skirt...

Page 114: ...oft aluminumof the piston Some rings and their grooves have the top tapered so be careful when cleaning the grooves I f the groovesaredamaged whilecleaning install a new piston 7 Carefully remove all carbon buildup from the ring grooves Inspect the piston for missing brokenor cracked ring lands Inspect the grooves carefully for cleanliness and for absenceof burrs or nicks Recondition or replace th...

Page 115: ...rt at a 90Âangle to the piston pin Figure37 typical 2 Clean the cylinder completely Wash the cylinder bore with soap and water to remove oil and carbon particles Thoroughlyclean the cylinderbore beforeattemptingany measurement to prevent inaccurate readings caused by debris 3 Measure the cylinder bore with a bore gauge or tele scoping gauge Figure 38 Then measurethe bore gauge or telescoping gauge...

Page 116: ...n marked to indicate their original cylinder location PTU MAG or CEN and the direction o f the exhaust port The manufacturer3mark arrow cast into the piston should point to the exhaust port as described in Step 4 4 Placethepistonovertheconnectingrod with thearrow cast in the top of the piston Figure 40 pointing toward the front exhaust side of the engine This is essentialso theends of thepiston ri...

Page 117: ...s of the ring carefully with your thumbs and slip the ring gently over the top of the piston 8 Makesure the ring s are free to enter the groove s all the way around the circumference and the ends are aligned with the locating pins See Figure 42 9 If new componentswere installed break in the engine as if it were new Refer to Break In Procedure in Chapter Three REED VALVE ASSEMBLY The engine is equi...

Page 118: ...e to the seat with a feelergauge Figure48 If theclearanceis 0 6 mm 0 024 in or more replace the reed petals NOTE Screw threads may be coated with Loctite and it may be necessaryto applyheat before loosening the screws 6 Remove the screws Figure 49 securingthe reed stop and reed petalsto the reed cage Be carefulthat the serew driver does not slip and damage parts 7 Carefully examine the removed par...

Page 119: ...alership for procedures that require precisionservice The specificationsand procedures that follow are pre sented to facilitate a complete step by step major lower end overhaul that can he followed when the engine is be ing completelyreconditioned Crankcase Disassembly This procedure describesdisassemblyof the crankcase halves and removal of the crankshaft 1 Removethe engine from the frame as desc...

Page 120: ...th Make sure to remove all traces of old sealer from the matingsurfaces 2 Clean all the oil passages in the crankcase then blow the passagesout with compressedair CAUTION Make sure the cleaning solvent used to clean the crankshaft is clean Ifany dirt en ters the close clearances of the bearings while cleaning it becomes difficzdt to re move and can cause bearing damage 3 Clean the crankshaftassemb...

Page 121: ...s of the coolant pump on the lower crankcasehalf Figure 59 for gouges or other damage 9 Inspect the coolant pump as described in Chapter Eight 10 If there is any doubt about the condition of the crank case halves and they cannot be repaired replace the crankcase halves as a set Crankshaft Inspection Do not remove any bearings that are pressed onto the crankshaft unless new bearings are available R...

Page 122: ...6 Key 7 Crankshaft 8 Washer 9 Connectingrod 10 Roller bearing 11 Roller bearing 12 Crankshaft 13 Bail bearing 14 Gear 15 Crankshaft 16 Crankshaft 17 Ball bearing 18 Labyrinth seal 19 Spring pin 20 Crankshaft 21 Washer 22 Crankshaft 23 Ball bearing 24 Spacer 25 Seal 26 Ball bearing 27 C ring ...

Page 123: ...lay Replacedefec tive bearings 8 Inspect the center gear Figure 64 for cracks deep scoring or excessive wear If the center gear is damaged check thegear Figure65 onthe coolantpumpand injee tion pump driveshaft for damage If one gear appears damaged while the other is in good condition replace both gears clearanceexceedsthe servicelimit specifiedin Table 2 or Table 3 replace the big end bearingand ...

Page 124: ...g cross threading or other damage Have threads repaired by a dealershipor machine shop 11 Remove thekey Figure67 and checkthe keyway in thecrankshaftforcracksorotherdamage If thekeywayis damaged refer service to a dealershipor machine shop 12 If the crankshaftexceededany of theservicelimitsor if one or more bearings are worn or damaged have the crankshaftrebuiltby a dealershipor crankshaftspeciali...

Page 125: ...e parts man ager identify each bearing and its position on the crankshaft It is critical to properly install the bearings 5 Install the roller bearing at the flywheel end of the crankshaftas follows a Clean the crankshaft main journal then coat the journal with engine oil b Lubricate the bearing with engine oil c Note the three holes in the roller bearing The blind hole A Figure 71 that stops befo...

Page 126: ...r and oil seal between the bearings f Refer to Ball BearingReplace ent in ChapterOne NOTE Heat the ball type bearings to 75 C 167 F in oil before installation Completely read Step 5 through before heating and in stalling bearings During bearing installa tion support the cranksha securely to install the bearings quickly I f a bearing cools and tightens on the crankshaft before it is completely inst...

Page 127: ...lf 5 Position the lower crankcase half over the crankshaft and the upper case half Makesurc the gearon thecoolant pump and oil injection pump driveshaft Figure 65 meshes properly with the crankshaft center gear Figure 64 6 Makesure thecase halvesclosetogetherbefore install ing the retaining screws If a gap remains between the cases make sure the bearings and locating pins are prop erly positioned ...

Page 128: ...Serviceis usuallyaccomplished in conjunction with crankshaftor crankcaseservice For completeservice of the shaft assenlbly proceed as follows driveshaft 1 Remove the lower crankcase half as described in this chapter 2 Remove the circlip 1 Figure 78 3 Push the oil pump shaft 3 Figure 78 and bearing 2 out toward the coolant pump side of the crankcase half 4 Remove the bearing 4 Figure 78 5 Inspectth...

Page 129: ...ameter 24 995 25 008 0 9841 0 9845 Large end diameter 34 020 34 033 1 3394 1 3398 Small end side play 0 8 1 O 0 03 0 04 Big end side clearance 0 25 0 75 0 010 0 030 Crankpin diameter 26 993 27 000 1 0627 1 0629 Crankshaft runout maximumy Inner bearings 0 04 0 0016 Crankshaft ends 0 03 0 0012 Cylinder head warpage max 0 03 0 001 2 Cylinder bore 65 000 65 014 2 5563 2 5565 Out of round maximum 0 1 0...

Page 130: ...ound maximum 0 1 0 0004 Taper maximum 0 5 0 002 Reed stop height 10 3 10 7 0 41 0 42 See text for measuringpoint Table 4 TORQUE SPECIFICATIONS N m ft lb in ib Carburetor adapter 14 124 Crankcasebolts First step 13 115 Final step 27 20 Crossmemberretainingbolts 48 35 Cylinder basenuts 28 21 Cylinder head nuts First step 11 97 Final step 23 17 Enginemounts Exhaust manifoldbolts 27 20 Spark plug 20 1...

Page 131: ...gine seizure The air box must be installed during carburetoradjustment 1 Open the shroud 2 Remove the air filter element B Figure 1 typical 3 On models with cables routed over the air box move the throttle and starter control cables away from the air box 4 Remove the mounting bolts for each ignition coil and move the ignition coils out of the way 5 Remove the ignition module mounting screws and mo...

Page 132: ...lve mechanism maintain a constant fuel level in the float bowl The pilot system supplies fuel at low speeds The main fuel system suppliesfuelat mediumand high speeds Finally a primer system supplies a rich mixture needed to start a cold en gine Float Mechanism To ensure a steady supply of fucl the carburetor is equippedwith a fuel inlet valve through which fucl flows into the float bowl Figure 3 I...

Page 133: ...edle jet Figure5 In addition theamountof cutawayin thelead ing edge of the throttle valve aids in controlling the fuel airmixture during partial throttle openings At full throttle the carburetor venturi is fully open and the needle is lifted far enough to permit the main jet to flow at full capacity See Figure 6 and Figure 7 CARBURETOR SERVICE 1 Open the shroud 2 Remove the air box as described in...

Page 134: ...y residual coolant that may dr fiomthe cat buretors 11 Remove the carburetorassembly Figure 13 12 Reversethe removalsteps to install thecarburetoras sembly while noting the following a Adjust the throttle cable as described in Chapter Three b Adjust the starter cable as described in Chapter Three c Refill with coolant and bleed the cooling system as described in Chapter Three d Make sure the fuel ...

Page 135: ...neachcarburetorso thescrewfits intothe hole in the throttleshaft b Install the starter rod arms so the retaining screw end fits into the indentationon the rod Carburetor DisassembIy 1 Center carburetor perform the following a Remove the throttle stop screw A Figure 22 by rotating it clockwise Remove the spring 25 Fig ure 231 springseat 261 screw washer 19 washer 20 and nut 21 b Remove the TORS swi...

Page 136: ...MBLY 3 Screw 2 Top cover 3 Gasket 4 Screw 5 Starter cable bracket 6 Starter rod arm 7 Hose 8 Collar 9 Spring 10 Starter rod 11 Lower mounting bracket 12 Throttle shaft 13 Connector 14 Upper mounting bracket 15 Spring ...

Page 137: ...FUEL AND EXHAUSTSYSTEMS 131 ...

Page 138: ...sher 21 Nut 22 Sprlng 23 TORS switch 24 Idlespeed screw 25 Spring 26 Spring seat 27 Throttleshaft 28 Throttlecable pulley 29 Sleeve 30 Spring 31 Needle jet 32 Ring 33 Main jet 34 O ring 35 Washer 36 Spring 37 Pilot screw 38 Pipe 39 Pilot jet 40 Gasket 41 Screw 42 FIoat 43 Float pin 44 Drain screw 45 Float bowl 46 0 rfng 47 Plug 48 Screw 49 O ring 50 Fuel inlet valve seat 51 Fue inlet valve 52 Star...

Page 139: ...etor Figure 29 8 Remove the float pin A Figure 30 NOTE Becarefulwhen removingthefloat The fuel inlet valve and clip canfazll offthefloattang when removing the float 9 Lift out die float B Figure 301 fuel inlet valve and clip Separate the fuel inlet valve and clip from the float ...

Page 140: ...l leaks Minor damage can be re paired with an epoxy or liquid aluminumtype filler 4 Blow out the jets with compressed air Good CAUTION Do not use wire or a drill bitto cleancarbu retor passages orjets This can enlarge the passages and change the carburetor cali bration If a passage or jet is excessively clogged useapiece of broomstrawto clean it 5 Inspect the tip of the fuel inlet valve for wear o...

Page 141: ... become hardened after prolonged use and heat and therefore lose their ability to seal prop erly Inspect all O ringsand replaceif necessary Assembly Refer to Figure 22 1 Clean and inspect the carburetor assembly as de scribed in this chapter 2 Install the pilot jet Figure 32 and sleeve NOTE Make sure the groove Figure 35 in the needle jet fits around the pin Figure36 in the 3 Install the needle je...

Page 142: ... transparenthose to the float howl drain fitting as shown in Figure 41 Hold the hose in a vertical position 5 Loosen the drain screw so fuel flows into the hose 6 Start the engine and let it idle Allow the fuel level to stabilizein the hose 7 Measure the distance from the fuel level in the hose to the centerline of the carburetor bore Figure 41 8 Record the fuel level for each carburetor 9 Refer t...

Page 143: ...through the heating system is controlled by a manualcontrol valve mounted on the air box Figure 44 If the valve leaks or is damaged replace the entire valve No individualparts are available Hoses Refer to Chapter Eight for hose service procedures FUELPUMP All models are equipped with a diaphragm type fuel pump Figure 45 mounted on the frame near the air box ...

Page 144: ...138 CHAPTER FIVE CARBURETOR HEATER SYSTEM Carburetorheater control valve ...

Page 145: ...nto a container 2 Connect the fuel pump to the fuel tar 3 Connect a hand operated L1acuumpump such as a Mity Vac pump to the vacuum port on the he1 pump 4 Operate the vacuum pump Fuel should flow from the he1hoses If not replace the fuel pump Replacethe file1 pump as a unit individualcomponents are not available FUEL TANK Refer to Figure 47 I Remove the seat 2 Open the shroud 3 Remove the air box ...

Page 146: ... Screw 11 Fuel senderassembly 12 Gasket 13 Hose 14 Screw 15 Fftting 16 Hose 17 Fuei filter WAMING the exhaust system i s hot waif until it cools before removingit Remove and install the exhaust system while referring to Figure49 typical system may cause decreasedengine performanceas well as excessive noise levels ...

Page 147: ... codd cause serious in jury Wear heavy shop gloves aad a face shield when usi g this equ ment 1 Clean all accessible exhaust passages with a blunt round nose tool To clean areas fartherdown the pipe at tach a piece of discarded control cable to an electric ill Figure50 Fray the loose end of the cable and insertthe cable into the pipe Operatethe drill while movingthe ca ble backand forthinsidethe p...

Page 148: ...th a hacksaw straighten it with a body dolly and hammer and weld it back into place Before cutting the exhaust pipe apart scribe alignment marksoverthearea wherethecuts will be madetoaidcor rect alignmentwhen the pipe is rewelded After completing the welding wire bmsh and clean all welds Paint the entire pipe with a high temperaturepaint to prevent rusting Table 1 CARBURETOR SPECIFICATIONS MM600 S...

Page 149: ...43 Table 2 CARBURETOR SPECIFICATIONS MM700 SX700 VT700 AND VX700SX SXS XT XTC XTCD XTCP lcontinued Throttlevalve cutaway Float height Fuel level Pilot air screw 3 5 11 3 15 3mrn 0 44 0 60 In 36 38 mm 1 42 1 50 in 1 1 2 turns out ...

Page 150: ...o not allowthe battery tofreeze If themachineis left outside during freezing temperatures make sure the bat tery is fully charged If the machine is stored in cold weatherforlongperiods removethe batteryandstoreit in a warm place CAUTION A discharged battery will freeze causing battery damage Keep the battery fully charged when using it in subzero weather Care and Inspection To service the electrol...

Page 151: ...d check the electrolytelevel Adddistilledwater ifnecessary to bring the level withinthe upperand lower levellines on the bat tery case Figure1 10 Place the battery in the battery tray 1 Reconnect the positive battery cable then the nega tive cable CAUTION Make sure the battery cables are connected to their proper terminals Connecting the battery backwards reverses the polarityand damages the recti...

Page 152: ... from which it came The specific gravity of the electrolyte in each battery cell is an excellentindicationof that cell s condition Ta ble 2 Afully charged cell reads 1 260 1 280 while a cell in good condition reads from 1 230 1 250 and anything below 1 140 is discharged Charging is also necessary if the specific gravity varies more than 0 050 from cell to cell NOTE If a temperature compensated hyd...

Page 153: ...rogengas 1 Remove the battery from the frame as described in this chapter 2 Connect the positive charger lead to the positive battery terminal and the negative 1 charger lead to the negative battery terminal See Figure 4 3 Remove all vent caps from the battery set the charger at 12 volts andswitch it on Normally a battery shouldbe charged at a slow charge rate of 1 10 its given capacity See Table ...

Page 154: ...h a new one make charged sure to charge it completely specific gravity 1 260 1 280 beforeinstallingit Failingto do so or using the battery with a low electrolyte level will permanently CAPACITORDISCHARGEIGNITION CDI damage the battery NOTE All models use a capacitor discharge ignition system When purchasinga new batteryfroma deal Figure 6 This section describes removal and installa ership orparts ...

Page 155: ...stator coils Flywheel replacement is usually necessary only if the magnets have been damaged by mechanical heat or shock Refer to Figure 6 when performing the following pro cedure NOTE The following procedure is shown with the variousengineassembliesremoved for clar ity It is not necessaryto remove the engine from the frame to remove the flywheel 1 Removethe recoilstarterasdescribedin ChapterN me ...

Page 156: ...baligned with the key in the crankshaft Push die flywheel onto the crankshaft 12 Install the lockwasher and flywheel retaining nut Tighten the nut finger tight 13 Install the spacer and starter pulley Figure 8 onto the face of the flywheel Tighten the starterpulley boltsto 23 N m I 7 ft lb 14 Hold the primary sheave to prevent crankshaft rota tion Then tightentheflywheelnutto 110Wm 81 lb 15 Instal...

Page 157: ...VOLTAGE REGULATOR The snowmobile is equipped with two voltage regula tors one of which is also a rectifier The rectifierlvoltage regulator A Figure 13 contacts the current to the bat tery and to the lights and instruments if so equipped The voltageregulator B Figure 13 directscurrentto the grip warmer circuit 1 Disconnect the rectifier1voltage regulator or voltage regulator wire connector 2 Remove...

Page 158: ...her 3 End cap 4 Grommet 5 Nut 6 O ring 7 Brush spring 8 Positivebrush 9 Grommet 10 O ring 11 Negative brush 12 Washers 13 Armature 14 Washer 15 Frame 16 O ring 17 Drivehousing 18 Drive assembly 19 Washer 20 Spring 21 Pinion stopper 22 Snap ring ...

Page 159: ...lts A Figure 15 Then re move the bolts and washers 4 Remove the end cap B Figure 15 5 Removethe washersinstalled betweenthe end cap and the armature Figure 16 NOTE Step 6 describes removing the pinion gear assembly However thepiniongeardoesnot require removal unless it is damaged or re quiresreplacement Theclip Figure17 se curing the pinion gear assembly may be difficult to remove Have an assistan...

Page 160: ...ure shaft In stall the spring and pinion stopper g Usingpliers open the new stopperclipuntilthe clip ends are 9 10 mm 0 35 0 40 in apart See Figure 21 Clip Pinion gear f 0 35 0 40 in 9 10 mm Pinion stopper I Return spring h Have an assistant hold the pinion stopper down and slip the clip into the groove in the armature shaft Close the clip with pliers See Figure 22 10 If the positive brush assembl...

Page 161: ...he bushings are damaged 3 Check all the O rings for flatness cracks hardness or other abnormal conditions Replace the 0 ring s as re quired 4 Check the fiber washer s and replaceif worn cracked or damaged in any way If this washer is not available from a Yamaha dealership check with an automotive electrical repair shop 5 Check the metal thrust washersfor damage Replace if necessary 6 Measure the l...

Page 162: ...ve the starter relay Reverse to install SWITCHES Switchescan be tested forcontinuitywith an ohmmeter see Chapter One or a test light at the switch connector plug by operating the switch in each of its operating posi tionsand comparingresultswith the switch operation For example Figure 29 shows a continuity diagram for the enginestopswitch It shows which terminalsshouldshow continuity when the swit...

Page 163: ...ELECTRICALSYSTEM 157 SWITCHES CARBURETOR SWITCH BRAKELIGHT SWITCH HEADLIGHT SWITCH THROTTLE SWITCH MAIN SWITCH YIB YIR Br R R W B B W Off  ...

Page 164: ...and brake switch Figure32 are in the left switch housing 1 Remove the rear handlebar cover 2 Disconnect the switch electricalconnector 3 Remove the switch as follows a Headlight beamswitch Removethe screw retain ing the back of the switch in the housing then re move the switch b Brake switch Gnscrew the brake lever pivot nut then remove the brake switch 4 Installationis the reverse of the precedin...

Page 165: ...Theoil level lightcomeson when the oil level in the oil tank is low Do not ride the snowmobileuntil the oil tank is filled WarningLight Check The water temperature and oil level warning lights can be checked for proper operation When the main switch is turned on the warning lights on the instrumentpanel Figure35 shouldturnon After a few seconds thewarninglightsshouldturnoff Interpret these results...

Page 166: ... 6 Check the bulb with the oil level sender held in its mountingpositionand then with the sender turned upside down Interpret the results as follows a Oil level sender held in original mountingposition The light should come on and stay on b Oil level sender turned upside down The light should come on and then after a few seconds the light goes out 7 If the oil level sender failed to operate as des...

Page 167: ...If the switches are not in the correct position the ground to the CDI unit is interrupted and the engine will turnoff If thecarburetoror throttlecableshouldmalfunc tion during operation removal of the rider s thumb from thethrottleleverwill deactivatethe throttleswitch and the enginewillturnoff If a ridershouldfall off of a snowmo bile with the TORS system the engine will return to idle If theengi...

Page 168: ...ect the electrical connector 4 Set an ohmmeteron the R x 1 scale 5 Connect the ohmmeter to the black yellow and black terminals on the carburetor switch connector Test as fol lows a The ohmmetershould read zero ohms when operat ing the throttle lever b The ohmmetershould read infinity with the throttle lever at rest 6 If the carburetor switch does not include the readings specified replacethe carb...

Page 169: ... removethe headlightbulb 5 Reversethe removalsteps to install the headlightbulb Make sure the bulb holder is securely in position Headlight Adjustment 1 Park the snowmobile on a level surface 25 ft 8 m from a vertical wall Figure 43 NOTE A rider should be seated on the snowmobile when performing the following 2 Measurethe distancefrom the floor to the centerof the headlight lens Figure 43 Make a m...

Page 170: ...n Commutatoroutside diameter 28 mm 1 10 in Wear limit 27 mm 1 06 in Mica undercut 0 4 0 8 mm 0 016 0 031 in Table 4 TORQUE SPECIFICATIONS N m ft lb Crossmemberretaining bolts 48 35 Flywheelnut 110 81 Recoil starter pulley bolts 23 17 Starter motor mounting bolts 23 17 Table 5 BULBS MM600 AFTER 19991 MM700 AFTER 19991 VT600 VX600ER VX600SX VX700SWSXS X17XTC XTCD XTCP Headlight 6OWl55W TaiVbrakeligh...

Page 171: ...BULBS MM700 PRIOR TO 20001 VT700 VX700SX PRIOR TO 20001 Headlight 60W155W Tail brakelight 8W123W Tachometerlight 1 7W Speedometer light 1 7W High beam Indicator light 3 4W Water temperaturelight 3 4W Oil level indicator light 3 4W ...

Page 172: ...timum lubrication at any speed or engine load condi tion Incontrast engineswithoutoil injectionrequirethat the oil be mixed with the gasoline The ratio of oil must be sufficientfor high speed and load conditions OILPUMPSERVICE Oil Pump Bleeding The oil lines must always be filled with oil If the oil tank ran dry any oil injection hose was disconnected or the machine was on its side bleed air from ...

Page 173: ...l hoseis detached Also plug the opened oil supply line to prevent the entrance of contamina tion Lift the oil tank up slightly and disconnectthe hosesat the tank Plug the outlet ports to preventoil leakage 7 Installationis the reverse of the precedingsteps 8 Bleed the oil pump as described in this chapter Oil Level Sender Refer to Chapter Six Oil Hoses Install new oil hoses whenever the old hoses ...

Page 174: ...168 CHAPTER SEVEN OIL PUMP 1 Oil pump controlcable 2 Bleed screw 3 Gasket 4 Nut 5 Sockethead screw 6 Clamp 7 Protectivespring 8 O ring 9 Oilpump 10 Oil hose 11 Check valve ...

Page 175: ...drain back Check the valves for proper operation 3 Check the oil hose fittings for tightness 4 Move the oil pump operating arm A Figure 8 and checkfor tightnessor other damage Replacethe oil pump if necessary 1 Install a new O ring seal B Figure 8 2 Alignthe slot in the oil pump with the tangon the drive shaft theninstallthepumpand secureit with theretaining screws Figure 7 3 Attach the hoses to t...

Page 176: ...s hot The coolant is very hot and under pressure Severe scalding could result if the coolant comes in contact withskin The cooling system must cool before removing any component of the system Coolant Pump The coolant pump impeller is mounted on the same shaft thatdrivesthe oil injection pump Theimpeller is lo catedunderthe cover Figure3 on thefront of the crank case The O ring seal Figure4 located...

Page 177: ...changer 4 Removethe right front enginemountingbracket Fig ure 6 NOTE The engine is shown removed or clarity 5 Remove the water pump cover Figure 3 NOTE When unscrewing the impeller retaining bolt it may be necessaryto hold the primary sheave so the impeller driveshaft does not rotate ...

Page 178: ...OLANT PUMP 1 Bolt 2 Washer 3 Bolt 4 Engine mount 5 Bolt 6 Bolt 7 Coolant hose 8 Clamp 9 Carburetor heatinghose 10 Clamp 11 Bolt 12 Washer 13 Pump cover 14 O ring 15 Bolt 16 Washer 17 Impeller 18 Driveshaft 19 Enginecrankcase ...

Page 179: ...owing pro cedure NOTE When tighteningthe impeller retaining bolt it may be necessary to hold the primary sheave so the impeller driveshaft does not rotate 1 Installthe impeller B Figure7 washerand retaining bolt A Tighten the bolt to 10 N m 89 in lb 2 If not previously installed install a new O ring A Figure8 onto the water pump cover NOTE An engine mount retaining screw also re tains the coolant ...

Page 180: ...on the new hose 2 Loosen the hose clamps from the hose to be replaced Slide the clampsalong the hose and out of the way 3 Twist the hose end to break the seal and remove from the connecting joint If the hose has been on for some time it may have fused to the joint If so insert a small picktool or screwdriverbetween the hoseand joint Work thetool aroundthe jointand carefullypry thehose loose CAUTIO...

Page 181: ...ee A broken or frayed rope is the most common malfunction StarterHousing Removal Installation 1 Open the shroud 2 Remove the handleas follows a Pull out the starter handle b Slide the rope through the handle A Figure1 NOTE Ifthe starterisnotbroken donotreleasethe rope after removing the handle in substep 2c After removing the handle tie a knot in the end of the rope to temporarily stop the rope fr...

Page 182: ...ve length at end of rope RECOIL STARTER 1 Screw 2 Washer 3 Bushing 4 Collar 5 Starter housing 6 Handle 7 Rope 8 Spring 9 Sheave 10 Spring 11 Cam guide 12 Spring 13 Drivepawl 14 Washer 15 Driveplate 16 Nut 17 Screw 18 Starter pulley 19 Spacer ...

Page 183: ... following a Apply Loctite 242 blue to the threads of the three retainingscrews b Install the spacer starter pulley Figure 5 and screws c Tighten the retaining screws evenly to 23 N m 17 ft lb d Reinstall the recoil starter housing as described in this chapter Starter Housing Disassembly WARNING The rewind spring usually remains in the cavityofthe housing but it may unwind sad den and violentlyast...

Page 184: ... agent is compatible with plastic Some types of solvents can perm nently damage the plastic pieces 1 Clean all parts thoroughlyand allow to dry 2 Visuallycheck thestarterpost B Figure9 forcracks deepscoringandexcessivewear Checkthe groovesinthe post for damage Replacethe housingif the starter post is damaged 3 Inspect the pawl Figure 10 and pawl spring for cracks and other damage 4 Inspect the she...

Page 185: ...in the starter housing with a low temperaturegrease 2 Attach the innerend of the starter rope to the sheaveas follows WARNING Beextremelycarefulwhenheatingthe recoil rope The hot melting rope and the flame used to heat the rope can cause serious in jury a Check the ends of the starter rope for fraying To tighten the end of the rope apply heat to melt the end Figure 13 b Insert the end of the rope ...

Page 186: ...wise 4 112 turns while holding the free end of the rope in the notch c Remove the rope from the notch and allow the springtowindtheropeintothegrooveofthesheave NOTE The rope should be too long to wind com pletely onto the sheave without binding in the housing When the rope completely fills the sheave groove there should be upproxi mate 50 em 20 in free to install through the frame and body d Pull ...

Page 187: ...wmobilehengine cum partment while wearing a scarf or other looseclothing whentheengineis runningor when the driver is startingthe engine I f the scarf or clothing should catch in the drive system severe injury or death could occur Makesurethe belt guard isalwaysin place DRIVE UNIT Torque is transferred from the engine crankshaft to the jackshafl by a centrifugallyactuated variablesheave type of tr...

Page 188: ... the sheave There is no engagement because the width of the belt is less than thespacebetweenthesides of the primary sheave At low speed the belt is located as shown at the low speed position in Figure 2 When engine speed in creases from idle centrifugal force causes the weight le vers mounted on the sliding half of the primary sheave to swingout Whencentrifugalforceof theweights 10 Fig ure 5 is s...

Page 189: ...he weight ramps SECONDARYSHEAVE NOTE Thesecondary sheave ofsomelatemodelsis slightly differentthan the one shown in Fig ure6 Operationof bothtypesis simiia Re fer to the appropriate paragraphs of this chapter when servicing Major components of the secondary sheave assembly are the sliding half fixed half secondary spring and torque cam bracket 6 10 14and 15 Figure6 The belt surfaces of the sheave ...

Page 190: ...ve half 4 Split collar 5 Sliding sheave half 6 Locknut 7 Collar 8 Rivet 9 Washer 10 Weight 11 Bushing 12 Setscrew 13 Bolt 14 Bushing 15 Slider 16 Pin 17 Locknut 18 Bushing 19 Washer 20 Bushing 21 Roller 22 Bolt 23 Spider 24 Spring 25 Sheave cap 26 Washer 27 Bolt 28 Bushing ...

Page 191: ...Cover if so equipped 3 Bushing 4 Flangebolt 5 Shim 6 Sliding sheave 7 Stud 8 Screw 9 Holder stopper 10 Fixed sheave 11 Ramp shoe 12 Cover 13 Screw 14 Spring 15 Spring seatfcam 16 Nut 17 Bushing 18 Collar if so equipped 19 Shims 20 Washer 21 Bolt ...

Page 192: ...p the sheaves will shift to a faster speed ratio sooner and will not be as responsiveto increasesin load Conversely low cam angles will exert more side pressure and will slow shifts until the load is reduced and speeds are higher DRIVE BELT The drive belt transmitspower from the primarysheave to the secondary sheave The belt provides a vital link in the operationand performance of the snowmobile T...

Page 193: ...nufac turer s marks on the belt or those made before removal face in the same direction forward When installing a new belt install it so the belt identificationmarksare visi ble while standing on the left side of the machinelooking into the engine compartment Inspection Check the drive belt frequently and at least once each season remove the belt and carefully inspect it 1 Remove the drive belt as...

Page 194: ...ingthe sheavesfrom shifting to a 1 1 ratio To compensatefor beltwear reduce the distance between the sheave halves by adding shim washers B Figure 14 onto the sliding sheave half retaining bolts Perform this procedurewheneverinstallinga new drive belt 1 Open and secure the hood 2 Remove the belt guard 3 Check that the drive belt isrestingat the topof the sec ondary sheave A Figure 14 4 Measure the...

Page 195: ...rethe distancebetween thesheaveswith the dis tance measuringgauge YS 91047 3 as shownin Figure 18 Refer to Table 3 for the correct sheave center to cen ter distance If the distance is correct proceed to Step 4 and measure the sheaveoffset If thesheavedistanceis in correct perform Step 3 3 Adjustthesheave center to centerdistanceasfollows a Loosen the front and rear engine mounting bolts Figure 19 ...

Page 196: ... Tighten the engine mounting bolts and remcasure the sheave distance Refer to Chapter Four for en gine mount torque specifications d Recheck sheave center to center distance and ad just if necessary e After adjusting the sheave offset perform the Sec ondary SheaveFree Play as describedin this chap ter 5 Reinstall the drive belt as described in this chapter PRIMARYSHEAVESERVICE The primary sheave F...

Page 197: ...move the puller 5 Remove the primary sheave Figure 22 assembly Disassembly WAAVING The primary sheave is under spring pres sure Use the Yamaha special tool or an equivalent tool during disassembly and re assembly or refer service to a dealership 1 Attach the sheave compressor Yamaha sheave com pressorpart No YS28891or equivalent onto the primary sheave and compress the primary sheave spring Figure...

Page 198: ...ring with the same color code 6 The spider is cast into the post Check both parts for loosenessby pullingthem by hand Replacethe assembly if loose 7 Inspect the sheave cap bushing A Figure 33 for damage and replace if it is 8 Measurethe clearance on each side of each slider half Figure 34 Add the clearances on both sides of each slider pair If the total clearance exceeds 0 3 mm 0 012 in for each p...

Page 199: ... bafance install therollerboltsso thethreaded endfaces in a counterclockwisedirectionas shown in Fig we 28 3 Install the spider roller assemblies Figure 28 Tighten the nut to 6 N m 53 in lb Check that each roller turns smoothly 4 Install the primary sheave spring Figure 27 5 Align the X mark on the sheave cap Figure33 with the X mark on the spider Figure 37 and install the sheave cap 6 Install the...

Page 200: ...xed sheave half 4 Split collar 5 Slidingsheave half 6 Locknut 7 Collar 8 Rivet 9 Washer 10 Weight 11 Bushing 12 Setscrew 13 Bolt 14 Bushing 15 Slider 16 Pin 17 Locknut 18 Bushing 19 Washer 20 Bushing 21 Roller 22 Bolt 23 Spider 24 Spring 25 Sheave cap 26 Washer 27 Bolt 28 Bushing ...

Page 201: ...ck and forth by hand The sheave shouldhave approximately1 0 2 0 mm 0 04 0 08 in axial clearance 3 If the axial clearance is incorrect proceed to Step 4 4 Remove the secondary sheave bolt as described under Removal 5 Adjust the secondary sheave free play by removingor installing the shims on the bolt Figure 40 6 Install the secondary sheave bolt washer and shims Tighten the bolt to 64 N m 47 ft Ib ...

Page 202: ...Cover if so equipped 3 Bushing 4 Flange bolt 5 Shim 6 Sliding sheave 7 Stud 8 Screw 9 Holder stopper 10 Fixed sheave 11 Ramp shoe 2 Cover 13 Screw 14 Spring 15 Spring seaucam 16 Nut 17 Bushing 18 Collar if so equipped 19 ShIms 20 Washer 21 Bolt ...

Page 203: ...nst alu minum wear is normally minimal Howcver if any ramp pad is gouged or damaged install new pads Replace the pads if any pad is worn to a thickness Figure 46 less than 1 O mm 0 04 in j 6 Inspect the secondary sbeave spring for cracks or dis tortion Replacethe spring if the fkeelengthis less than 75 mm 2 95 in Sheave spring specifications are listed in Table 12 and Table 13 7 Inspect the bushin...

Page 204: ... install the spring into the fixedsheavehalfbyinsertingthe springend intothe numberedhole specified e Refcr to Table 17 and install thc spring seatham onto thespringso the springend residesin the num bered hole specified d While holding the spring seat cam rotate the fixed sheavehalfat the specifiedanglelisted in Table 17 The studs on the sliding sheave half should align with the bolt holes in the...

Page 205: ...VX6OOER VX7OOXTCD 18 5 21 5 mm 0 73 0 84 in All other models 13 5 16 5 mm 0 53 0 65 in Table 4 PRIMARY SHEAVE SPRING fMM600 MM700 AFTER iW9k Color code Yellow White Yellow Outside diameter 60 mm 2 36 in Wire diameter 6 0 mm 0 236 in Preload 450 N 101 Ib 1 Spring rate 25 Nlmm 143 IbAn Number of coils 5 39 Freelength 91 4 mm 3 6 in Table 5 PRIMARY SHEAVE SPRING SX600 SX700 VX6OOER VX6OOSXj Color cod...

Page 206: ...ter 5 8 mm 0 23 in Preload 300 N 67 lb Spring rate 27 5 Wmm 157 IbJin Humberof coils 4 64 Free length 76 3 mm 3 0in Table I 0 PRIMARY SHEAVE SPRING VX7OOXT XTC XTCD SXSl Color code White Silver White Inside diameter 48 mm 1 89in Wire diameter 5 5 mm 0 21 in Preload 342 N 77 lb Spring rate 22 1 Wmm 126 Ibhn Number of coils 4 66 Free length 81 mm 3 38 in Table II PRIMARY SHEAVE SPRING VT700 Color co...

Page 207: ...eave free play 1 O 2 0 mm 0 04 0 08 in Secondarysheave spring free length 75 mm 2 95 in Table 16 TORQUE SPECIFICATIONS N m ft lb in Ib Primary sheave weightbolts 6 53 Primary sheave roller bolts 6 53 Primary sheave spider 200 145 Primary sheavecap bolts 14 124 Primary sheave bolt See text Secondarysheave bolt 64 47 Secondarysheave half positioning bolts 10 88 Secondary spring seatlcam retaining nu...

Page 208: ...ork area and all tools be absolutely clean Any tiny particlesof dirt and debris in the hydraulic sys tem can damage the components 2 Use only DOT 4 brake fluid from a sealed container WARh ING Do not intermix silicone based DOT 5 brakefluidbecause it can cause brake corn ponent damage leadingto brakesystemfail we 3 Do not allow disc brake fluid to contact any plastic partsor painted surfaces as da...

Page 209: ...it is stickingin thecaliper remove the caliper as describedin Caliper Overhaul in this chapter 9 Install brake pads as follows a Assemble each brake pad with the shims as shown in Figure 1 Note that the tabs on the outer shim fit over the inner shim and brake pad Figure 9 b Install the brake pads and shims into the caliper so the frictionsurface on both pads face each other c Install the pad retai...

Page 210: ...PTER ELEVEN BRAKE CALIPER 1 Lockscrew 2 Pad retainingpin 3 Allen screw 4 Caliperhalf 5 Bleed valve screw 6 Cap 7 Caliperhalf 8 Piston 9 Seals 10 Piston 11 Spring plate 12 Outer shim 13 Inner shim 14 Brake pad ...

Page 211: ...BRAKES 205 Wear limit ...

Page 212: ...r piece of wood between the pistons b Remove the cap on each bleedscrew Figure13 c Open the bleed screw on the side of the caliper for the piston being removed d Performthisstepoverandclosetoa workbenchtop Hold the caliperso that while removing the piston the piston is facing away from you WARNING In the next step the piston may shoot out of the cal er half with considerable force Keep fingers out...

Page 213: ...op of the master cylinder of all dirt and de bris 5 Remove the screws securingthe cover B Figure 15 Remove the cover and the diaphragm WARNI VG I f using a cooking baster for this purpose DO NOT reuse it for cooking purposes be cause there will be brake fluid residue within it 6 Usinga shopsyringe drawallthebrake fluidoutof the master cylinder reservoir 7 Place a shopcloth under the brake hose fit...

Page 214: ...ke line 7 Fitting 8 Jam nut 9 Pivot bolt 10 Spring 11 Primary cup 12 Secondarycup 13 Piston 14 Snap ring 15 Boot 16 Parkingbrake lever 17 Washer 18 Dowel pin 19 Screw 20 Screw 21 Clamp 22 Parking brake cable 23 Brake switch 24 Washer 25 Locknut 26 Brake lever 27 Screw 28 Washer 29 Pin ...

Page 215: ...curingthe brake lever and remove the brake lever 4 Remove the rubber boot Figure 18 from the area where the hand lever actuates the internalpiston 5 Using snap ring pliers remove the internal snap ring Figure 19 from the body 6 Remove the piston secondary cup assembly Figure 20 7 Remove the spring and primary cup Figure21 Inspection 1 Clean all parts in denaturedalcohol or brake fluid In spect the...

Page 216: ...r wear and dam age If less than perfect replace the master cylinder as sembly Individualcomponentsare not available Assembly 1 Soak the new or existing piston assembly in fresh brake fluid for at least 15 minutes to make the cups pli able Coat the insideof the cylinder bore with fresh brake fluid before assemblingthe parts CAUTION When installingthe piston assembly do not allow thecupsto turn insi...

Page 217: ... leg 11 Pin 12 Cotter pin 13 Parkingbrake cable on the hydraulic brake master cylinder operates the park ing brake Refer to Chapter Three to adjust the parking brake Brake Pad Inspection Refer to Figure 24 1 Open and secure the shroud 2 Measurethe thicknessof each parking brake pad Fig ure 25 The wear limit is 6 0 mm 0 24 in ...

Page 218: ...ote the following a Refer to Figure 28 for parts arrangement b Tighten the jam nut and flange nut to 10 N m 88 in lb c Adjust the parking brake as described in Chapter Three BRAKE HOSE REPLACEMENT Yamaha recommends flexible brake hose replacement every four years or when it shows signs of cracking or damage Note the routingof the brake line before removalin or der to install it in the correct posi...

Page 219: ...dure is necessary only when the brake feels spongy there is a leak in the hydraulicsystem a compo nent has been replaced or the brake fluid has been re placed 1 Removethe caps Figure 33 thenconnect a length of clear hose to each bleeder valve on the caliper Place the other end of each hose into a cleancontainer Fill the con tainer with enough freshbrake fluid to keepthe hose ends submerged The hos...

Page 220: ...d tighten the bleeder valves Remove the bleeder tubes 6 If necessary addfluid to correct the level in the master cylinder reservoir It must be above the level line 7 Install the cover and tighten the screws 8 Test the feel of the brake lever It should feel firmand offer the same resistanceeach timeit is operated If it feels spongy bleed it again because it is likely that air is still in the system...

Page 221: ...er until the chain is completely loose 6 Remove the chain tensioner B Figure 4 7 Have an assistant apply the hydraulic brake Loosen the drive sprocket nut A Figure 5 and the driven sprocket bolt B 8 Remove the drive sprocket nut A Figure 5 and washer 9 Remove the driven sprocket bolt B Figure 5 and washer 10 Removethe chain and sprockets as an assembly 11 Remove the spacers from the jackshaft and ...

Page 222: ... Bearing 11 Bolt 12 Washer 13 Driven sprocket 14 Spacer 15 Washer 16 Bearing 17 Roller 18 Snap ring 19 Shaft 20 Chain tensioner 21 Gasket 22 Nut 23 Seal 24 Collar 25 O ring 26 Oil plug 27 Snap ring 28 Bearing 29 Bolt 30 Dipstick 31 Chain tensioner bolt 32 Nut 33 Chaincase 34 Seal washer 35 Drain bolt 36 Seal 37 Collar 38 O ring ...

Page 223: ...5 andwasher 4 Apply Loctite242 blue to thedrivensprocketbolt B Figure 51 then install the bolt and washer 5 Have an assistant apply the hydraulic brake Tighten thedrive sprocketnut A Figure5 to 60 N m 43 fi lb Tighten the driven socket bolt B to 48 N m 35 ft lb 6 Install the chain tensioner Figure 4 7 Install the gasket and chaincasecover Figure 3 onto the chaincase Make sure the rubber gasket pro...

Page 224: ...horoughly in solvent 2 Check the drive and driven sprockets for cracks deep scoring excessive wear or tooth damage Check the splines for the same abnormal conditions 3 Check the chain for cracks excessive wear or pin breakage 4 If the sprockets and or chain are excessively worn or damaged replace all three componentsas a set 5 Check the chain tensioner for wear and damage Also replace the chain te...

Page 225: ...in this chapter 4B On all other models remove the drive chain and sprockets as described in this chapter 5 Remove the chaincase Figure 27 6 Remove the collars and O rings on the jackshaft Fig ure 28 and front axle Figure 29 Inspection 1 Remove the oil seals Figure 30 2 Inspectthe bearings A Figure31 Ifbearing removal is necessary remove the snap ring B and press or drive out the bearing When insta...

Page 226: ...220 CHAPTER TWELVE ...

Page 227: ... Bearing 29 Reverse pinion gear 30 Spring 31 Reversepinion gear 32 Shaft 33 Bolt 34 Shaft holder 35 Pin 36 Bolt 37 Washer 38 Spring seat 39 Spring 40 Reverse gear 41 Spring 42 Coupler 43 Snap ring 44 Splined shaft 45 Washer 46 Driven sprocket 47 Spacer 48 Chain 49 Spacer 50 Snap ring 51 Shaft 52 Chain tensioner 53 Washer 54 Bearing 55 Roller 56 Gasket 57 Snap ring 58 Bearing 59 Dipstick 60 Chain t...

Page 228: ...222 CHAPTER TWELVE ...

Page 229: ...CHAINCASE JACKSHAFTAND FRONT AXLE 223 ...

Page 230: ...224 CHAPTER TWELVE ...

Page 231: ...CHAINCASE JACKSHAFT AND FRONT AXLE 225 1 Collar 2 O ring 3 Brake disc 4 Key 5 Washer 6 Snap ring 7 Jackshaft 8 Nut 9 Bearing plate 10 Bolt 11 Setscrew 12 Bearing 13 Bearingplate 14 Bolt 15 Washer ...

Page 232: ...ft for cracks or other damage 5 Inspect the splines for excessive wear and damage 6 Checkboth endsof the jackshaftfor cracks deep scar ing or excessive wear 7 Ifthereisany doubtas tothe conditionof the jackshaft repair or replace it Installation 1 Insert the jackshaftinto the frame 2 Install thejackshaft bearing and flange assembly 3 Tighten the bearing flange nuts securely 4 Tighten the bearing c...

Page 233: ... lip contacts the collar Replacethe collar if worn or damaged Replace theO ring in thegrooveon the insideof thecollar Figure 32 5 Inspect the sprockets for excessive wear cracks dis tortion or other damage Replace the sprockets as de scribed in this chapter 6 If there is any doubt as to the conditionof any part re place it with a new one Sprocket Replacement Use a press for this procedure 1 Note t...

Page 234: ...n 4 01 in Figure 41 VT600 Figure 42 VT700 Figure 43 VX60OSX Figure 44 VX7OOSXS Figure 45 VX7OOXT XTC XTCD XTCP Installation I When installingthe track orient the acklugsto runin the directionshown in Figure 46 2 Align the fiont axleso the splinedend facestoward the right side then instal1the front axle ...

Page 235: ...CHAINCASE JACKSHAFT AND FROX I AXLE 229 104 mm 123 mm 104 mm 4 09 in 4 84 in 4 09 in L L L A 102 mm 123mm 102 mm 4 01 in 4 84 in 4 01 in 132 6tnm 5 22 i n ...

Page 236: ...230 CHAPTER TWELVE 104 mm 123 mm 104mm 4 09 in 4 84 in 4 09 in 164 mm 6 46 in 111 9 mm 4 41 in 201 mm 7 91 in 104 mm 123 mm 104 mm 4 09in 4 84 in 4 09 in ...

Page 237: ...nt axle and speedometer gear Install the retaining nuts and tighten securely Apply Loetite 242 blue to the bearing lock collar setscrews Install the setscrews Figure 37 and tighten to 8 N m 71 in lb 5 Install the rear suspension as described in Chapter Fourteen 6 Install the collar Figure 29 onto the front axle and push the collar against the shafi shoulder 7 Install the chain and sprockets as des...

Page 238: ...9 70 VT600 20139 68 W O O 21 39 68 VX6OOER 21139 68 VX6OOSX 21J40 68 VX7OOSX 23 40 70 VX7OOSXS 23 40 70 VX7OOXT XTC 23 40 70 VX7OOXTCD 22 3S 70 VX7OOXTCP 22 40 70 Refer to Chapter Three for high altitudeadjustments Table 3 TORQUE SPECIFfCATIONS N m ft lb in lb Drive sprocket nut 60 44 Driven socket boEt 48 35 Chaincasecover 24 18 Chaincase 48 35 Front axle lock collar setscrews 8 71 Reverse axle s...

Page 239: ...Remove the cotter pin Figure3 typical from the end of the ski pivot bolt Loosen and remove the nut bolt and ski 4 If necessary remove the ski stopper 1 Figure 1 or Figure 2 5 If necessary on models so equipped remove the ski mounting bracket 7 Figure 2 6 Inspecttheskis and hardwareandreplaceas necessary 7 On MM700A VT600 VX600ER and VX700SXA modelseach ski is protected by a removableski cover 8 Fi...

Page 240: ...234 CHAPTER THIRTEEN SKI ASSEMBLY MM700A VT600 700 EARLY VX600ER VX700 EARLY il 1 Ski stopper 2 Collar 3 Nut 4 Washer 5 Cotter pin 6 Nut 7 Ski 8 Cover 9 Rivet 10 Washer 11 Skag 12 Bolt ...

Page 241: ...I ASSEMBLY MM600 700 LATER SX600 700 VX6001700 LATER 1 Ski stopper 2 Collar 3 Nut 4 Washer 5 Cotter pin 6 Nut 7 Mounting bracket 8 Handle 9 Nut 10 Washer 11 Nut 12 Washer 13 Ski 14 Washer 15 Bolt 16 Skag 17 Bolt 18 Washer 19 Bolt 20 Bolt ...

Page 242: ...uter Steering Arm Spindle and Bushings Removal Installation The spindle A Figure 4 rides inside the trailing arm B and is supported by two bushings The outer steering arm C is bolted to the top of thespindleand connectsthe spindleto the front tie rod D To maintainsteeringalign ment mark thesteeringarmand spindlebeforeseparating them Refer to Figure 5 1 Supportthe frontof the machineso bothskis are...

Page 243: ...rod 10 Cotter pin 11 Nut 12 Cap 13 Bolt 14 Nut 15 Washer 16 Steering arm 17 Bushing 18 Nut 19 Bushing 20 Link 21 Bolt 22 Rivet 23 Plate 24 Nut 25 Controlrod end 26 Nut 27 Control arm 28 Bushing 29 Collar 30 Bolt 31 Nut 32 Washer 33 Bushing 34 Bolt 35 Bolt 36 Bolt 37 Trailingarm 38 Grease fitting 39 Washer 40 Bushing 41 Bolt 42 Nut 43 Spindle ...

Page 244: ... If new parts were installed check steering align ment as described in this chapter Inspection 1 Clean all components thoroughly in solvent Remove all dirt and other residuefrom all surfaces NOTE Ifpaint was removed from the steering arm duringcleaning touch up these areas as re quired before installation 2 Cheek the steering arm Figure 10 for cracks cxces sive wear or other damage Check the splin...

Page 245: ...rse of the preceding steps Note the following Tighten the trailing arm pivot bolt to 78 N m 58 ft lb Install the upper sway bar link bolt in the same di rection as originally installed Apply low temperaturegrease to the bushing in the sway bar link Tightenthesway barlinkboltto 23 N m 17 ft lb Apply a low temperaturegrease to the control arm bushings before installation Tighten the outer control ar...

Page 246: ...trol arm rod ends from the pan Do not loosen the rod end to controlarm nuts 4 Remove the control arms 5 Inspect the control arms as described in the following procedure NOTE The outer control arm end is angled Make sure the outer control arm end properly en gagesthe bracket onthetrailingarm during installation 6 Installationis the reverse of the precedingsteps Note the following a Clean the contro...

Page 247: ...hock spring without the use of a spring compressor At temptingto removethe spring without using a spring compressor may cause severe in jury I f a spring compressor is not on hand refer spring removal to a Yamaha dealer ship 4 Install a spring compressor onto the shock absorber followingthe manufacturer sinstructions Thencompress the spring with the tool and remove the spring stopper from the top ...

Page 248: ...houldbefelt on the compression stroke and a considerable amount of resistancefelt on the return stroke d Replace the shock absorber if necessary HANDLEBAR AND GRIPS The handlebar is attached to a flange on the top of the steering column Refer to the followingsections to adjust 4 Check the spring for cracks or damage handlebar position or to remove the handlebar ...

Page 249: ... fora verticalpo sition replace the handlebar clamp Note that the upper clampshaveadifferentthicknessat eachend Whenprop erly installed there will be small gap between the upper and lower clamps at the front and a wider gap at the rear See Figure 21 4 Position the handlebar so the ends are an equal dis tance from the center 5 Tighten the front handlebar clamp bolts first then tighten the rear bolt...

Page 250: ...ure 26 so the cable loop is down d Tighten the bearingholder retainingnuts to 23 N m 17 ft lb Tighten the relay rod end nut to 35 N m 25 ft lb j Inspection 1 Clean all components thoroughly in solvent Remove all grease residue from the bearing halves 2 Visually check the steering column for cracks deep scoring or other damage 3 Inspect the steering bearing halves for cracks deep scoring or excessi...

Page 251: ...7 Cotter pin 8 Nut 9 Plate 10 Plate 11 Steering shaft end 12 Nut LH 13 Steering shaft 14 Nut 15 Steering shaft end 16 Bolt 17 Washer 18 Bearing 19 Collar 20 Steering arm 21 Cotter pin 22 Nut 23 Tie rod end 24 Nut 25 Tie rod 26 Nut LH 27 Cotter pin 28 Nut 29 Tie rod end 30 Washer 31 Steeringarm 32 Bolt 33 Steeringarm ...

Page 252: ... describedin the followingpro cedure 9 Installationis the reverse of the precedingsteps Note the following Wipe away any old grease on the components Install the bushings into the steering arm so the bushings are approximately1 mm 0 031 in below the end of the bore Lubricate moving parts with a low temperature grease before installation Refer to Figure 22 and assemble the steering relay arm assemb...

Page 253: ...si tion of the handlebar 6 Tightenthe jam nuts on the steeringrod to 25 N m 18 ft lb Ski Toe Out 1 Park the snowmobileon a level surface 2 Position the snowmobile so the skis are pointing straight ahead 3 Measurethe distancebetweenthe ski centerlinesat the front A Figure 30 and rear B of the skis 4 Distance A must be greater than distance B which re sults in ski toe out Refer to Table 2 for the sp...

Page 254: ...248 CHAPTER THIRTEEN FORWARD Negative Positive O0Camber Angle finder ...

Page 255: ...l The tool should indicate plus or minus O S Ofrom vertical 5 To adjust spindle camber proceed as follows a Loosen the jam nut at the inner end on the lower control arm Figure 36 b Remove the bolt at the outer end of the control arm Figure 37 and separate the control arm end from the spindle c Rotate the control arm to change the length of the control arm d Reattachthe control arm end to the spind...

Page 256: ...column bearing holder Steering relay rod Rod end Jam nuts Tie rod Inner tie rod end nuts Outer tie rod end bolts Jam nuts Steering relay arm pivot bolt Table 2 TOE OUT SPECIFICATIONS 1 Model Toe out 1 MM700 VX700SX prior to 2000 MM700 VX700SX after 1999 All other models 3 18 mm 0 12 0 71 in 0 15 mm 0 0 59 in 0 15 mm 0 0 59 in ...

Page 257: ...re multiple holes are present mark the original location with a marker or paint to facilitate assembly 3 Removethe bolts Figure 3 on each side securingthe rear suspension assembly to the tunnel NOTE Before UP ning the snowmobileon its side in Step 4 placealarge piece of cardboardnext to the snowmobile to protect it from body damage Also plug any fluid container or vent hose to prevent leakage 4 Ti...

Page 258: ...lace the slide rail as described in this procedure 3 Install new wear strips if the thicknessis less than 10 mm 0 39 in thick NOTE Replace the wear strips as a set 4 Remove the wear strips as follows Turn the rear suspension over and rest it upside down on the workbench Remove thescrew Figure5 from the frontof each wear strip NOTE Some mechanicsprefer to use apipe wrench to roll the wearstrip rom ...

Page 259: ...he screw hole in the wear strip aligns with the hole in the rail d Install the screw and tighten securely END CAPS The end caps are attached to the front end of the slide rail with a rivetas shownin Figure6 Inspecttheend caps for wear cracksor otherdamage Replacetheprotectorby removing the rivet Reverse the procedure to install ...

Page 260: ...e the rear suspension as described in this chap ter 2 Remove the boltssecuring the shock absorber Figure 8 3 Remove the shock absorber 4 Inspecttheshockabsorberasdescribedin thischapter 5 Installationis the reverse of these steps Note the fol lowing a Apply a light coat of low temperaturegrease to the shock bolts before assembly b Tighten the shock absorber retaining bolts to 48 N m 35 8 lb Shock ...

Page 261: ...as described in this chap ter 2 Remove the front axle Figure 13 as described in Chapter Twelve 3 Remove the track 4 Installation is the reverse of the preceding steps Ob serve the followingstep 5 When installingthe track positionthe tracklugs to run in the direction shown in Figure 14 Inspection 1 Check for missing or damaged track clips Replace clips as described in this chapter 2 Visually inspec...

Page 262: ...35 ft lb 14 Bushing 15 Collar FRONT COMPONENTS REAR SUSPENSION LATER MM600 MM700 16 Bushing 17 Collar 18 Nut 19 Washer 20 Washer 21 Bolt 22 Strap 23 Nut 24 Washer 25 Bolt 26 Rubber collar 27 Rubber collar 28 Shaft 29 Washer 30 Nut 72 N m 52 ft lb 31 Bushing 32 Collar 33 Bolt 30 Ngm 22 ft lb 34 Bolt 72 Nem 52 ft lb 35 Washer 36 Wheel bracket 37 Bolt 38 Washer 39 Collar 40 Wheel 41 Washer 42 Bolt 43...

Page 263: ...Bolt 13 Collar 14 Bolt 71 N m 50 ft 4b Y 15 Nut 16 Washer 17 Washer 18 Bolt 19 Strap 20 Nut 21 Washer 22 Bolt 23 Shaft 24 Washer 25 Bolt 71 Nom 50 ft 1b Y 26 Nut 24 Nom 17 ft lb 27 Wheel bracket 28 Bolt 29 Washer 30 Collar 31 Wheel 32 Washer 33 Nut 34 Front suspension 35 Bolt 36 N u t 4 9 N m 35 ft lb 37 Sliding frame 38 Bracket 39 B o l t 4 0 N m 22 ft lb 40 Washer 41 Bolt 71 N m 50 ft 4b Y 42 Bu...

Page 264: ...Washer 14 Sliding frame 15 Washer 16 Track tension adjuster 17 Nut 18 Collar 19 Wheel 20 Washer 21 Bushing 22 Collar 23 Controlrod 24 Bushing 25 Washer 26 Wheel 27 Snap ring 28 Collar if so equipped 29 Washer if so equipped 30 Mountingbracket if so equipped 31 Bolt 71 N m 50 ft lb 32 Collar if so equipped 33 Collar 34 Nut 71 Nem 50 ft lb 35 Washer 36 Washer 37 Washer 38 Bolt 39 Washer 40 Collar 41...

Page 265: ...4 Bolt 71 N m 50 ft 1b y 55 Washer 56 Washer Apply Loctite 57 Snap ring 5 8 Wheel 59 Shaft 60 Wheel 61 Sliding frame 62 Bushing 63 Collar 64 Bushing 65 Collar 66 Control rod 67 Shock absorber 68 Washer 69 Collar 70 Bushing 71 Collar 7 2 Washer 73 Bolt 49 N m 35 ft lb 74 Bolt 7 5 Washer 7 6 Rear suspensionbracket 77 N u t 4 9 N m 35 ft lb 78 B o l t 4 9 Nom 35 ft 4b y 79 Shaft 80 Bushing 81 Washer ...

Page 266: ...260 CHAPTERFOURTEEN FRONT Track I Ground fevel OBSTRUCTION DAMAGE 0 LUG DAMAGE 0 RATCHETING DAMAGE ...

Page 267: ...ficient track tension can allow the trackto poundagainstthe track stabilizersinsidethe tunnel h Edge damage Figure 22 caused by tipping the snowmobileon its side to clear the track and allow ing the track edge to contact an abrasive surface Track Clip Replacement Followthe sameclippatternwhen installingnew clips Use a hand grinder safety glasses and a universal track clip installer to remove and i...

Page 268: ...27 Check the clip to make sure it is tight Table 1 TORQUE SPECIFICATIONS N m ft lb Track and suspension assembly Front and center mounting bolts Rear mountingbolts Singlebolt Three bolts Front shock absorber Table 2 CONTROL ARM LENGTH Modellitem mm in MM600 MM700 Upper controlarm 429 2 430 2 16 90 16 94 Lower control arm 428 2 429 2 16 86 16 90 VX700SX Upper controlarm 459 7 460 7 18 10 18 14 Lowe...

Page 269: ...TRACK AND REAR SUSPENSION 263 Table 2 CONTROL ARM LENGTH continued Modelfitem mm in SX600D SX700D Upper control a r m Lower control a r m VT700 VX7OOXTfXTC XTCD XTCP Uppercontrol arm Lower control arm ...

Page 270: ...bed in Chapter Eight Make sure all hose clamps are tight Replacequestionablehose clamps as required 3 Change the chaincase oil as described in Chapter Three CAUTION Donotallowwaterto entertheengine when performing Step 4 4 Clean the snowmobilefrom front to back Remove all debris from the pan and tunnel Clean out debris caughtin the track 5 Check the frame skis and other metal parts for cracks or o...

Page 271: ...l throughout the cylinder j Wipe a film of oil onto the spark plug threads and reinstallthe sparkplugs Reconnectthe hightension leads to the plugs CAUTION During the storage period do not run the engine 10 On electric start models remove the battery and coat the cable terminals with petroleum jelly Check the elec trolyte leveland refill with distilledwaterif it is low Store the battery in an area ...

Page 272: ...n Chapter Three If the oil was not changed before storage change the oil as described in Chapter Three 5 Cheek and adjust drive belt tension 6 Check the coolant level and refill if necessary 7 Check all the control cables for proper operation Ad just them as describedin Chapter Three 8 Fill the oil injection tank If the tank was dry or if a hose was disconnected bleed theoil pumpas describedin Cha...

Page 273: ...uespecifications 232 Chargingsystem test specifications 58 Clip position main jet and pilot jet 593 cc engines 92 698 cc engines 92 93 Clutch specifications high altitude 3000 5000 ft 89 4500 7000 ft 89 90 6500 10 000 ft 90 tuning 84 Controlarm length 262 263 Conversion formulas 36 37 Coolant pump and oil injectionpump drive shaft 122 Cooling system 170 Crankcase and crankshaft 112 122 Cylinder 10...

Page 274: ... 139 Gears sprockets and drive chain VT6OO VT7OO VX600ERand X700XTCDmodels 218 219 General information conversionformulas 36 37 decimal and metric equivalents 36 electrical system fundamentals 22 24 engine specifications 122 123 fasteners 4 6 metric tap and drill sizes 38 serial numbers 3 shop supplies 6 8 snowmobile operation 29 3 1 safety 31 technical abbreviations 37 38 tools basic 8 12 precisi...

Page 275: ...X700SX SXS XT XTC XTCD XTCP 142 143 chaincasesprocket 3000 5000 ft 90 91 6500 10 000 ft 91 4500 7000 ft 91 3500 ft 232 chargingsystem test 58 control arm length 262 263 conversionformulas 36 37 decimal and metricequivalents 36 drive belt 199 chain 231 engine speeds 199 general engine 122 123 torque 37 high altitudeclutch 3000 5000 ft 89 4500 7000 ft 89 90 6500 10 000 ft 90 ignition system test 57 ...

Page 276: ...ctricstarting system 46 48 engine 49 53 fuel system 48 49 ignition system 40 44 test specifications 57 lightingsystem 46 test specifications 58 operating requirements 39 power train 56 57 skis and steering 57 testing electricalcomponents 39 track assembly 57 two strokepressure testing 53 56 Tune up e n 74 83 high altitude clutch specifications 3000 5000 ft 89 4500 7000 ft 89 90 6500 10 000 ft 90 h...

Page 277: ...1 Wiring Diagrams ...

Page 278: ...meter assembly Main switch Engine stop Throttle Carb Variable Thumb switch switch switch meter G f B 1 I 2 3 4 I I Water temp Indicatorlight 1 oil level à t o r sigh SO È beam switch Condenser s Oil level switch Fuel Left and right sender grip warmer ...

Page 279: ... Noconnection Bectlfleri regulator Tail light brake B color Code B Black R Bed G Green L Blue Y Yellow 0 orange P Pink Br Brown BiW BlacWWhite WR BlackiRed BiY BlackJVellow W R WhitdRed WIC Whitmreen WB Onwn BHiCk G R Gra6niF fe d UB Blumad Y B YÈmÈwBla Br R BrowMIaeik Spark plugs ...

Page 280: ...ht G 5 Headlight beam switch Condenser spmdometer  3 light Hgh beam 3 indicator light 1 Water temp d i c a bight Main switch Engine Variable Thumb resistor warmer Tachometer assembly 1 meter GIB 1 t 2 3 4 5 Fuel Left andright sender grip warmer Oil level switch ...

Page 281: ...onnection Aft DC back buzzer Gear position Brake light switch Lm hpassenger Color Code B Black R Red G Green L Blue Y Yellow 0 Orange P Pink Br Brown B W BlackWhite BIR Blacmed B Y BlacWellow WIR White Red WIG WhiteIGreen GIB GreenIBlack GIR GreenIRed UR BlueIRed YE4 YellowIBlack Br R BrownIBlack ...

Page 282: ...NOTES ...

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