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Yamaha MM700A Manual Download Page 158

152 

CHAPTER SIX 

STARTER 

1. 

Throughbolt 

2. 

Washer 

3.  End cap 

4. 

Grommet 

5. 

Nut 

6.  O-ring 
7. 

Brush spring 

8. 

Positive brush 

9.  Grommet 

10. 

O-ring 
Negative brush 

12. 

Washers 

13.  Armature 
14. 

Washer 

15. 

Frame 

16.  O-ring 
17. 

Drive housing 

18. 

Drive assembly 

19.  Washer 
20. 

Spring 

21. 

Pinion stopper 

22. 

Snap ring 

Summary of Contents for MM700A

Page 1: ...d 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...

Page 2: ...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...

Page 3: ...r 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 sende...

Page 4: ...00 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...

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Page 7: ...ue specifications Table 8 liststechnicalabbreviations Table 9 lists metric tap and drill sizes Table 10 lists decimaland metric equivalents MANUALORGANIZATION All dimensions and capacities are express...

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...

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 Topreventc...

Page 10: ...ause 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...

Page 11: ...king 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...

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 combusti...

Page 13: ...ds 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 flui...

Page 14: ...se 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 ke...

Page 15: ...hance 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 fastenerac...

Page 16: ...d 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 w...

Page 17: ...t 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...

Page 18: ...em 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...

Page 19: ...y 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 produc...

Page 20: ...icrometer 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...

Page 21: ...f 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 readi...

Page 22: ...form 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...

Page 23: ...leeve 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...

Page 24: ...er 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...

Page 25: ...ks 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...

Page 26: ...ble 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 b...

Page 27: ...ession 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 en...

Page 28: ...natoroutput 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...

Page 29: ...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 ha...

Page 30: ...geor 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 a...

Page 31: ...inutes 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 in...

Page 32: ...n 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 screwd...

Page 33: ...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 rac...

Page 34: ...temperature rises to approximately 120 C 248 F remove the bearing from the pot and quicklyinstallit If necessary placea socketon the inner bearingraceandtap thehearinginto place As the bearing chills...

Page 35: ...ure 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 combust...

Page 36: ...ions 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 loosen...

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...

Page 38: ...00 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 des...

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 30...

Page 40: ...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...

Page 41: ...ION 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 WE...

Page 42: ...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...

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 Kilogra...

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...

Page 45: ...ver 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 basic...

Page 46: ...mentwithout 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 ob...

Page 47: ...maged 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...

Page 48: ...ebris 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 t...

Page 49: ...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 specif...

Page 50: ...ce 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 ign...

Page 51: ...minaland 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 1...

Page 52: ...n 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 shro...

Page 53: ...forming 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...

Page 54: ...tem 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 malfunctioning...

Page 55: ...ture 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 overheat...

Page 56: ...oat 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...

Page 57: ...rburetormixture 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 Incorr...

Page 58: ...rsnear 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 p...

Page 59: ...n 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 issimpleb...

Page 60: ...ot 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 timi...

Page 61: ...range Execessivecarbonbuildupin combustionchamber Incorrect fuel oilmixtureratio Poor quality fuel Abnormalnoiseduringengine idle with a coldengine Check Excessivepistonclearance Excessivepistonring...

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...

Page 63: ...function 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...

Page 64: ...gcoil 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...

Page 65: ...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 FLUIDCHE...

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 20 C 68O F before attempting to mix the oil and gasoline 2 Mix the...

Page 67: ...e 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...

Page 68: ...ess 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 te...

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 lu...

Page 70: ...he 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...

Page 71: ...raying 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 receptacle...

Page 72: ...he 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 mo...

Page 73: ...he 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 d...

Page 74: ...just 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 align...

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...

Page 76: ...gainst 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...

Page 77: ...our 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...

Page 78: ...d 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 coolanttoma...

Page 79: ...gine 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 e...

Page 80: ...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 fi...

Page 81: ...lug 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...

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

Page 83: ...xamina 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 condition...

Page 84: ...rodes 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...

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 carbu...

Page 86: ...mobile and check performance If theenginehesitatesduringaccelerationfroma stop rotate each pilot mixture screw slightly counterclockwise Re check engine performanceand readjust the pilot mixture screw...

Page 87: ...cation Take this information into account along with altitude and temperature conditions previouslymentioned NOTE It is importantto note that the followingjet ting guidelinesare guidelinesonly Individ...

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...

Page 89: ...en 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 f...

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...

Page 91: ...pring 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...

Page 92: ...g 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 brack...

Page 93: ...ounting 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 dr...

Page 94: ...d 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...

Page 95: ...13 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...

Page 96: ...TCH 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...

Page 97: ...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...

Page 98: ...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...

Page 99: ...NGINES continued Temperature Altitude 4OoF 2W F OoF 20 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 6...

Page 100: ...dying 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 li...

Page 101: ...ne 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 se...

Page 102: ...move 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 re...

Page 103: ...me 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...

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

Page 105: ...e 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 syste...

Page 106: ...let 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...

Page 107: ...installthe 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 sligh...

Page 108: ...der 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...

Page 109: ...iece 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 Rotateth...

Page 110: ...ghtenthe 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 ex...

Page 111: ...he 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 thepistona...

Page 112: ...ing 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 place...

Page 113: ...t 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 t...

Page 114: ...ft 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 c...

Page 115: ...t at a 90 angle 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 before...

Page 116: ...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 describe...

Page 117: ...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 a...

Page 118: ...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 loos...

Page 119: ...lership 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 whe...

Page 120: ...h 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...

Page 121: ...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...

Page 122: ...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 Cran...

Page 123: ...ay 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 dr...

Page 124: ...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...

Page 125: ...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...

Page 126: ...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 heat...

Page 127: ...f 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 ce...

Page 128: ...erviceis usuallyaccomplished in conjunction with crankshaftor crankcaseservice For completeservice of the shaft assenlbly proceed as follows driveshaft 1 Remove the lower crankcase half as described i...

Page 129: ...meter 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 06...

Page 130: ...und 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 F...

Page 131: ...ine 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 thro...

Page 132: ...ve 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...

Page 133: ...dle 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 ventur...

Page 134: ...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 throt...

Page 135: ...eachcarburetorso 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...

Page 136: ...BLY 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 br...

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

Page 138: ...her 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 Sp...

Page 139: ...tor 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 fu...

Page 140: ...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...

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 carbureto...

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...

Page 143: ...hrough 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...

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

Page 145: ...to 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...

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...

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...

Page 148: ...h 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 alignm...

Page 149: ...3 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...

Page 150: ...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 batter...

Page 151: ...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 p...

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 co...

Page 153: ...ogengas 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 te...

Page 154: ...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 CAPACITORDISCHAR...

Page 155: ...tator 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 pr...

Page 156: ...aligned 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...

Page 157: ...OLTAGE 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 li...

Page 158: ...er 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 Wash...

Page 159: ...ts 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...

Page 160: ...re 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 sto...

Page 161: ...e 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 dama...

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...

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: ...nd 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 sc...

Page 165: ...heoil 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 c...

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...

Page 167: ...f 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...

Page 168: ...ct 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...

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...

Page 170: ...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 R...

Page 171: ...ULBS 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 O...

Page 172: ...imum 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...

Page 173: ...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 lea...

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: ...rain 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 ne...

Page 176: ...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 P...

Page 177: ...hanger 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 ma...

Page 178: ...LANT 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 Drives...

Page 179: ...wing 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 reta...

Page 180: ...n 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 th...

Page 181: ...e 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...

Page 182: ...e 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...

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 Reins...

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 deepsc...

Page 185: ...n 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 f...

Page 186: ...ise 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...

Page 187: ...mobilehengine 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 sever...

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...

Page 189: ...e 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...

Page 190: ...e 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 Rolle...

Page 191: ...over 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 Coll...

Page 192: ...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 r...

Page 193: ...ufac 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 l...

Page 194: ...ngthe 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 Perfor...

Page 195: ...ethe 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 t...

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...

Page 197: ...ove 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...

Page 198: ...ing 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 damag...

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...

Page 200: ...ed 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 2...

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...

Page 202: ...over 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 Colla...

Page 203: ...st 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 th...

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 b...

Page 205: ...X6OOER 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 i...

Page 206: ...er 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 I...

Page 207: ...ave 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 P...

Page 208: ...rk 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 i...

Page 209: ...t 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 th...

Page 210: ...TER 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 Br...

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

Page 212: ...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 workbenc...

Page 213: ...p 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...

Page 214: ...e 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...

Page 215: ...uringthe 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...

Page 216: ...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...

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 Figur...

Page 218: ...te 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 Yama...

Page 219: ...ure 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 l...

Page 220: ...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 s...

Page 221: ...r 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 Re...

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...

Page 223: ...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...

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 exces...

Page 225: ...n 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 an...

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 S...

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: ...t 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...

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 da...

Page 234: ...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 F...

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: ...t 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...

Page 238: ...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 altitu...

Page 239: ...emove 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...

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: ...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 Sk...

Page 242: ...ter 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 thes...

Page 243: ...od 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 Coll...

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 Ifpai...

Page 245: ...se 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 temper...

Page 246: ...rol 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 i...

Page 247: ...ock 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...

Page 248: ...ouldbefelt 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 flang...

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...

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...

Page 251: ...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...

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 b...

Page 253: ...i 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 ahea...

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

Page 255: ...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 t...

Page 256: ...olumn 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...

Page 257: ...e 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 Be...

Page 258: ...ace 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 T...

Page 259: ...e 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 Fi...

Page 260: ...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 Installationi...

Page 261: ...s 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...

Page 262: ...5 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 col...

Page 263: ...olt 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 Bol...

Page 264: ...asher 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...

Page 265: ...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...

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

Page 267: ...icient 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 tr...

Page 268: ...7 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 ab...

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: ...ed 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 whe...

Page 271: ...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 engin...

Page 272: ...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 al...

Page 273: ...especifications 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 8...

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 en...

Page 275: ...700SX 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...

Page 276: ...tricstarting 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 stee...

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

Page 278: ...hometer 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 t o r sigh SO beam switch Condenser s Oil lev...

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...

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...

Page 281: ...nnection 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...

Page 282: ...NOTES...

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