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Yamaha MM600D, Service 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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WIRING DIAGRAM
MM600/MM700

B

R

B

L

Y

W

L

R

B

L

W

Y

Y

/

B

B

W

/

R

W

W

/

G

L

B

Y

/

B

W

/

R

W

/

G

W

B

OFF

ON1

ON2

START

Y

/

B Y

/

R Br

R

/

W

R

B B

/

W

R

B

/

W

Y

/

R

R

/

W

B
R

Y

/

B

B
R

Br

Br

Y

/

B

B

/

W

R

/

W

Y

/

R

Y

/

B

B

/

W

B

B

R

R

R

B

B

/

R

B

Y

/

R

Y

/

W

(BLUE)

Y

/

W

Y

/

R

B

B

/

R

(BLUE)

Y

/

W

B

/

R

Y

/

W

B

/

R

Y

/

W

B

/

R

Y

/

R

B

B

W

B

W

B

Y

/

R

Y

/

R

Y

/

R

(L)

(R)

B

B

/

Y

B

/

Y B

/

W

B

/

W B

/

Y

Ch

B

B

/

R Br

Br B

/

R

Br

/

R

Br

/

R

RUN

OFF

B B

/

W

OFF

OPEN

B B

/

Y

B

/

W

RUN

IDLE

B B

/

Y

B

B

B

Ch

Ch

B

B

/

Y

B

/

Y

W

/

G

Br

/

R

B

/

W

B

/

R

W

/

G

Br

/

R

W

/

R

B

/

R

Br

Y

/

B

Br

B

L

/

R

O

B

L

/

R

B

HI

LO

L

Y G

G

Y

L

Y

G

L

L

B

L

B

Y

G

/

R

R

/

B

R

/

B

L

B

Br

Y

G

/

R

L

B

G

/

B

L

B

Br

Br

G

/

B

B

R

/

B

Gy

Br

R

/

B

G

/

R

R

/

B

R

/

B

A

L

L

B

B

B

(GREEN)

(GREEN)

G

/

B

G

/

B

G

/

B

G

/

B

A

G

/

R

G

/

R

A

L

L

A

A

Br

Br

A

B

B

B

B

G

Br

OFF

ON

L G

/

Y

G

/

Y

L

G

/

Y

L

B

G

/

Y

G

/

Y

G

/

Y

G

/

Y

B

C

G

/

Y

G

/

Y

L

B

L

G

/

Y

G

/

Y

B

B G

/

R L

/

R W

/

G

B

/

R

B

/

Y

(BLACK)

O B

/

W

Br

/

R

Br

(BLACK)

C

SUB HARNESS CORD TAIL LIGHT

L

B

L

G

/

Y

G

/

Y

B

B

MAIN HARNESS SUB HARNESS

L

B

L

G

/

Y

G

/

Y

B

A

WIRE HARNESS

SUB HARNESS

R

/

B

G/R

B

G/B

Br

R

/

B

B

G/R

Br

G/B

G

Y

G

Y

L

L

B

G

/

R

L

B

Y

G

G

B

Y

Y

G

G

A

G

A

Y

Y

L

L

B

L

L

L

C

Y

L

L

B

Br

Y

/

R

1

3

4

6

5

D

D

0

9

9

0

0

R

H

I

M

N

G

L

E

F

9

J

K

2

A

S

B

P

O

C

7

8

Q

Summary of Contents for MM600D

Page 1: ...MM600D MM700D SERVICE MANUAL LIT 12618 02 12 8EJ 28197 10 981033 ...

Page 2: ... g Bearings Pitting Damage Replace EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct dis assembly and assembly procedures NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics It is not possible to put an entire mechanic s education into one manual so it is assumed th...

Page 3: ...luid A Lubricant B Tightening C Wear limit clearance D Engine speed E Special tool F Ω V A Illustrated symbols G to O in the exploded dia gram indicate grade of lubricant and location of lubrication point G Apply locking agent LOCTITE H Apply Yamabond No 5 I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply low temperature lithium soap base gre...

Page 4: ...L INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE COOLING SYSTEM CARBURETION ELECTRICAL SPECIFICATIONS INDEX GEN INFO CHAS ENG POWR TR CARB ELEC SPEC COOL 1 INSP ADJ 2 3 4 5 6 7 8 9 ...

Page 5: ...E CABLE FREEPLAY ADJUSTMENT 2 13 THROTTLE OVERRIDE SYSTEM T O R S CHECK 2 14 STARTER CHOKE CABLE FREEPLAY ADJUSTMENT 2 15 EXHAUST SYSTEM INSPECTION 2 15 POWER TRAIN 2 16 SHEAVE DISTANCE AND OFFSET ADJUSTMENT 2 16 DRIVE V BELT 2 18 ENGAGEMENT SPEED CHECK 2 20 PARKING BRAKE PAD INSPECTION 2 20 PARKING BRAKE ADJUSTMENT 2 20 BRAKE FLUID LEVEL INSPECTION 2 21 BRAKE PAD INSPECTION 2 21 BRAKE HOSE INSPEC...

Page 6: ...TION 4 28 INSPECTION 4 30 BRAKE MASTER CYLINDER ASSEMBLY 4 30 INSTALLATION 4 30 SLIDE RAIL SUSPENSION 4 31 INSPECTION 4 36 ASSEMBLY 4 37 INSTALLATION 4 37 FRONT AXLE AND TRACK 4 38 INSPECTION 4 39 INSTALLATION 4 39 CHAPTER 5 ENGINE EXHAUST ASSEMBLY 5 1 INSTALLATION 5 2 ENGINE ASSEMBLY 5 3 INSPECTION 5 4 INSTALLATION 5 4 CYLINDER HEAD AND CYLINDER 5 5 REMOVAL 5 6 INSPECTION 5 7 INSTALLATION 5 12 OI...

Page 7: ...SYSTEM 8 8 CIRCUIT DIAGRAM 8 8 TROUBLESHOOTING 8 9 BULB S 8 10 HEADLIGHT BEAM SWITCH 8 10 CDI MAGNETO 8 11 SIGNAL SYSTEM 8 12 CIRCUIT DIAGRAM 8 12 TROUBLESHOOTING 8 13 TAIL BRAKE LIGHT BULB 8 15 BRAKE LIGHT SWITCH 8 15 WATER TEMPERATURE SENSOR 8 16 OIL LEVEL SWITCH 8 17 FUEL SENDER 8 17 CONDENSER 8 18 GRIP WARMER SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 20 GRIP AND THUMB WARMER COIL 8 21...

Page 8: ...MBER The frame serial number 1 is located on the right hand side of the frame just below the front of the seat ENGINE SERIAL NUMBER The engine serial number 1 is located on the right hand side of the crankcase NOTE Designs and specifications are subject to change without notice SEJ1010 SEJ1020 1 ...

Page 9: ...ed through normal wear Mated parts must be reused or replaced as an assembly 4 During disassembly of the machine clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help ensure that all parts are reinstalled correctly 5 Keep all parts away from any source of fire 6 Be sure to keep to the tightening torque specifications When tightening bolts nut...

Page 10: ...r numbers facing outwards In other words the stamped letters must be on the side exposed to view When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil the bearings liberally when installing CAUTION Do not use compressed air to spin the bearings dry This causes damage to the surface of the bearings CIRCLIPS All circlips should be inspected carefully...

Page 11: ... gauge P N YS 42421 1 15 mm offset This gauge is used to measure the sheave distance and for offset adjustment Dial gauge P N YU 03097 for U S A Canada 90890 03097 for Europe This gauge is used for run out measurement Fuel level gauge P N YM 01312 A for U S A Canada 90890 01312 for Europe This gauge is used to measure the fuel level in the float chamber Distance gauge P N YS 91047 3 for U S A Cana...

Page 12: ...da 90890 01701 for Europe This tool is used to hold the primary sheave Primary sheave puller 18 mm P N YS 39962 This tool is used for removing the primary sheave Clutch spider separator P N YS 28890 B for U S A Canada 90890 01711 for Europe This tool is used when disassembling and assembling the primary sheave Clutch separator adapter P N YS 34480 for U S A Canada 90890 01740 for Europe This tool ...

Page 13: ...22 This tool is used for checking and adjusting the ski spindle camber FOR CARBURETION SERVICE Mity vac P N YB 35956 for U S A Canada 90890 06756 for Europe This tool is used to check the fuel pump FOR ELECTRICAL SERVICE Pocket tester P N YU 03112 for U S A Canada 90890 03112 for Europe This instrument is necessary for checking the electrical components Electro tester P N YU 33260 A for U S A Cana...

Page 14: ...ve track idler wheels Slide runners Pre operation check Daily Initial 1 month or 800 km 500 mi 40 hr Every Seasonally or 3 200 km 2 000 mi 160 hr Check condition Adjust gap and clean Replace if necessary Check oil level Air bleed the oil pump if necessary Check fuel level Check condition Replace if necessary Check fuel hose for cracks or damage Replace if necessary Check oil hose for cracks or dam...

Page 15: ...ecessary Check proper placement Whenever operating elevation is changed Whenever operating elevation is changed Initial at 80 km 50 mi and every 800 km 500 mi thereafter See NOTE Brake parking brake Drive chain oil Drive chain Skis and ski runners Steering system Strap Lights Primary sheave Secondary sheave Steering column bearing Ski and front suspension Suspension component Parking brake cable e...

Page 16: ... Regap Use a wire thickness gauge Spark plug gap a 0 7 0 8 mm 0 028 0 031 in If necessary clean the spark plugs with a spark plug cleaner Standard spark plug BR9ES NGK Before installing a spark plug clean the gasket surface and spark plug surface 4 Install Spark plugs Spark plug 20 Nm 2 0 m kg 14 ft lb NOTE Finger tighten a the spark plug before torquing b it to specification T R SEJ2010 SEJ2020 S...

Page 17: ... 2 US qt 2 Remove Carburetors Refer to CARBURETORS in CHAPTER 7 3 Place a rag under the oil pump assembly to soak up any spilled oil 4 Disconnect Oil hose 5 Drain the oil until no more air bubbles appear in the oil hose 6 Connect Oil hose 7 Disconnect Oil delivery hose 8 Feed the YAMALUBE 2 cycle oil into the oil delivery hose using an oil can for complete air bleeding 9 Connect Oil delivery hose ...

Page 18: ...e throttle cable distance should be adjusted Adjustment steps Slide back the adjuster cover Loosen the locknut 1 Turntheadjuster2inoroutuntilthespecified distance a is obtained Distance a MM600 23 1 mm 0 906 0 04 in MM700 22 1 mm 0 866 0 04 in Turning in Distance a is increased Turning out Distance a is decreased Tighten the locknut and push in the adjuster cover SEJ2060 SEJ2070 ...

Page 19: ...Cracks damage Replace 3 Install Intake silencer Refer to FUEL PUMP in CHAPTER 7 COOLING SYSTEM Coolant replacement NOTE The coolant should be changed at least every season 1 Place the machine on a level surface 2 Remove Exhaust pipe Exhaust joint Refer to EXHAUST ASSEMBLY in CHAP TER 5 3 Make sure that the carburetor heating lever 1 is turned to ON a SEJ2080 SEJ2090 SEJ2100 ...

Page 20: ...ntil it stop Thisallowsanyresidualpressuretoescape Whenthehissingsoundhasstopped pressdown on the cap while turning it counterclockwise to remove it 5 Place an open container under the coolant drain bolt 1 6 Remove Coolant drain bolt Gasket coolant drain bolt 7 Drain the coolant NOTE Lift up the tail of the machine to drain the coolant 8 Remove Right side cover 1 9 Disconnect Coolant hose 3 1 10 D...

Page 21: ... wash it away with soap and water 11 Connect Coolant hose 3 12 Install Right side cover 1 Bolt side cover 3 Nm 0 3 m kg 2 2 ft lb 13 Disconnect Coolant reservoir hose 1 14 Remove Coolant reservoir cap 1 15 Drain the coolant from the coolant reservoir 16 Install Coolant reservoir cap 17 Connect Coolant reservoir hose 18 Inspect Gasket coolant drain bolt Damage Replace 19 Install Gasket Coolant drai...

Page 22: ...ant water mixed ratio 3 2 60 40 Total amount 4 2 L 3 65 lmp qt 4 41 US qt Reservoir tank capacity 0 17 L 0 15 lmp qt 0 18 US qt From LOW to FULL level 0 13 L 0 11 lmp qt 0 14 US qt CAUTION Hard water or salt water is harmful to engine parts If soft water is not available use boiled or distilled water Do not use water containing impurities or oil 22 Bleed the air from the cooling system 23 Inspect ...

Page 23: ... reservoir drain the coolant until no more air bubbles appear Tighten the bleed bolt Bleed bolt 4 Nm 0 4 m kg 2 9 ft lb Add coolant to the coolant cold level a Loosen the bleed bolt 2 on the thermostatic cover Drain the coolant until no more air bubbles appear Tighten the bleed bolt 2 Bleed bolt 2 7 Nm 0 7 m kg 5 1 ft lb Install the coolant filler cap Apply and lock the parking brake Start the eng...

Page 24: ...ear could occur or the machine could unexpectedly move forward if the clutch engages Operate the engine only in a well ventilated area Remove the coolant filler cap and bleed the cooling system again as described above No air bubbles OK Add coolant to the specified level Pour coolant into the coolant reservoir 3 until the coolant level reaches the FULL level mark 3 Install Bleed bolt cap SEJ2210 ...

Page 25: ...times Make sure that all of the carburetor throttle valves are at the same height 3 Install Carburetors Refer to CARBURETORS in CHAPTER 7 ENGINE IDLE SPEED ADJUSTMENT 1 Adjust Engine idle speed Adjustment steps Start the engine and let it warm up Turn the throttle stop screw 1 in or out until the specified engine idle speed is obtained Turning in Idle speed is increased Turning out Idle speed is d...

Page 26: ...ation Adjust Throttle cable freeplay a 1 0 2 0 mm 0 04 0 08 in 2 Adjust Throttle cable freeplay Adjustment steps Loosen the locknut 1 Turn the adjusting nut 2 in or out until the specified freeplay is obtained Turning in Freeplay is increased Turning out Freeplay is decreased Tighten the locknut NOTE After adjusting the freeplay turn the handlebar to rightandleft andmakesurethattheengineidling doe...

Page 27: ...ine 2 Hold the pivot point of the throttle lever away fromthethrottleswitchbyputtingyourthumb above and forefinger below between the throttle lever pivot 1 and stop switch housing 2 While holding as described above press the throttle lever 3 gradually TheT O R S willoperateandtheengineshould run between 2 800 and 3 000 r min WARNING If the engine does not run between 2 800 and 3 000 r min stop the...

Page 28: ... until the specified freeplay is obtained Turning in Freeplay is increased Turning out Freeplay is decreased Tighten the locknut EXHAUST SYSTEM INSPECTION 1 Open the shroud 2 Remove Springs Refer to EXHAUST ASSEMBLY in CHAP TER 5 3 Inspect Exhaust joint 1 Exhaust pipe 2 Exhaust silencer 3 Cracks damage Replace Exhaust gasket 4 Exhaust gasket 5 Exhaust gasket 6 Exhaust gas leaks Replace 4 Check Tig...

Page 29: ...uge YS 91047 3 4 Measure Sheave offset a Use the sheave gauge Out of specification Adjust Sheave offset a 13 5 16 5 mm 0 53 0 64 in Sheave gauge YS 42421 1 15 mm offset 5 Adjust Sheave distance Adjustment steps Loosen the engine mounting bolts Adjust the position of the engine so that the sheave distance is within the specification Tighten the engine mounting bolts Mounting bolt front 1 90 Nm 9 0 ...

Page 30: ...04 0 08 in 7 Adjust Secondary sheave freeplay clearance Adjustment steps Apply the brake to lock the secondary sheave Remove the bolt 1 and washer 2 Adjust the secondary sheave freeplay clear ance by adding or removing a shim s 3 Shim size Part number Thickness 90201 222F0 0 5 mm 0 02 in 90201 225A4 1 0 mm 0 04 in SHEAVE DISTANCE AND OFFSET ADJUSTMENT SEJ2340 SEJ2350 ...

Page 31: ...ving or adding a spacer 1 on each adjusting bolt 2 CAUTION As the V belt wears adjustment may be neces sary To ensure proper clutch performance the V beltpositionshouldbeadjustedbyaddingaspacer on each adjusting bolt when the V belt position reaches 1 5 mm 0 06 in below the edge New belt width 34 5 mm 1 36 in Belt wear limit width 32 5 mm 1 28 in 1 Measure V belt position a NOTE Install the new V ...

Page 32: ...ft lb 4 Inspect Drive V belt Cracks damage wear Replace Oil or grease on the V belt Check the primary and secondary sheaves 5 Inspect Primary sheave Secondary sheave Oil or grease on the primary and secondary sheaves Use a rag soaked in lacquer thinner or solvent to remove the oil or grease Check the primary and secondary sheaves 6 Measure Drive V belt length a Out of specification Replace Drive V...

Page 33: ...N 1 Measure Parking brake pad thickness a Out of specification Replace as a set Wear limit a 6 0 mm 0 24 in PARKING BRAKE ADJUSTMENT 1 Measure Clearance a Out of specification Adjust Clearance a 1 2 1 3 mm 0 047 0 051 in 2 Adjust Clearance a Adjustment steps Loosen the locknut 1 Turn the cable adjuster 5 in or out to until the specified clearance between the brake pad 6 and disc 4 is obtained Turn...

Page 34: ...ING Use only the designated brake fluid Other fluids may deteriorate the rubber seals caus ing leakage and poor brake performance Refill with the same type of fluid Mixing fluids may result in a harmful chemical reaction lead ing to poor brake performance When refilling be careful that water does not enter the brake master cylinder reservoir Wa ter will significantly lower the boiling point of the...

Page 35: ...system Air bleeding steps Fill the brake master cylinder reservoir with the proper brake fluid Install the diaphragm Be careful not to spill any fluid or allow the brake master cylinder reservoir to overflow Connect a clear plastic hose 1 tightly to the brake caliper bleed screw 2 Place the other end of the hose in a container a Slowly apply the brake lever several times b Pull the lever in then h...

Page 36: ...BRAKE FLUID LEVEL INSPECTION WARNING After bleeding the brake system check the brake operation DRIVE CHAIN Oil level inspection WARNING The engine and muffler will be very hot after the engine has run Avoid touching a hot engine and muffler while they are still hot with any part of your body or clothing during inspection or repair 1 Place the machine on a level surface 2 Check Oil level Checking s...

Page 37: ...he oil is between the upper a and lower b levels If not add oil to the upper level Å For models without reverse transmissions ı For models with reverse transmissions not applicable Recommended oil Gear oil API GL 3 SAE 75 or 80 CAUTION Make sure that no foreign material enters the gear case Reinsert the dipstick and fit the loop 2 of the dipstick handle onto the projection 3 of the gear case Oil r...

Page 38: ... or bystanders Observe the following precautions Do not allow anyone to stand behind the machine when the engine is running When the rear of the machine is raised to allow the track to spin a suitable stand must be used to support the rear of the machine Never allow anyone to hold the rear of the machine off the ground to allow the track to spin Never allow anyone near a rotating track Inspect the...

Page 39: ...just Track deflection a 20 25 mm 0 79 0 98 in 3 Adjust Track deflection Adjustment steps Place the machine onto a suitable stand to raise the track off of the ground Loosen the rear axle nut 1 NOTE It is not necessary to remove the cotter pin 2 a Start the engine and rotate the track once or twice Stop the engine b Check the track alignment with the slide run ner 3 If the alignment is incorrect tu...

Page 40: ... adjuster 5 Right adjuster More than specified Turn in Turn in Less than specified Turn out Turn out CAUTION The adjusters should be turned an equal amount Recheck the alignment and deflection If nec essary repeat steps a to c until the speci fied amount is obtained Tighten the rear axle nut Nut rear axle 75 Nm 7 5 m kg 54 ft lb SLIDE RUNNER INSPECTION 1 Inspect Slide runner 1 Cracks damage wear R...

Page 41: ... SYSTEM Freeplay check 1 Check Steering system freeplay Move the handlebar up and down and back and forth Turn the handlebar slightly to the right and left Excessivefreeplay Checkthatthehandle bar tie rod ends and relay rod ends are installed securely in position If freeplay still exists checkthesteeringbearing frontsus pension links and ski mounting area for wear Replace if necessary Toe out adju...

Page 42: ...knuts tie rod 1 Locknut rod end 1 25 Nm 2 5 m kg 18 ft lb LOCTITE CAUTION After tightening the inside and outside ball joint locknut 1 makesurethetierod2 canberotated freely through the ball joint travel If not loosen the locknut 1 and re position the ball joint so that the tie rod 2 can be rotated freely Tighten the locknut to specification Å Left side ı Right side Ç Inside SEJ2650 SEJ2660 C SEJ2...

Page 43: ... Å Front ı Rear SEJ2680 SEJ2690 SEJ2700 SEJ2670 LUBRICATION Brake lever throttle lever and throttle cable end 1 Lubricate the brake lever pivot throttle lever and the ends of the throttle cables Recommended lubricant ESSO Beacon 325 Grease WARNING Apply a dab of grease onto only the end of the cables Do not grease the throttle cables They could freeze and cause a loss of control ...

Page 44: ...ght s high beam and check the height of the projected beam on the wall The projection should be at the position marked in step 3 or 1 2 lower distance S D 3 0 m 10 ft 7 6 m 25 ft S 26 mm 1 0 in 66 mm 2 6 in D Distance S Set range 6 Adjust Headlight beam vertically Vertical adjustment Higher Turn the adjusting screw 1 2 clockwise Lower Turn the adjusting screw 1 2 counter clockwise 7 Adjust Headlig...

Page 45: ...ing on the throttle opening Therefore after the carbu retors have been tuned or maintained or after the float chambers are removed for cleaning or jet replacement be sure to idle the engine for about three minutes in order to avoid engine trouble CAUTION Before performing the carburetor tuning make sure that the following items are set to specification Engine idle speed Throttle cable freeplay Car...

Page 46: ...park plug insulator 1 color A medium to light tan color indicates nor mal conditions Distinctly different color Replace the main jet 4 The main jet should be adjusted on the basis of the Main jet selection chart NOTE By checking the condition of the spark plugs it is easy to get some idea of the condition of the engine This may diagnose potential problems before engine damage occurs High altitude ...

Page 47: ...2 34 INSP ADJ CARBURETOR TUNING Guide for carburetion SEJ2750 ...

Page 48: ...encer box is removed from the carbu retors the change in pressure in the intake will create a lean mixture that may cause severe engine damage The air silencer box has no effect on performance characteristics and must be se curedtothecarburetorsduringcarburetortuning and adjustment Also it must always be in place when the engine is operated Regularly clean the silencer and keep it free from obstru...

Page 49: ...ixture screw 2 MM600 2 turns out MM700 1 1 2 turns out Pilot mixture screw effects Turn in STD setting Turn out Leaner Richer Mixture Mixture 2 Settheengineidlespeedbyturningthethrottle stop screw in to increase engine speed or out to decrease engine speed Standard idle speed 1 600 100 r min 3 Iflow speedperformanceisstillpoorathigher elevationsunderextremeconditions thestan dard pilot jets may ne...

Page 50: ...oubleshooting Trouble Hard starting Poor idling Poorperformanceat low speeds Poor acceleration Slow response to throttle Engine tends to stall Diagnosis Insufficient fuel Excessive use of the starter or choke Fuel passage is clogged or frozen Overflow Improper idling speed adjustment Damaged pilot screw Clogged bypass hole Clogged or loose pilot jet Air leaking into the car buretor joint Defective...

Page 51: ...lean it with compressed air and then install it Make sure that the pilot jet is fully tightened Overhaul the carburetors Remove the air vent hose and clean it Remove the main jet clean it with compressed air and then install it Make sure that the main jet is fully tightened Check and if necessary clean the float and float valve Return the starter lever to its seated position so that the starter va...

Page 52: ... screw Ó Gearing 21 39 68 links 19 39 68 links È Primary spring 90501 603L2 Ô Color Y W Y Length 91 4 mm Ò Preload rate 45 kg 2 5 kg mm Wire diameter 6 0 mm ˆ Outside diameter 60 0 mm Ø Weight ID 8DG00 Weight rivet Steel 17 2 OUT Steel 13 3 OUT Steel 13 3 OUT Aluminum 10 3 OUT Steel 17 2 IN Steel 13 9 IN Steel 10 3 IN Steel 10 3 IN Œ Weight bushing Duralon  Roller outer dia 15 6 mm Í Roller bushi...

Page 53: ...inks È Primary spring 90501 603L2 Ô Color Y W Y Length 91 4 mm Ò Preload rate 45 kg 2 5 kg mm Wire diameter 6 0 mm ˆ Outside diameter 60 0 mm Ø Weight ID 8CR00 Weight rivet Steel 13 9 OUT Steel 10 3 OUT Aluminum 10 3 OUT Aluminum 10 3 OUT Steel 17 2 IN Steel 13 3 IN Steel 13 9 IN Aluminum 10 3 IN Œ Weight bushing Duralon  Roller outer dia 14 5 mm Í Roller bushing Duralon Ê Pri clutch shim None Ë ...

Page 54: ...wet snow icy snow hills or rough ter rain however engine speed may decrease after the shifting speed has been reached Å Engine speed ı Good condition Ç Bad condition Î Clutch shifting speed Clutch engagement speed Ï Starting position Ì 200 300 m 650 1 000 ft Ó Distance travelled GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow condi tions If...

Page 55: ...1 739 68 links 68 links 70 links 70 links 70 links ı Driven gear 3 Secondary spring Å Part no 90508 500B1 90508 536A9 90508 556A2 90508 556A7 4 Secondary spring twist angle 90508 500B1 brown 90508 536A9 red 90508 556A2 green 90508 556A7 silver 0 3 6 9 1 10 40 70 100 2 20 50 80 110 3 30 60 90 120 ı Sheave Ç Part no Å Seat È Standard MM600 MM700 ı Spring rate N mm rad kg mm rad 6003 612 6 7147 729 3...

Page 56: ...secondary spring seat Ç Part no 8BV 17604 71 8BV 17604 51 8BV 17604 31 8BV 17604 11 8BV 17604 91 GEAR SELECTION SEJ2820 Ç Standard MM600 MM700 Î Cam angle 47 45 43 41 39 ı Effects Identification mark 8BV71 8BV51 8BV31 8BV11 8BV91 ...

Page 57: ...ire gauge mm in È Outside diameter mm in Spring rate N mm kg mm Ï Preload N mm kg 88 4 3 48 90 9 3 578 93 4 3 677 85 4 3 362 84 3 3 318 87 4 3 44 86 1 3 389 91 2 3 59 89 4 3 519 95 9 3 775 93 4 3 677 89 0 3 503 86 7 3 413 83 4 3 283 82 6 3 251 85 1 3 35 87 9 3 46 86 7 3 413 91 4 3 598 89 8 3 535 84 2 3 314 Free length mm in 4 91 4 91 4 91 4 92 4 66 4 92 4 66 5 25 4 92 5 65 5 25 5 25 5 25 4 82 4 60...

Page 58: ...NSP ADJ GEAR SELECTION 7 Clutch weights 8CH 17605 10 35 32 g Å Standard 8CR 17605 10 38 09 g 8DF 17605 10 37 84 g MM700 8DG 17605 00 34 26 g 8DJ 17605 00 37 77 g MM600 SEJ2900 SEJ2890 SEJ2870 SEJ2860 SEJ2850 ...

Page 59: ...METER Ç BUSHING TYPE P N Î IDENTIFICATION MARK Width Standard Ï EFFECTS 8CR 17624 00 00 8CR 17624 10 00 8CR 17624 20 00 8CR 17624 30 00 14 5 mm 0 57 in 15 0 mm 0 59 in 15 6 mm 0 61 in 16 0 mm 0 63 in Duralon 90380 09245 00 Duralon 90380 09245 00 Duralon 90380 09245 00 Duralon 90380 09245 00 MM700 MM600 ...

Page 60: ...e Adjust the primary clutch as required Adjust the secondary clutch as re quired High altitude tuning OK OK Check to see if the gearing is too high or low OK Not OK Not OK Not OK OK Not OK Not OK OK Check STD settings Carburetors Spark plugs HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions carefully tune the snowmobile as outlined below Test the main jet performance ...

Page 61: ...n Preload Standard 1 2 3 4 5 FRONT SUSPENSION Spring preload 1 Adjust Spring preload Adjustment steps Turn the adjusting ring 1 to the proper posi tion CAUTION Be sure that the left and right spring preload is the same Softer Harder MM600 3 MM700 3 SEJ2960 ...

Page 62: ...pper band tension Adjuster 10 0 5 mm 0 39 0 02 in thread Longer Shorter length a Maximum Minimum Effects More weight Less weight on skis less on skis more weight weight transfer transfer Tighten the locknut Locknut 16 Nm 1 6 m kg 11 ft lb Spring preload 1 Adjust Spring preload Adjustment steps Turn the adjusting ring 1 to the proper posi tion 1 2 3 4 5 Softer Harder MM600 3 MM700 3 Spring adjuster...

Page 63: ...2 or 3 4 turns while hold ingtheadjustingbolt2securelywithawrench so it does not move CAUTION Never allow the adjusting bolt 2 to move while loosening the nut Turn the adjusting bolt 2 to the desired posi tion CAUTION Be sure the adjusting bolt ends are set at the same position on each side While holding the adjusting bolt securely tighten the nut 1 Nut shock absorber 49 Nm 4 9 m kg 35 ft lb CAUTI...

Page 64: ...just Rear suspension position Refer to SLIDE RAIL SUSPENSION in CHAPTER 4 NOTE Select the rear suspension position according to the snow conditions a standard b deep new snow Bolt slide rail suspension 72 Nm 7 2 m kg 52 ft lb REAR SUSPENSION T R SEJ2A40 ...

Page 65: ...reverse the removal proce dure Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Job name Part name Handlebar removal Handlebar cover Plastic band Oil tank breather hose Thumb warmer coupler Engine stop switch coupler Brake switch coupler Headlight beam switch coupler Grip warmer lead Throttle cable holder Throttle cable Oil pump cable Brake lever holder Master cylinder assembly Handlebar holder upp...

Page 66: ... 10 11 12 13 14 15 Job name Part name Steering column and tie rod removal Engine assembly Handlebar Cotter pin Clip Relay rod Lock washer Bearing holder Bearing Collar Steering column Cotter pin Tie rod Washer Washer Bushing Collar Relay arm 80 Nm 8 0 m kg 58 ft lb 23 Nm 2 3 m kg 17 ft lb 35 Nm 3 5 m kg 25 ft lb 42 Nm 4 2 m kg 30 ft lb Q ty 1 1 1 2 3 4 4 1 4 2 2 2 2 1 1 SEJ3020 3 1 ESSO beacon 325...

Page 67: ... 2 Wear damage Replace Steering column 3 bearing contact surfaces Scratches wear damage Replace 3 Inspect Relay rod 1 Tie rods 2 Bends cracks damage Replace WARNING Do not attempt to straighten bent rods This may dangerously weaken the rods 4 Check Rod end movement Rod end freeplay exists Replace the rod end Rod end turns roughly Replace the rod end 5 Inspect Relay arm Cracks damage Replace SEJ303...

Page 68: ...n both rod ends must be the same length CAUTION Always use new cotter pins Locknut rod end 25 Nm 2 5 m kg 18 ft lb LOCTITE Nut tie rod relay arm 35 Nm 3 5 m kg 25 ft lb Nut tie rod steering arm 42 Nm 4 2 m kg 30 ft lb 3 Install Relay rod 1 NOTE Make sure that the end of the relay rod with the indentation a is connected to the relay arm CAUTION Always use new cotter pins Nut relay rod 35 Nm 3 5 m k...

Page 69: ... 1 Locknut relay rod 25 Nm 2 5 m kg 18 ft lb LOCTITE 5 Install Handlebar CAUTION Be sure the projection on the handlebar is not installed into the area a shown Be sure the side of the holder with the small gap b faces forward Center the match mark c on the handlebar 1 between the handlebar holders lower 2 Bolt handlebar holder 23 Nm 2 3 m kg 17 ft lb CAUTION First tighten the bolts on the front si...

Page 70: ...erse the removal proce dure Order 1 2 3 4 5 6 7 8 9 Job name Part name Ski removal Cotter pin Ski column lower bracket Ski stopper Collar Washer Ski Ski runner Washer Ski handle 11 Nm 1 1 m kg 8 0 ft lb Å 21 Nm 2 1 m kg 15 ft lb ı 48 Nm 4 8 m kg 35 ft lb ç 1 ESSO beacon 325 grease or Aeroshell grease 7A SEJ3140 ...

Page 71: ...3 7 CHAS SKI INSPECTION 1 Inspect Ski 1 Ski runner 2 Ski stopper 3 Ski column lower bracket 4 Ski handle 5 Wear cracks damage Replace Mounting bolt 6 Collar 7 Bolts 8 Wear damage Replace SEJ3150 ...

Page 72: ...proce dure Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name Part name Front suspension removal Ski Tie rod Shock absorber Cap Steering arm Ski column Bushing Washer Control rod Collar Bushing Connecting rod Collar Front arm 1 ESSO beacon 325 grease or Aeroshell grease 7A 48 Nm 4 8 m kg 35 ft lb Ç 50 Nm 5 0 m kg 36 ft lb Î 56 Nm 5 6 m kg 40 ft lb 78 Nm 7 8 m kg 56 ft lb Ï 42 Nm 4 2 m kg 30 ft lb ı SEJ3...

Page 73: ...mage Replace Bushing 3 Wear scratches damage Replace 3 Inspect Control rod 1 Cracks bends damage Replace Bushing 2 Collar 3 Wear scratches damage Replace 4 Inspect Connecting rod 1 Stabilizer 2 Cracks bends damage Replace Collar 3 Wear scratches damage Replace 5 Inspect Front arm 1 Cracks bends damage Replace SEJ3170 SEJ3180 SEJ3190 SEJ3200 SEJ3210 ...

Page 74: ... a on the ski column with the punch mark b on the steering arm Nut steering arm 56 Nm 5 6 m kg 40 ft lb SEJ3220 SEJ3230 Å Left hand ı Set length a mm 93 1 93 1 429 7 0 5 mm 16 9173 0 0197 in 428 7 0 5 mm 16 8779 0 0197 in Upper Ï Lower Ç Set angle Ì color b Green Î Right hand ı Set length a mm 87 1 87 1 429 7 0 5 mm 16 9173 0 0197 in 428 7 0 5 mm 16 8779 0 0197 in Upper Ï Lower Ç Set angle Ì color...

Page 75: ...y pan 2 Place the angle finder up against the vertical flat surface on the trailing arm just behind the spindle weld and check the spindle camber 3 To adjust the camber loosen the lower radius rod ball joint locknut and remove the bolt securing the radius rod to the trailing arm Turn the rod in or out as necessary until the proper camber angle is obtained Ski spindle camber 0 5 to 0 5 Angle finder...

Page 76: ...e to keep the ball joint outer housing centered with the ball to prevent binding Ski alignment NOTE Besuretoverifythespringpreloadsettingandtheskispindlecamberbeforeadjustingtheskitoeoutsince either of those adjustments may affect the ski toe out setting Point the skis straight forward and measure the amount of ski toe out Refer to STEERING SYSTEM in CHAPTER 2 FRONT SUSPENSION Å Ski toe out 0 15 m...

Page 77: ...E V BELT Q ty 1 1 1 Remarks Remove the parts in the order listed below For installation reverse the removal proce dure Order 1 2 3 Job name Part name Primary sheave removal V belt Blind cap Primary sheave assembly Å 1st 120 Nm 12 0 m kg 87 ft lb 2nd 60 Nm 6 0 m kg 43 ft lb SEJ4010 ...

Page 78: ...me Primary sheave disassembly Primary sheave cap Primary sheave spring Collar Roller Washer Collar Weight Washer Fixed sheave Stopper Sliding sheave Bushing Spider Slider 3 Nm 0 3 m kg 2 2 ft lb Å 14 Nm 1 4 m kg 10 ft lb Ç 6 Nm 0 6 m kg 4 3 ft lb ı 200 Nm 20 m kg 145 ft lb Î SEJ4020 4 Clean the threads Apply LOCTITE 648 as illustrated in Ï And then tighten the spider The spider must be turned coun...

Page 79: ...er piece of the clutch spider separator 6 onto a rigid table using suitable mounting bolts Then install the clutch separator adapter 7 onto the separator Clutch spider separator 90890 01711 YS 28890 B Clutch separator adapter 90890 01740 YS 34480 Fit the primary sheave assembly onto the adapter and secure the supporting plates 8 NOTE Securelyfittheprojectionsontheadapterintothe fixed sheave holes ...

Page 80: ...g sheave from the spider INSPECTION 1 Inspect Spider 1 Sliding sheave 2 Fixed sheave 3 Primary sheave cap 4 Cracks damage Replace 2 Inspect Primary sheave spring 1 Cracks damage Replace 3 Measure Primary sheave spring free length a Out of specification Replace the primary sheave spring Primary sheave spring free length a 91 4 mm 3 6 in NOTE When changing the primary sheave springs refer to GEAR SE...

Page 81: ...rk 2 side Press or peen the rivet head so that the diameter a of the rivet head measures 8 2 mm 0 32 in or larger 6 Measure Bushing inside diameter Out of specification Replace as a set Bushing inside diameter Å Roller New 9 077 mm 0 357 in Wear limit 9 3 mm 0 366 in ı Weight New 8 077 mm 0 318 in Wear limit 8 3 mm 0 327 in NOTE When replacing the weight and roller bushings use the YXR clutch bush...

Page 82: ...e specified area Never apply it to the bushings and other areas a 16 mm 0 63 in b 30 35 mm 1 18 1 38 in 3 Install Fixed sheave stoppers 1 NOTE Stoppertaperedportionshouldfacefixedsheave 4 Tighten Spider Tightening steps Finger tighten the spider until it is stopped by the fixed sheave stopper Hold the fixed sheave with the clutch spider separator 1 Clutch spider separator 90890 01711 YS 28890 B NO...

Page 83: ... sure the spider fixed sheave and special tool are well secured Tighten the spi der carefully to prevent cracks and damage to the sheaves and spider 5 Install Weight Nut 1 6 Nm 0 6 m kg 4 3 ft lb NOTE To maintain the primary sheave balance the bolts 2 must be installed with their threaded portionspointinginacounterclockwisedirection as illustrated 6 Install Primary sheave spring 1 Primary sheave c...

Page 84: ...e primary sheave 3 using the primary sheave holder 2 and tighten the bolt primary sheave to specification Primary sheave holder 90890 01701 YS 01880 Bolt primary sheave 1 initial tightening 120 Nm 12 m kg 87 ft lb Loosen the bolt primary shave completely Retighten the bolt primary sheave to specifi cation Bolt primary sheave 1 60 Nm 6 0 m kg 43 ft lb 4 Adjust V belt position Refer to DRIVE V BELT ...

Page 85: ...ts in the order listed below Refer to SHEAVE DISTANCE AND OFFSET ADJUSTMENT in CHAPTER 2 For installation reverse the removal proce dure Order 1 2 3 4 5 Job name Part name Secondary sheave removal V belt Washer Shim Collar Secondary sheave assembly 64 Nm 6 4 m kg 46 ft lb Å SEJ4250 ...

Page 86: ... reverse the disassembly pro cedure Order 1 2 3 4 5 Job name Part name Secondary sheave disassembly Spring seat Secondary sheave spring Fixed sheave Stopper Sliding sheave 1 ESSO beacon 325 grease or Aeroshell grease 7A 10 Nm 1 0 m kg 7 2 ft lb ı 23 Nm 2 3 m kg 17 ft lb Ç 6 5 Nm 0 65 m kg 4 6 ft lb Å SEJ4260 ...

Page 87: ...he instruc tions thoroughly 1 Remove Nuts spring seat INSPECTION 1 Inspect Sliding sheave 1 Fixed sheave 2 Spring seat 3 Cracks damage Replace Stopper 4 Wear damage Replace 2 Inspect Bushing spring seat 1 Sliding sheave V belt contact surface 2 Scratches wear damage Replace Sliding bushing 3 Unsymmetrical wear damage Replace 3 Inspect Secondary sheave spring 1 Cracks damage Replace 4 Measure Secon...

Page 88: ...5 Nm 0 65 m kg 4 6 ft lb 2 Install Fixed sheave 1 Bolts 2 along with the shims Bolt 10 Nm 1 0 m kg 7 2 ft lb 3 Install Secondary sheave spring 1 Spring seat 2 NOTE Hook the end of the secondary sheave spring into the spring holes in the fixed sheave Hook the other end of the spring into the holes in the spring seat Standard spring position 2 6 MM600 1 6 MM700 T R T R SEJ4310 SEJ4320 SEJ4330 ...

Page 89: ...til the bolts come through the holes While pushing down on the spring seat install the nuts and tighten them to the specified torque Nut spring seat 23 Nm 2 3 m kg 17 ft lb 4 Measure Secondary sheave clearance a Out of specification Adjust Secondary sheave clearance a 35 0 35 8 mm 1 38 1 41 in 5 Calculate Shim thickness NOTE For example if the clearance is 36 mm 1 42 in install a 0 5 mm 0 02 in sh...

Page 90: ...commendskeepingtheoriginalshims Shims Part number Thickness 90201 061H1 0 5 mm 0 02 in 90201 06037 1 0 mm 0 04 in SECONDARY SHEAVE SEJ4370 INSTALLATION 1 Lubricate Splines fixed sheave Recommended grease ESSO beacon 325 grease or Aeroshell grease 7A 2 Tighten Secondary sheave bolt 64 Nm 6 4 m kg 46 ft lb 3 Adjust V belt position Refer to DRIVE V BELT in CHAPTER 2 Sheave distance Sheave offset Seco...

Page 91: ...e removal proce dure Order 1 2 3 4 5 6 7 8 9 10 Job name Part name Drive chain housing removal Brake caliper Parking brake Tension adjuster Bolt Drive chain housing cover Chain tensioner Roller Drive sprocket Collar Drive chain Driven sprocket Collar Drive chain housing 16 Nm 1 6 m kg 11 ft lb Å 24 Nm 2 4 m kg 17 ft lb ı 48 Nm 4 8 m kg 35 ft lb Ç 60 Nm 6 0 m kg 43 ft lb Î DRIVE CHAIN HOUSING SEJ43...

Page 92: ...s a set Replacement steps Remove the circlip 5 drive chain housing Remove the bearing s 3 using a general bearing puller Install the new bearing s NOTE Use a socket 6 that is the same size as the outside diameter of the bearing race CAUTION Do not strike the inner race 7 or ball bearings 8 Contact only the outer race 9 Install a new circlip drive chain housing CAUTION Always use new circlips 2 Ins...

Page 93: ...hain Maximum 14 link drive chain section length 133 35 mm 5 25 in Limit 137 35 mm 5 41 in NOTE Measure the length between drive chain pin 1 and E as shown Perform this measurement at two or three dif ferent places If replacement is necessary always replace the chain and the sprockets as a set 4 Inspect Drive chain 1 Stiffness Clean and lubricate or replace Drive chain plates 2 Damage wear Replace ...

Page 94: ...g making sure that there are no gaps C1 C2 Be sure to install the spacers in their original positions otherwisethebrakediscandjackshaft will stick Î 0 1 0 5 mm 0 004 0 020 in ESSO beacon 325 grease or Aeroshell grease 7A For the jackshaft and drive chain housing installa tion refer to JACKSHAFT 2 Fill Drive chain housing oil Refer to DRIVE CHAIN in CHAPTER 2 3 Adjust Drive chain slack Refer to DRI...

Page 95: ...o FUEL PUMP in CHAPTER 7 Refer to DRIVE CHAIN HOUSING For installation reverse the removal proce dure Order 1 2 3 4 5 6 7 8 Job name Part name Jackshaft removal Secondary sheave Silencer Drive chain housing Collar Brake disc Key Washer Circlip Jackshaft Bearing holder Bearing 8 5 Nm 0 85 m kg 6 1 ft lb Å 23 Nm 2 3 m kg 17 ft lb ı SEJ4440 ...

Page 96: ...earing contact surface 3 Scratches wear damage Replace the jackshaft 2 Inspect Bearing holder 1 Cracks damage Replace Bearing 2 Pitting damage Replace 3 Measure Brake disc thickness a Out of specification Replace Minimum thickness a 10 mm 0 39 in Measuring point 1 3 mm 0 04 0 12 in from the edge of the brake disc SEJ4450 SEJ4460 SEJ4470 ...

Page 97: ...ghten the nuts 3 Tighten the nuts 4 Nut jackshaft 4 60 Nm 6 0 m kg 43 ft lb Retighten the nuts 3 Nut bearing holder 3 23 Nm 2 3 m kg 17 ft lb Tighten the set screws 5 Set screw bearing 5 8 5 Nm 0 85 m kg 6 1 ft lb Install the drive chain housing cover 6 Å Properlyinstalltherubbersealontothedrivechain housing making sure that these are no gaps Tighten the bolts 7 Bolt drive chain housing cover 7 24...

Page 98: ...arts in the order listed below For installation reverse the removal proce dure Order 1 2 3 4 5 6 Job name Part name Brake pad removal Cap bolt Retaining pin Pad spring Brake pad Shim 1 Shim 2 6 Nm 0 6 m kg 4 3 ft lb Å 48 Nm 4 8 m kg 35 ft lb ı BRAKE SEJ4490 ...

Page 99: ...ccur Do not disconnect any hydraulic connection otherwise the entire system must be disas sembled drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE It is not necessary to disassemble the brake cali per and brake hose in order to replace the brake pads 1 Remove Brake pads 1 NOTE Do not depress the brake lever when the caliper or disc is off the machine ot...

Page 100: ...caliper with your finger Tighten the caliper bleed screw 2 Bleed screw 2 6 Nm 0 6 m kg 4 3 ft lb Install the brake pads and pad spring NOTE The tangs a of the pad spring must point in the direction of the disc rotation 3 Inspect Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 2 4 Check Brake lever operation A soft or spongy feeling Bleed brake system Refer to AIR BLEEDING HYDRA...

Page 101: ...1 2 2 2 Remarks Remove the parts in the order listed below Drain For installation reverse the removal proce dure Order 1 2 3 4 5 6 7 8 9 Job name Part name Brake caliper and parking brake re moval Brake fluid Brake hose Brake caliper assembly Cotter pin Parking brake cable Pin Pin Collar Spring Brake shoe SEJ4540 ...

Page 102: ...emove the parts in the order listed below For assembly reverse the disassembly pro cedure Order 1 2 3 4 5 6 7 8 9 Job name Part name Brake caliper disassembly Cap bolt Retaining pin Pad spring Brake pad Shim 1 Shim 2 Bleed screw Oil seal Piston SEJ4550 ...

Page 103: ... the piston seals and reinstall the piston Repeat the previous steps to force out the right piston from the caliper body WARNING Never try to pry out the pistons Do not loosen the retaining pin 3 BRAKE CALIPER INSPECTION AND REPAIR Recommended brake component replacement schedule WARNING All internal brake components should be cleaned only with new brake fluid Do not use solvents as they will caus...

Page 104: ...ever a caliper is disassembled BRAKE CALIPER ASSEMBLY WARNING All internal parts should be cleaned only with new brake fluid Internal parts should be lubricated with brake fluid when installed Recommended brake fluid DOT 4 Replace the piston seals and dust seals when ever a caliper is disassembled BRAKE CALIPER INSTALLATION 1 Install Brake hose 1 CAUTION When installing the brake hose 1 onto the b...

Page 105: ...ster cylinder body Q ty 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed below Drain For installation reverse the removal proce dure Order 1 2 3 4 5 6 7 Job name Part name Brake master cylinder removal Brake fluid Parking brake cable Brake switch Brake lever Parking brake lever Brake hose joint Holder Master cylinder assembly 14 Nm 1 4 m kg 10 ft lb Å 30 Nm 3 0 m kg 22 ft lb ı SEJ4610 ...

Page 106: ...R CYLINDER ASSEMBLY WARNING All internal parts should be cleaned only with new brake fluid Internal parts should be lubricated with brake fluid when installed Recommended brake fluid DOT 4 Replace the piston seals and dust seals when ever a caliper is disassembled INSTALLATION 1 Connect Brake hose NOTE Install the brake hose with the mark a facing upwards as shown in the diagram Brake hose joint B...

Page 107: ...ON Q ty 2 1 Remarks Remove the parts in the order listed below Loosen For installation reverse the removal proce dure Order 1 2 Job name Part name Slide rail suspension removal Tension adjuster Collar Slide rail suspension 72 Nm 7 2 m kg 52 ft lb Å SEJ4650 ...

Page 108: ... 35 ft lb 72 Nm 7 2 m kg 52 ft lb Ï Job name Part name Slide rail suspension disassembly Stopper band Hook Rubber collar Rubber collar Shaft Bushing Collar Front shock absorber Front pivot arm Bushing Collar Bushing Collar Front suspension bracket Suspension wheel Collar Wheel bracket SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Î 30 Nm 3 0 m kg 22 ft lb SEJ4660 1 ESSO beacon 325 grease or Aerosh...

Page 109: ...Job name Part name Suspension wheel Collar Wheel bracket Front pivot arm bracket Circlip Suspension wheel Collar Bushing Collar Rear suspension bracket Spacer Bushing Collar 24 Nm 2 4 m kg 17 ft lb Å 49 Nm 4 9 m kg 35 ft lb ı 72 Nm 7 2 m kg 52 ft lb Ç SEJ4670 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 110: ...Remarks Order U V W X Y Z a Job name Part name Rear shock absorber Bushing Collar Pull rod Collar Bushing Suspension wheel Control rod Bushing Bushing Shaft 49 Nm 4 9 m kg 35 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı SEJ4680 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 111: ...e Part name Rear pivot arm Bushing Collar Collar Rear pivot arm bracket Collar Circlip Suspension wheel Wheel bracket shaft Rear axle Guide wheel Collar Tension adjuster Collar Collar Sliding frame SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı 75 Nm 7 5 m kg 54 ft lb Ç SEJ4690 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 112: ... Replace 2 Inspect Stopper band 1 Frayed damage Replace Pull rod 2 Bends damage Replace Shock absorber 3 Oil leaks damage Replace Bushings Wear cracks damage Replace Front pivot arm 4 Rear pivot arm 5 Rear pivot arm bracket 6 Suspension wheel bracket 7 Sliding frame 8 Cracks damage Replace Slide runner 9 Wear damage Replace SEJ4700 SEJ4710 ...

Page 113: ... 7 2 m kg 52 ft lb 2 Install Stopper band 1 NOTE Install the stopper band with a toward the hook and b toward the shaft Nut stopper band 4 Nm 0 4 m kg 2 9 ft lb INSTALLATION 1 Install Slide rail suspension NOTE Select the rear suspension position according to the snow conditions a standard b deep new snow Bolt slide rail suspension 72 Nm 7 2 m kg 52 ft lb SEJ4720 SEJ4730 SEJ4740 T R T R T R ...

Page 114: ...ARY SHEAVE For installation reverse the removal proce dure Order 1 2 3 4 5 6 Job name Part name Front axle and track removal Drive chain housing Slide rail suspension Secondary sheave Speedometer gear assembly Cable joint Set bolt Front axle assembly Bearing Track FRONT AXLE AND TRACK 8 Nm 0 8 m kg 5 8 ft lb Å 20 Nm 2 0 m kg 14 ft lb ı Q ty 1 1 2 1 1 1 SEJ4750 ...

Page 115: ...ct Sprocket wheel 1 Wear break damage Replace Front axle 2 Bends scratches excessive damage Replace INSTALLATION 1 Install Sprocket wheels Guide wheels NOTE When pressing the sprocket wheels onto the frontaxle alignthelugsoneachsprocketwheel Position each sprocket wheel on the axle as shown in the illustration 2 Place the track in the chassis NOTE For track with a direction of rotation mark a Inst...

Page 116: ... listed below Open For installation reverse the removal proce dure Q ty 2 2 1 1 1 1 1 1 2 1 1 Job name Part name Exhaust assembly removal Shroud Shroud s stopper wire Spring 1 Spring 2 Spring 3 Exhaust pipe Gasket 1 Gasket 2 Exhaust joint Gasket 3 Spring 4 Spring 5 Exhaust silencer 27 Nm 2 7 m kg 19 ft lb Å SEJ5010 5 ...

Page 117: ...t with its projection a facing the primary sheave side Tighten the bolts 1 6 in a crisscross pattern Bolt exhaust joint 27 Nm 2 7 m kg 19 ft lb 2 Install Spring 5 1 Springs 4 2 Spring 3 3 Springs 2 4 Springs 1 5 NOTE Install the springs as shown T R SEJ5020 SEJ5030 4 1 5 3 2 6 a 5 3 2 4 1 2 1 ...

Page 118: ...t Disconnect Disconnect Disconnect Disconnect For installation reverse the removal proce dure Q ty 1 1 1 1 1 1 1 1 2 1 1 Job name Part name Engine removal Exhaust assembly Carburetors Recoil starter CDI Magneto rotor Primary sheave Coolant Coolant hose 1 Coolant hose 2 Carburetor heating hose 1 Plastic band Carburetor heating hose 2 Water temperature sensor coupler Rear bracket right Oil pump cabl...

Page 119: ...ll parts refer to CABLE ROUT ING in chapter 9 to check the cable lead and hose routings 1 Bleed Oil system Refer to OIL PUMP in CHAPTER 2 Cooling system Refer to COOLING SYSTEM in CHAPTER 2 2 Adjust Oil pump cable distance Refer to OIL PUMP in CHAPTER 2 Distance MM600 22 24 mm 0 87 0 94 in MM700 21 23 mm 0 83 0 91 in SEJ5050 ...

Page 120: ...plug Cylinder head Gasket Cylinder Gasket Clamp Intake manifold Spacer Reed valve seat Reed valve stopper Reed valve Gasket Piston ring Piston pin Piston Bearing Remarks Remove the parts in the order listed below For installation reverse the removal proce dure 14 Nm 1 4 m kg 10 ft lb Å 20 Nm 2 0 m kg 14 ft lb ı 1st 11 Nm 1 1 m kg 8 0 ft lb 2nd 23 Nm 2 3 m kg 17 ft lb Ç 28 Nm 2 8 m kg 20 ft lb Î SE...

Page 121: ...into the crankcase Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and the piston pin is still difficult to remove use the piston pin puller Putidentificationmarksoneachpistonheadfor reference during reinstallation Piston pin puller 90890 01304 YU 01304 CAUTION Do not use a hammer to drive out the piston pin out 1 Piston pin 2 Piston 3 P...

Page 122: ...of minerals rust Clean 3 Measure Cylinder head warpage Out of specification Resurface Warpage limit 0 03 mm 0 0012 in Straight edge 1 Thickness gauge 2 4 Eliminate Carbon deposits from the cylinders Use the rounded scraper 1 CAUTION Do not use a sharp instrument Avoid damaging or scratching the surface 5 Eliminate Carbon deposits from the piston crown and ring grooves 6 Inspect Piston crown Burrs ...

Page 123: ...NOTE Measure the cylinder bore C parallel to and at right angles to the crankshaft Then find the aver age of the measurements C Maximum D T Maximum of D1 or D2 Maximum of D5 or D6 R Maximum of D1 D3 or D5 Minimum of D2 D4 or D6 If out of specification replace cylinder and replace piston and piston rings as a set Standard Wear limit MM600 65 000 65 014 mm 2 5591 2 5596 in MM700 70 500 70 520 mm 2 7...

Page 124: ...ion replace the piston and piston rings as a set 3rd step Calculatethepiston to cylinderclearancewith the following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P If out of specification rebore or replace cylin der and replace piston and piston rings as a set Piston to cylinder clearance MM600 0 065 0 070 mm 0 0026 0 0028 in Limit 0 1 mm 0 004 in MM700 0 070 0 075 mm ...

Page 125: ...nd 0 02 0 06 mm 0 0008 0 0024 in 10 Install Piston ring into the cylinder Push in the ring with the piston crown NOTE Insert the ring into the cylinder and push it ap proximately 20 mm 0 8 in into the cylinder Push in the ring with the piston crown so that the ring is at right angles to the cylinder bore 11 Measure End gap piston rings Use the feeler gauge 1 Out of specification Replace the rings ...

Page 126: ... clearance Bore size piston pin b Outside diameter piston pin a Piston pin to piston clearance 0 009 0 015 mm 0 000354 0 000591 in 14 Inspect Reed valves 1 Bends cracks damage Replace 15 Measure Valve stopper height a Out of specification Replace the valve stopper Valve stopper height a 10 4 10 8 mm 0 41 0 43 in 16 Measure Reed valve bending limit a Out of specification Replace the reed valve Reed...

Page 127: ...E Tighten each screw gradually to avoid warping 3 Install Small end bearing Piston Piston pin Piston pin clip Piston rings NOTE The arrowa on the piston must point toward to the front of the engine Before installing the piston pin clip cover the crankcase with a clean rag so that you do not accidentallydropthepinclipandothermaterial into the crankcase Position each piston very carefully in its ori...

Page 128: ...rings face upward 5 Install Gasket cylinder NOTE Install the gasket cylinder with its projection a facing the CDI magneto side CAUTION Always use new gasket 6 Install Cylinder NOTE Install the cylinder with one hand while com pressing the piston rings with the other hand 7 Install Gaskets cylinder head NOTE Install with the mark a facing upwards and the projection b on the intake side 8 Tighten Nu...

Page 129: ...arily tighten the cylinder head nuts 1 E as follows 1st step Tighten the nuts 1 E Nut cylinder head 1 E 11 Nm 1 1 m kg 8 0 ft lb 2nd step Retighten the nuts 1 E Nut cylinder head 1 E 23 Nm 2 3 m kg 17 ft lb CYLINDER HEAD AND CYLINDER SEJ5330 ...

Page 130: ...eft Front lower bracket Damper Front upper bracket Water pump cover Gasket Oil hose 2 Lower crankcase Crankshaft assembly Oil seal Upper crankcase 8 Nm 0 8 m kg 5 8 ft lb Å 13 Nm 1 3 m kg 9 4 ft lb ı 15 Nm 1 5 m kg 11 ft lb Ç 40 Nm 4 0 m kg 29 ft lb Remarks Remove the parts in the order listed below For installation reverse the removal proce dure 2nd 27 Nm 2 7 m kg 19 ft lb 1st 11 Nm 1 1 m kg 8 0 ...

Page 131: ...ay a Use the dial gauge Outofspecification Replacethedefective parts Small end freeplay a 0 8 1 0 mm 0 03 0 04 in Big end side clearance b Use the feeler gauge Outofspecification Replacethedefective parts Big end side clearance b 0 25 0 75 mm 0 01 0 03 in 3 Inspect Crankshaft bearing 1 Pitting damage Replace Stopper ring 2 Bends damage Replace Crankshaft oil seals 3 Impeller drive gear teeth 4 Wea...

Page 132: ... brackets 3 Front upper brackets 4 Rear bracket 5 Dampers 6 Cracks damage Replace 5 Inspect Impeller driven gear teeth 1 Wear damage Replacetheimpellershaft Impeller shaft 2 Bearing 3 Pitting damage Replace 6 Inspect Oil pump Cracks damage Replace Oil hoses Clogs damage Replace SEJ5380 SEJ5390 SEJ5400 ...

Page 133: ...o the upper crankcase Å NOTE Turn the bearings and labyrinth seal to set the knock pins 1 on the bearings and labyrinth seal into the pin holes 2 in the upper crankcase Å 3 Bearing CDI magneto side NOTE Turn bearing 3 to set the knock pin 4 on the upper crankcase Å into the pin hole 5 in the bearing CAUTION The oil seal lip must fit into the crankcase groove SEJ5410 SEJ5420 SEJ5440 SEJ5430 ...

Page 134: ...lts be sure to check that the crankshaft turns smoothly 4 Tighten Crankcase bolts 1 F M8 80 NOTE Tighten the bolts in order starting with the lowest number and torque the bolts in two stages Bolt crankcase First 13 Nm 1 3 m kg 9 4 ft lb Final 27 Nm 2 7 m kg 19 ft lb 5 Tighten Crankcase bolts 1 6 M8 35 NOTE Tighten the bolts in order starting with the lowest number Bolt crankcase 15 Nm 1 5 m kg 11 ...

Page 135: ...5 20 ENG a OIL PUMP CRANKCASE AND CRANKSHAFT 5 Install Oil hose 1 NOTE Install so that the mark a on the check valve faces the crankcase SEJ5480 ...

Page 136: ...isconnect For installation reverse the removal proce dure Order 1 2 3 4 5 6 7 8 9 Job name Part name CDI Magneto removal Recoil starter Frame cross member CDI magneto coupler Starter pulley Spacer Magneto rotor Woodruff key Clamp Plate Stator coil 23 Nm 2 3 m kg 17 ft lb Å 48 Nm 4 8 m kg 35 ft lb ı 110 Nm 11 m kg 80 ft lb Ç SEJ5490 ...

Page 137: ...sheave holder 90890 01701 YS 01880 2 Remove Magneto rotor 1 NOTE Remove the magneto rotor using the rotor puller 2 Fully tighten the tool holding bolts making sure the tool body is parallel with the magneto rotor If necessary one screw may be backed out slightly to level the tool body Rotor holding puller 90890 01362 YU 33270 SEJ5500 SEJ5510 ...

Page 138: ...l the grommet in the crankcase 2 Install Magneto rotor Washer Nut magneto rotor CAUTION Be sure to remove any oil or grease from the tapered portion of the magneto rotor using a cloth dampened with thinner NOTE When installing the magneto rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 3 Tighten Starter pulley bolt 1 23 Nm 2 3 m kg 17 ft lb Magneto rotor nut 2 1...

Page 139: ...5 24 ENG 1 2 CDI MAGNETO SEJ5540 4 Install Stator coil NOTE Routethepickupcoillead1underandbehindthe pickup coil 2 as shown ...

Page 140: ...For installation reverse the removal proce dure Order 1 2 3 4 5 6 7 8 9 10 11 12 Nm 1 2 m kg 8 7 ft lb Å 18 Nm 1 8 m kg 13 ft lb ı Job name Part name Recoil starter removal Exhaust silencer Starter handle Recoil starter case Drive plate Washer Drive pawl Return spring Cam guide Drive plate spring Sheave drum Starter rope Starter spring SEJ5550 ...

Page 141: ...o that it is not pulled into the recoil starter case 4 INSPECTION 1 Inspect Drive plate 1 Cracks bends damage Replace Drive pawl 2 Return spring 3 Cam guide 4 Wear cracks damage Replace Drive plate spring 5 Wear damage Replace Sheave drum 6 Cracks damage Replace Starter spring 7 Cracks bends damage Replace Starter rope 8 Wear breaks damage Replace SEJ5560 SEJ5570 SEJ5580 ...

Page 142: ...ler diameter Mesh the sheave drum hook 4 with the spring hook 5 3 Install Drive pawl 1 Cam guide 2 Drive plate 3 NOTE The cam guide2 should not be on top of the drive pawl 1 4 Pullaboutfourinchesofstarterropeoutofthe cutout portion in the sheave drum and rotate thesheavedrum41 2timescounterclockwise to preload the starter spring NOTE Pass the rope through the case hole and make a knot 1 in the rop...

Page 143: ...9 10 11 12 13 14 15 16 17 18 19 20 Job name Part name Heat exchanger removal Coolant Coolant filler cap Coolant hose 1 Spring 1 Filler cap body Carburetor heating hose 1 Carburetor heating lever assembly Carburetor heating hose 2 Plastic band Carburetor heating hose 3 Clamp Coolant hose 2 Spring 2 Coolant hose 3 Heat exchanger right Coolant hose 4 Coolant hose 5 Heat exchanger left Heat exchanger ...

Page 144: ...essure Cap opens with a pressure below the speci fied pressure Replace Cap opening pressure 100 120 kPa 1 0 1 2 kg cm2 14 17 psi Measurement steps Attach the cooling system tester 1 to the coolant filler cap 2 Cooling system tester 90890 01325 YU 24460 01 Apply the specified pressure for 10 seconds and make sure there is no pressure drop INSTALLATION 1 Install Heat exchangers Use the rivet gun SEJ...

Page 145: ...llation reverse the removal proce dure Order 1 2 3 4 5 6 7 8 9 10 Job name Part name Water pump and thermostatic valve removal Exhaust joint Coolant Thermostatic cover Plain washer Gasket Plastic band Engine bracket Carburetor heating hose Coolant hose Water pump cover Gasket Impeller 10 Nm 1 0 m kg 7 2 ft lb Å 13 Nm 1 3 m kg 9 4 ft lb ı 33 Nm 3 3 m kg 24 ft lb Ç 90 Nm 9 0 m kg 65 ft lb Î SEJ6040 ...

Page 146: ...Water pump cover 2 Thermostatic cover 3 Cracks damage Replace INSTALLATION 1 Install Impeller 1 NOTE Attach the primary sheave holder to hold the primary sheave Primary sheave holder 90890 01701 YS 01880 Bolt impeller 10 Nm 1 0 m kg 7 2 ft lb 2 Fasten Carburetor heating hose 1 Plastic band 2 NOTE Fasten the carburetor heating hose without squashing it T R SEJ6050 SEJ6060 SEJ6070 SEJ6080 ...

Page 147: ...uretor heating lever is turned to OFF Unfasten Loosen Disconnect For installation reverse the removal proce dure Order 1 2 3 4 5 6 7 8 9 Job name Part name Carburetors removal Intake silencer Carburetor heating lever Carburetor switch T O R S lead Throttle cable Starter cable Clamp Carburetor heating hose Clamp screw Fuel hose Carburetor CARBURETION CARBURETORS SEJ7010 ...

Page 148: ...verse the separation proce dure Order 1 2 3 4 5 6 7 8 9 0 A B C D E Job name Part name Carburetor separation Carburetor heating hose Starter cable holder Collar Spring Screw Starter rod Spring Starter lever Breather hose Top cover Gasket Throttle shaft connecting screw Clamp Connecting plate upper Connecting plate lower SEJ7020 7 ...

Page 149: ...rt name Carburetor disassembly Throttle stop screw Carburetor switch T O R S Throttle cable holder Throttle valve assembly Inner throttle lever assembly Boot Starter plunger assembly Pilot mixture screw Spring Washer O ring Float chamber 0 7 Nm 0 07 m kg 0 51 ft lb Å 1 Nm 0 1 m kg 0 7 ft lb ı 1 8 Nm 0 18 m kg 1 3 ft lb Ç 2 5 Nm 0 25 m kg 1 8 ft lb Î SEJ7030 ...

Page 150: ...G H I J K L M N Job name Part name Gasket Main jet Main jet ring Main nozzle Pilot jet Pilot jet sleeve Float pin Float Needle valve Screw valve seat Valve seat assembly O ring CARBURETORS 0 7 Nm 0 07 m kg 0 5 ft lb Å 1 Nm 0 1 m kg 0 7 ft lb ı 1 8 Nm 0 18 m kg 1 3 ft lb Ç 2 5 Nm 0 25 m kg 1 8 ft lb Î SEJ7040 ...

Page 151: ...sed air 2 Inspect Rubber seals 1 Bearing 2 Wear damage Replace 3 Inspect Float 1 Damage Replace 4 Inspect Valve seat assembly 1 Main nozzle 2 Main jet 3 Main jet ring 4 Pilot jet 5 Pilot jet sleeve 6 Pilot mixture screw assembly 7 Starter plunger assembly 8 Jet needle 9 Bends wear damage Replace Blockage Blow out the jets with com pressed air SEJ7050 SEJ7060 SEJ7070 SEJ7080 ...

Page 152: ...clean gasoline Always use new gaskets and O rings 1 Tighten Inner parts Pilot air jet 0 7 Nm 0 07 m kg 0 51 ft lb Screw valve seat 1 Nm 0 1 m kg 0 7 ft lb Pilot jet 0 7 Nm 0 07 m kg 0 51 ft lb Main jet 1 8 Nm 0 18 m kg 1 3 ft lb Starter plunger assembly 2 5 Nm 0 25 m kg 1 8 ft lb 2 Measure Float height a Out of specification Adjust Float height a 11 3 15 3 mm 0 44 0 60 in T R SEJ7090 SEJ7100 ...

Page 153: ...at height is not within specification inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by bending the float arm tang 1 on the float Recheck the float height 3 Install Return springs 1 Carburetors No 1 No 3 NOTE Hook the spring hooks 2 to the projections on the connecting lever 3 and carburetor body 4 while twisting the spring cloc...

Page 154: ...01312 A NOTE Use the adapter outside diameter ø6 hose 2 when attaching the fuel level gauge Loosen the drain screw 3 and start the en gine Place the tube along the seam line 4 of the carburetor body Measure the fuel level a with the gauge If the fuel level is incorrect adjust the fuel level Remove the carburetor Inspect the valve seat and needle valve If either is worn replace them both If both ar...

Page 155: ...heck the cable lead and hose routings 1 Fasten Carburetor heating hose 1 NOTE Fasten the carburetor heating hose with a clamp 2 at the white mark a 2 Adjust Starter cable freeplay Refer to STARTER CHOKE CABLE FREEPLAY ADJUSTMENT in CHAPTER 2 3 Bleed Cooling system Refer to COOLING SYSTEM in CHAPTER 2 SEJ7160 ...

Page 156: ...l proce dure Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Job name Part name Fuel pump removal CDI unit Carburetor heating lever assembly Air filter element Screw Ignition coil 1 Ignition coil 2 3 Plastic band Plastic clip Wire harness Intake silencer Fuel hose Fuel delivery hose Vacuum hose Oil hose Fuel pump assembly 3 Nm 0 3 m kg 2 2 ft lb Å 5 Nm 0 5 m kg 3 6 ft lb ı 10 Nm 1 0 m kg 7 2 ft lb Ç SEJ...

Page 157: ... Mity vac 90890 06756 YB 35956 Place a container 3 under the end of the fuel delivery hoses 4 Operate the Mity vac 1 while checking that fuel flows from the fuel delivery hoses 4 If fuel does not flow out replace the fuel pump INSTALLATION NOTE After installing all parts refer to CABLE ROUT ING in chapter 9 to check the cable lead and hose routings 1 Bleed Oil system Refer to OIL PUMP in CHAPTER 2...

Page 158: ...n it on and off a few times INSPECTING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the left column and the switch lead colors in the top row For each switch position indicates the terminals with continuity The example c...

Page 159: ... R B Gy Br R B G R R B R B A L L B B B GREEN GREEN G B G B G B G B A G R G R A L L A A Br Br B B B B G Br L OFF ON L G Y G Y L G Y L B L G Y G Y G Y G Y B C G Y G Y L B L G Y G Y B B G R L R W G B R B Y BLACK O B W Br R Br BLACK C SUB HARNESS CORD TAIL LIGHT L B L G Y G Y B B MAIN HARNESS SUB HARNESS L B L G Y G Y B A WIRE HARNESS SUB HARNESS R B G R B G B Br R B B G R Br G B G Y G Y L L B G R B Y...

Page 160: ...place the spark plug cap Check the ignition coil resistance OK OUT OF SPECIFICATION Replace the ignition coil Check the stator coil OK FAULTY Replace the CDI magneto Check the engine stop switch throttle switch carburetor switch and main switch OK FAULTY Replace the handlebar switch right carburetor switch and or main switch Correct the connection and or replace the CDI unit IGNITION SYSTEM ...

Page 161: ...tance 1 Secondary coil resistance 2 Out of specification Replace Primary coil resistance 1 0 05 0 07 Ω at 20 C 68 F Secondary coil resistance 2 2 7 3 7 kΩ at 20 C 68 F CDI MAGNETO 1 Disconnect CDI magneto coupler 2 Connect Pocket tester to the CDI magneto coupler 3 Measure Source coil pickup coil resistances Out of specification Replace Source coil resistance 1 Brown Black Red 392 479 Ω at 20 C 68...

Page 162: ...min if the carburetor fails to return to idle when the lever is released WARNING If T O R S operates make sure that the cause of the malfunction is corrected and that the engine can be operated without a problem before restarting the engine Be sure to use the standard resistance type spark plug and spark plug cap Otherwise T O R S will not work properly Throttle switch OFF OFF T O R S operating ON...

Page 163: ...tinuity RUN pulled out Yes OFF pushed in No 4 Check Throttle switch continuity Faulty Replace the handlebar switch right Throttle switch position Continuity Throttle lever is operated Yes Throttle lever is not operated No CARBURETOR SWITCH 1 Disconnect Carburetor switch lead 2 Connect Pocket tester 3 Check Carburetor switch continuity Faulty Replace Carburetor switch position Continuity Throttle l...

Page 164: ...TCH 1 Disconnect Main switch coupler 2 Connect Pocket tester 3 Check Main switch continuity Faulty Replace Switch position Continuity OFF Yes ON No Switch Color code position Y B Y R Br R R W B B W OFF ON1 ON2 START Continuity SEJ8180 ...

Page 165: ...R B Gy Br R B G R R B R B A L L B B B GREEN GREEN G B G B G B G B A G R G R A L L A A Br Br B B B B G Br L OFF ON L G Y G Y L G Y L B L G Y G Y G Y G Y B C G Y G Y L B L G Y G Y B B G R L R W G B R B Y BLACK O B W Br R Br BLACK C SUB HARNESS CORD TAIL LIGHT L B L G Y G Y B B MAIN HARNESS SUB HARNESS L B L G Y G Y B A WIRE HARNESS SUB HARNESS R B G R B G B Br R B B G R Br G B G Y G Y L L B G R B Y ...

Page 166: ...ND OR METER LIGHT DO NOT COME ON Check the bulb s OK NO CONTINUITY Replace the bulb s Check the headlight beam switch and lighting coil OK FAULTY Replace the headlight beam switch and or the CDI magneto Correct the connection and or replace the rectifier regulator ...

Page 167: ...rom the bulb while it is on it will be hot Do not touch the bulb until it cools down 3 Check Bulb s Terminal Continuity 1 2 Yes 1 3 Yes HEADLIGHT BEAM SWITCH 1 Disconnect Headlight beam switch coupler 2 Connect Pocket tester to the headlight beam switch coupler 3 Check Headlight beam switch continuity Faulty Replace Switch position a Continuity b Continuity HI No Yes LO Yes No SEJ8200 SEJ8210 SEJ8...

Page 168: ...1 Disconnect CDI magneto coupler 2 Connect Pocket tester to the CDI magneto coupler 3 Measure Lighting coil resistance Outofspecification ReplacetheCDImag neto Lighting coil resistance Yellow Black 0 255 0 311 Ω at 20 C 68 F SEJ8230 SEJ8240 ...

Page 169: ... GREEN GREEN G B G B G B G B A G R G R A L L A A Br Br B B B B G Br L OFF ON L G Y G Y L G Y L B L G Y G Y G Y G Y B C G Y G Y L B L G Y G Y B B G R L R W G B R B Y BLACK O B W Br R Br BLACK C SUB HARNESS CORD TAIL LIGHT L B L G Y G Y B B MAIN HARNESS SUB HARNESS L B L G Y G Y B A WIRE HARNESS SUB HARNESS R B G R B G B Br R B B G R Br G B G Y G Y L L B G R B Y G G B Y Q Y G G A G A Y Y L L B L L L...

Page 170: ...RATURE AND OR OIL LEVEL INDICATOR LIGHTS DO NOT COME ON NOTE The indicator lights come on for a few seconds after the engine starts If the lights do not come on check the indicator light circuit and bulb s Check the water temperature and or oil level indicator light bulb s OK NO CONTINUITY Replace the bulb s Check the lighting coil OK FAULTY Replace the CDI magneto Check the water temperature sens...

Page 171: ... FAULTY Replace the fuel sender Check for voltage on the condenser coupler OK OUT OF SPECIFICATION Correct the connection and or replace the rectifier regulator Check the condenser OK OUT OF SPECIFICATION Replace the condenser Check the fuel meter OK DOES NOT MOVE Replace the fuel meter Correct the connection for the fuel meter system ...

Page 172: ...Tail brake light bulb Terminal Continuity 1 2 Yes 1 3 Yes BRAKE LIGHT SWITCH 1 Check Brake light switch continuity Faulty Replace Switch position Continuity Brake lever operates Yes Brake lever does not operate No SIGNAL SYSTEM SEJ8260 SEJ8270 ...

Page 173: ...ter temperature sensor 2 in coolant 3 and check the water temperature sensor operation Water temperature sensor resistance 2 21 2 70 kΩ at 20 C 68 F 1 03 1 26 kΩ at 40 C 104 F 0 52 0 65 kΩ at 60 C 140 F 0 29 0 35 kΩ at 80 C 176 F 4 Temperature gauge CAUTION Never heat the coolant to a temperature of 120 C 248 5 F or more 4 If the water temperature sensor operation is defective replace it 5 Install...

Page 174: ...tinuity FUEL SENDER 1 Remove Intake silencer Refer to FUEL PUMP in CHAPTER 7 Fuel sender 1 from the fuel tank 2 Connect Pocket tester to the fuel sender coupler 3 Measure Fuel sender resistance Out of specification Replace Fuel sender resistance up a 4 10 Ω at 20 C 68 F Fuel sender resistance down b 90 100 Ω at 20 C 68 F Switch position Good condition Bad condition Down position Up position Å ı SE...

Page 175: ...8 18 ELEC SIGNAL SYSTEM CONDENSER 1 Disconnect Condenser 1 2 Connect Condenser to the LCR meter 3 Measure Condenser capacity Out of specification Replace Condenser capacity 4 700 µF at 20 C 68 F SEJ8340 ...

Page 176: ... Y G G Y L Y G L L B L B Y G R R B R B L B Br Y G R L B G B L B Br Br G B B R B Gy Br R B G R R B R B A L L B B B GREEN GREEN G B G B G B G B A G R G R A L L A A Br Br B B B B G Br L OFF ON L G Y G Y L G Y L B L G Y G Y G Y G Y B C G Y G Y L B L G Y G Y B B G R L R W G B R B Y BLACK O B W Br R Br BLACK C SUB HARNESS CORD TAIL LIGHT L B L G Y G Y B B MAIN HARNESS SUB HARNESS L B L G Y G Y B A WIRE ...

Page 177: ...place the grip warmer and or thumb warmer Check the variable resistor CORRECT INCORRECT Replace the variable resistor Check the grip warmer coil CORRECT INCORRECT Replace the CDI magneto Check the lighting coil CORRECT INCORRECT Replace the CDI magneto Check the stator coil and or connection OK NO CONTINUITY Replace the CDI magneto and or correct connec tion Replace the voltage regulator ...

Page 178: ... warmer 2 continuity No continuity Replace both grips to gether or separately and or the handlebar switch VARIABLE RESISTOR 1 Disconnect Variable resistor coupler 2 Connect Pocket tester to the variable resistor coupler 3 Check Variable resistor resistance When pulley is turned once Out of specification Replace the variable resistor Variable resistor resistance Yellow White Black Red 400 600 Ω at ...

Page 179: ...sconnect CDI magneto coupler 2 Connect Pocket tester to the CDI magneto coupler 3 Measure Grip warmer coil resistance Outofspecification ReplacetheCDImag neto Grip warmer coil resistance Yellow Black Black 1 51 1 85 Ω at 20 C 68 F SEJ8410 SEJ8420 ...

Page 180: ...uantity Manufacturer Spark plug Type Manufacturer Gap Model 8EJ 8ED 2 990 mm 117 7 in 1 115 mm 43 9 in 1 215 mm 47 8 in 232 kg 511 lb 4 2 m 13 8 ft 4 2 m 13 8 ft Liquid cooled 2 stroke piston port Crankcase reed valve Forward inclined parallel 3 cylinder 593 cm3 36 2 cu in 698 cm3 42 6 cu in 65 0 59 6 mm 2 56 2 35 in 70 5 59 6 mm 2 78 2 35 in 6 6 1 6 7 1 8 500 r min 8 250 r min Recoil hand starter...

Page 181: ...on system Manufacturer Generator system Bulb wattage Quantity Headlight Tail Brake light Tachometer light Speedometer light High beam indicator light Water temp indicator light Oil level indicator light V Belt 3 8 1 0 1 Automatic centrifugal engagement Chain 2 05 39 19 1 90 40 21 No Monocoque 22 5 980 mm 38 6 in Leading arm Slide rail suspension Internal drive type 381 mm 15 0 in 887 mm 34 9 in 20...

Page 182: ...0 mm 0 7872 0 7874 in 55 7 56 0 mm 2 193 2 205 in Keystone B 1 20 mm 0 047 in T 2 55 mm 0 100 in Keystone B 1 20 mm 0 047 in T 2 55 mm 0 100 in 0 35 0 55 mm 0 014 0 022 in 0 35 0 55 mm 0 014 0 022 in 0 02 0 06 mm 0 0008 0 0024 in 0 02 0 06 mm 0 0008 0 0024 in Chrome plated Ferox coating PB1 coat Chrome plated Ferox coating Model Cylinder head Volume with spark plug Warp limit Cylinder Material Bor...

Page 183: ...nd diameter Read valve Material Thickness Bending limit Stopper height 55 95 56 00 mm 2 203 2 205 in 291 75 292 30 mm 11 486 11 508 in Below 0 03 mm 0 0012 in Below 0 04 mm 0 0016 in Below 0 03 mm 0 0012 in 90 mm 3 54 in 85 mm 3 35 in 0 25 0 75 mm 0 01 0 03 in 0 8 1 0 mm 0 03 0 04 in Needle bearing Needle bearing 26 993 27 000 mm 1 0627 1 0630 in 24 995 25 008 mm 24 995 25 005 mm 0 9841 0 9845 in ...

Page 184: ...essure Water pump type Coolant type Coolant mixing ratio coolant water Coolant capacity Reservoir tank capacity TM31 3 pcs TM33 3 pcs MIKUNI 8DG10 8CH10 1 136 3 1 145 2 3 133 8 2 3 143 8 42 5 45 6DHN50 3 6DGM05 3 1 Q 4 Q 8 2 3 Q 2 2 3 Q 4 1 0 ø0 8 ø0 9 ø0 8 2 1 1 2 3 0 3 5 ø1 3 ø1 2 ø1 5 ø1 1 11 3 15 3 mm 0 44 0 60 in 36 38 mm 1 42 1 50 in 1 600 100 r min Diaphragm TAIYO GIKEN 23 1 mm 0 91 0 04 in...

Page 185: ... Color code Outside diameter Wire diameter Model V belt automatic 3 8 1 0 1 4 600 200 r min 4 700 200 r min 4 400 4 800 r min 4 500 4 900 r min 8 500 200 r min 8 300 250 r min 8 250 8 750 r min 8 050 8 550 r min 267 270 mm 10 52 10 62 in 13 5 16 5 mm 0 53 0 64 in 8DN 17641 00 MITSUBOSHI 1 129 1 137 mm 44 4 44 7 in 34 5 mm 1 36 in 32 5 mm 1 28 in 90501 603L2 Yellow White Yellow 60 0 mm 2 36 in 6 0 ...

Page 186: ... rail suspension Front travel Rear travel Suspension spring rate Front Rear Spring wire diameter Front Rear 2 6 80 1 6 70 7 4 N mm 8 7 N mm 0 74 kg mm 41 57 lb in 0 87 kg mm 48 72 lb in 5 53 75 mm 2 95 in 43 S37TNB13 68 L 70 L 8ED 47110 00 381 mm 15 0 in 3 584 mm 141 1 in 64 mm 2 52 in 56 7 25 mm 0 28 in 50 8 mm 2 00 in 20 25 mm 0 79 0 98in 203 mm 7 99 in 267 mm 10 51 in 30 0 N mm 3 0 kg mm 168 lb...

Page 187: ...f teeth Rear guide wheel Material Outside diameter Brake Pad thickness Pad wear limit Disc outside diameter Disc thickness 10 mm 0 39 in B 680 N 0 3 m s 69 kg 0 3 m s 152 lb 0 3 m s 1 060 0 3 m s N 108 kg 0 3 m s 2 337 lb 0 3 m s 1 470 N 0 3 m s 150 kg 0 3 m s 3 241 lb 0 3 m s 860 N 0 3 m s 88 kg 0 3 m s 1 896 lb 0 3 m s 17 8 mm 0 70 in 10 mm 0 39 in Polyethylene 8T Aluminum with rubber 158 mm 6 2...

Page 188: ...Spring type Spring rate Wire diameter Shock absorber damping force Extension Compression Aluminum 730 mm 28 7 in Rear side of seat 26 7 R ski 32 0 L ski 32 0 R ski 26 7 L ski Toe out 0 15 mm 0 0 59 in 22 5 Plastic 1 068 mm 42 in 139 7 mm 5 50 in Proaction system 169 mm 6 65 in Coil spring 21 0 N m 2 1 kg mm 117 6 lb in 7 5 mm 0 295 in 490 N 0 3 m s 49 0 kg 0 3 m s 109 5 lb 0 3 m s 270 N 0 3 m s 27...

Page 189: ...ode CDI unit model Manufacturer Rectifier regulator Model Manufacturer No load regulated voltage AC DC Water temperature sensor Model Manufacturer Resistance 12 V 18 at 1 500 r min 25 at 5 000 r min Electrical type 8ED 00 L C 8DG 00 R YAMAHA 3 mm 0 118 in or more 0 05 0 07 Ω at 20 C 68 F 2 7 3 7 kΩ at 20 C 68 F Rubber type 8DF TOKAI DENSO 5 kΩ at 20 C 68 F Flywheel magneto F4T326 MITSUBISHI 189 23...

Page 190: ...128 8 PJ 42 5 PS 2 1 2 JN 2 MJ 1 128 8 MJ 2 3 126 3 PJ 42 5 PS 3 JN 2 MJ 1 126 3 MJ 2 3 123 8 PJ 45 PS 3 JN 1 5 40 C 29 C 18 C 7 C 4 C 16 C 40 F 20 F 0 F 20 F 40 F 60 F MJ 1 142 5 MJ 2 3 140 PJ 42 5 PS 2 JN 3 MJ 1 141 3 MJ 2 3 138 8 PJ 42 5 PS 2 JN 3 MJ 1 140 MJ 2 3 137 5 PJ 42 5 PS 2 JN 3 MJ 1 138 8 MJ 2 3 136 3 PJ 42 5 PS 2 JN 3 MJ 1 136 3 MJ 2 3 133 8 PJ 42 5 PS 2 JN 2 5 MJ 1 133 8 MJ 2 3 131 3...

Page 191: ...N 3 MJ 1 145 MJ 2 3 143 8 PJ 45 PS 1 1 2 JN 3 MJ 1 142 5 MJ 2 3 141 3 PJ 50 PS 1 1 2 JN 2 5 MJ 1 140 MJ 2 3 138 8 PJ 55 PS 1 5 8 JN 2 MJ 1 137 5 MJ 2 3 136 3 PJ 57 5 PS 1 7 8 JN 2 MJ 1 135 MJ 2 3 133 8 PJ 60 PS 2 JN 2 MJ 1 132 5 MJ 2 3 131 3 PJ 62 5 PS 2 1 8 JN 2 40 C 29 C 18 C 7 C 4 C 16 C 40 F 20 F 0 F 20 F 40 F 60 F MJ 1 148 8 MJ 2 3 147 5 PJ 45 PS 1 1 2 JN 3 MJ 1 147 5 MJ 2 3 146 3 PJ 45 PS 1 ...

Page 192: ...frame Engine bracket damper front rear Engine bracket front and engine Engine bracket right rear and engine Engine bracket left rear and engine Engine bracket rear and frame Exhaust joint Water pump cover Cylinder head Nut first final Cylinder Nut Spark plug Ignition coil Thermostatic cover Oil pump Fuel pump Starter pulley Drive plate Recoil starter case Intake manifold Read valve assembly Carbur...

Page 193: ...n housing cover Chain housing and brake caliper Bleed screw brake caliper Nut parking brake Brake hose Brake hose joint Brake master cylinder side Brake hose side Bearing set screw jackshaft Bearing holder jackshaft Stopper band Hook and front pivot arm Wheel bracket and sliding frame Front suspension bracket bolt rear Front suspension bracket bolt front Shaft and sliding frame Front pivot arm and...

Page 194: ...liding frame Set bolt front axle Speedometer gear assembly 72 8 20 7 2 0 8 2 0 52 5 8 14 NOTE Tightening steps 1 Tighten the bolt to a torque of 120 Nm 12 m kg 85 ft lb 2 Loosen the bolt completely 3 Retighten the bolt to a torque of 60 Nm 6 0 m kg 43 ft lb MAINTENANCE SPECIFICATIONS Apply LOCTITE ...

Page 195: ...holder Steering column Upper Lower Steering column and relay rod Relay rod and relay arm Relay arm and tie rod Tie rod and steering arm Relay arm Locknut relay rod tie rod Ski Ski runner Ski column lower bracket Shock absorber upper Shock absorber lower Steering arm and ski column Lower control rod and frame Upper control rod and frame Control rod and front arm Front arm pivot bolt Stabilizer bar ...

Page 196: ...eral torque specifications Nm m kg ft lb A nut B bolt 4 3 11 22 40 61 94 6 15 30 55 85 130 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 0 6 1 5 3 0 5 5 8 5 13 0 A Distance across flats B Outside thread diameter DEFINITION OF UNITS Unit Read Definition Measurement mm cm kg N Nm m kg Pa N mm L cm3 r min Millimeter Centimeter Kilogram Newton Newton meter Meter kilogram Pascal...

Page 197: ...SPEC 9 19 CABLE ROUTING SEJ9140 N M A L K J I H 30 G F E D C B A 0 9 8 7 6 5 4 3 2 1 P D C O B B 45 B B A O D C Q ...

Page 198: ...with a coupler cap 6 Fasten the coolant reservoir hose and coolant hose with a plastic clamp 7 Ensure this is not kink 8 Brake hose 9 Route the main switch wire harness under the oil tank breather hose and fuel tank breather hose 0 Install the main switch coupler behind the instrument panel A Make sure that the main switch wire harness is on the inside of the instrument panel screw away from the e...

Page 199: ...SPEC 9 21 CABLE ROUTING SEJ9150 N M A L K J I H 30 G F E D C B A 0 9 8 7 6 5 4 3 2 1 P D C O B B 45 B B A O D C Q ...

Page 200: ...ss with a plastic clamp Install the clamp as close to the drive V belt guard bracket as possible rearward M Fasten the oil pump cable and starter cable to the claws on the ignition coil and intake silencer with the plastic clamps N 2 4 Notches O Starter cable P Wire harness Q Ignition coil 3 ...

Page 201: ...SPEC 9 23 CABLE ROUTING SEJ9160 ...

Page 202: ...e 9 Fasten the oil tank breather hose fuel tank breather hose and wire harness at the inside of the instrument panel screw with a plastic band Route the tail brake light lead between the fuel tank and the snowmobile body Make sure that the fuel tank does not crush the tail brake light lead Then fasten the three pieces of adhesive tape below the fuel tank as shown A Adhesive tapes B To the tail bra...

Page 203: ...SPEC 9 25 CABLE ROUTING SEJ9170 ...

Page 204: ...ll the condenser so it is flush with the inner edge of the tab 5 Plastic band 6 Clamp 7 Headlight leads 8 Speedometer cable 9 Fasten the headlight leads and speedometer cable at the white tape mark with a plastic band 0 Route the wire harness and speedometer cable over the shroud s stopper wire ...

Page 205: ...SPEC 9 27 CABLE ROUTING SEJ9180 ...

Page 206: ... light switch lead headlight beam switch lead and grip warmer leads with a plastic band A Parking brake cable B Oil tank breather hose C Fasten the oil tank breather hose with a plastic band D Fasten the wire harness and the oil tank breather hose behind the steering column with a plastic band Do not fasten the parking brake cable and brake hose E Fasten the wire harness and fuel tank breather hos...

Page 207: ...SPEC 9 29 CABLE ROUTING SEJ9190 ...

Page 208: ...wire harness at the white tape mark with a clamp S Oil hose T Coolant reservoir hose U To filler cap body V Voltage regulator W Rectifier regulator X Fasten the wire harness with a plastic band Y Pass the brake hose through the hose guide Z Ensure this is not kink Fasten the wire harness fuel tank breather hose and oil tank breather hose with a plastic band Install the starter lever to the positio...

Page 209: ...SPEC 9 31 CABLE ROUTING SEJ9200 ...

Page 210: ...rojection located on the silencer when fastening it around the wire harness 4 Connectors of the carburetor switch 5 Water temperature sensor coupler 6 Make sure a plastic band is fastened around the wire harness to prevent the coolant reservoir hose from kinking 7 CDI magneto couplers 8 Starter relay coupler 9 To the reservoir tank 0 Coolant reservoir hose A CDI unit coupler B Wire harness C Make ...

Page 211: ... magneto 2 Rectifier regulator 3 Main switch 4 Engine stop switch 5 Throttle switch 6 Carburetor switch 7 CDI unit 8 Water temperature sensor 9 Ignition coil 0 Spark plug A Voltage regulator B Variable resistor C Thumb warmer D Grip warmer E Brake light switch F Tail brake light G Fuel sender H Oil level switch I Speedometer J Oil level indicator light K Water temperature indicator light L High be...

Page 212: ...W R B R Br Y B Br B L R O B L R B HI LO L Y G G Y L Y G L L B L B Y G R R B R B L B Br Y G R L B G B L B Br Br G B B R B Gy Br R B G R R B R B A L L B B B GREEN GREEN G B G B G B G B A G R G R A L L A A Br Br A B B B B G Br OFF ON L G Y G Y L G Y L B G Y G Y G Y G Y B C G Y G Y L B L G Y G Y B B G R L R W G B R B Y BLACK O B W Br R Br BLACK C SUB HARNESS CORD TAIL LIGHT L B L G Y G Y B B MAIN HARN...

Page 213: ...PRINTED ON RECYCLED PAPER 99 06 1 E CR ...

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