Yamaha SX500D Page 110 Supplementary Service Manual Download

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CABLE ROUTING

SPEC

Fasten the wire harness and start-
er cable with a plastic clamp.
Route the wire harness and
starter cable through the slot on
the intake silencer.

CDI unit

Carburetor switch coupler

Water temperature sensor coupler

Starter relay coupler

CDI unit

Make sure a plastic-locking tie is
routed through wire harnesses
as shown.

CDI unit coupler

Fasten the wire harness with a
plastic clamp.
Route the wire harness through
the slot on the intake silencer.

Clamp
Does no kink.

CDI magneto coupler

Starter relay coupler (without
electric starter model)

Clamp

Coolant breather hose

To the coolant reservoir tank

CDI unit coupler

To the conduction

Wire harness

Summary of Contents for SX500D

Page 1: ...SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ...his manual OE022 SX500 SX600 SX700 SUPPLEMENTARY SERVICE MANUAL 1999 by Yamaha Motor Corporation U S A 1st Edition June 1999 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A OE011 HOW TO USE THIS MANUAL Particularly important information is distin guished in this manual by the following ...

Page 3: ...cations 10 Optional kit Illustrated symbols 11 to 17 are used to identify the specifications which appear 11 Filling fluid 12 Lubricant 13 Tightening 14 Wear limit clearance 15 Engine speed 16 Special tool 17 Ω V A Illustrated symbols 18 to 25 in the exploded dia gram indicate grads of lubricant and location of lubrication point 18 Apply locking agent LOCTITE 19 Apply Yamabond No 5 20 Apply engine...

Page 4: ...CHASSIS SKI 27 INSPECTION 28 FRONT SUSPENSION 29 INSTALLATION 30 POWER TRAIN PRIMARY SHEAVE AND DRIVE V BELT 31 INSPECTION 33 SECONDARY SHEAVE 34 ASSEMBLY 35 DRIVE CHAIN HOUSING 36 INSTALLATION 37 BRAKE 38 BRAKE PAD REPLACEMENT 39 SLIDE RAIL SUSPENSION 41 INSPECTION 46 FRONT AXLE AND TRACK 47 INSPECTION 48 INSTALLATION 48 ENGINE CYLINDER HEAD AND CYLINDER 49 51 INSPECTION 50 52 COOLING SYSTEM HEAT...

Page 5: ...ht 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 Designs and specifications are subject to change without notice IMPORTANT INFORMATION LOCTITE After installing fasteners that have LOCTITE applied wait 24 hours before using the ma chine This will give the LOCTITE time to properly dry ...

Page 6: ... Recommended oil YAMALUBE 2 cycle oil or equivalent 2 Place a rag under the oil pump assembly to soak up any spilled oil 3 Disconnect Oil hose 4 keep the oil running out until air bubbles dis appear from the oil hose 5 Connect oil hose 6 Disconnect Oil delivery hose 7 Feed the YAMALUBE2 cycle oil into the oil delivery hose using an oil for complete air bleeding 8 Connect Oil delivery hose 9 Remove...

Page 7: ... oil or equivalent 2 Remove Carburetor 3 Place a rag under the oil pump assembly to soak up any spilled oil 4 Disconnect Oil hose 5 Keep the oil running out until air bubbles dis appear from 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 for complete air bleeding 9 Connect Oil delivery hose 10 Remove Bleed scre...

Page 8: ...N a 4 Remove Coolant filler cap 1 Do not remove the coolant filler cap 1 when the engine is hot Scalding hot fluid and steam may be blown out under pressure which could cause serious injury When the engine has cooled place a thick rag or a towel over the coolant filler cap Slowly rotate the cap counterclockwise to the detent This allows any residual pres sure to escape When the hissing sound has s...

Page 9: ... Disconnect Coolant hoses rear 1 9 Drain the coolant Lift up the front of the machine to drain the cool ant completely Coolant is poisonous It is harmful or fatal if swallowed If coolant is swallowed induce vomiting immediately and get immediate medical attention If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor If coolant splashes on your skin or clothes quic...

Page 10: ...rain bolt 23 Nm 2 3 m kg 17 ft lb Bolt exhaust pipe 30 Nm 3 0 m kg 22 ft lb 14 Fill Cooling system Recommended coolant Long life coolant Coolant and water mixed ratio 60 40 Total amount 3 2 L 2 8 Imp qt 3 4 US qt Reservoir tank capacity 0 17 L 0 15 lmp qt 0 18 US qt Hard water or salt water is harmful to en gine parts If soft water is not available use boiled or distilled water Do not use water co...

Page 11: ...ester 1 90890 01325 YU 24460 01 to the coolant filler 2 Apply 100 kPa 1 0 kg cm2 14 psi Measure the pressure with gauge 2E081 Water pump belt deflection adjustment 1 Remove Muffler 2 Check Drive belt deflection Out of specification Adjust Drive belt deflection 8 mm 0 31 in 120 N 12 kg 26 lb NEW BELT 8 mm 0 31 in 130 220 N 13 20 kg 28 7 44 1 lb ...

Page 12: ...dding or removing a shim 4 Add shim Tension decreases Remove shim Tension increases Shim size Part number Thickness 8CA 15721 00 0 5 mm 0 02 in 8CA 15722 00 1 0 mm 0 04 in 4 Install Install the starter pulley and drive belt Recheck the drive belt deflection If out of specification readjust the drive belt deflec tion Install the recoil starter 5 Tighten Starter pulley bolt 23 Nm 2 3 m kg 17 ft lb S...

Page 13: ...to ON a 4 Remove Coolant filler cap 1 Do not remove the coolant filler cap 1 when the engine is hot Pressurized scalding hot fluid and steam may be blown out which could cause serious injury When the engine has cooled place a thick rag or a towel over the coolant filler cap Slowly turn the cap counterclockwise until it stop This allows any residual pressure to escape When the hissing sound has sto...

Page 14: ...Disconnect Coolant hoses rear 1 9 Drain the coolant Lift up the front of the machine to drain the cool ant completely Coolant is poisonous It is harmful or fatal if swallowed If coolant is swallowed induce vomiting immediately and get immediate medical attention If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor If coolant splashes on your skin or clothes quick...

Page 15: ...rain bolt 13 Nm 1 3 m kg 9 4 ft lb Bolt exhaust pipe 27 Nm 2 7 m kg 19 ft lb 14 Fill Cooling system Recommended coolant Long life coolant Coolant and water mixed ratio 60 40 Total amount 3 4 L 3 0 Imp qt 3 6 US qt Reservoir tank capacity 0 17 L 0 15 Imp qt 0 18 US qt Hard water or salt water is harmful to en gine parts If soft water is not available use boiled or distilled water Do not use water c...

Page 16: ...Pa 1 0 kg cm2 14 psi Measure the pressure with gauge 2E101 ENGINE IDLE SPEED ADJUSTMENT 500 1 Adjust Engine idle speed Adjustment steps Start the engine and let warm up Turn the throttle stop screw 1 in or out to ad just the engine idle speed Turning in Idle speed increases Turning out Idle speed decreases Engine idle speed 1 600 100 r min 1 500 X 1 700 r min After adjusting the engine idle speed ...

Page 17: ...belt position by removing or ad ding a spacer 1 on each adjusting bolt 2 As the V belt wears adjustment may be nec essary To ensure proper clutch perfor mance the V belt position should be ad justed by adding a spacer 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...

Page 18: ...n below the edge Add spacer 3 Tighten Adjusting bolt 2 Adjusting bolt 2 10 Nm 1 0 m kg 7 2 ft lb 4 Inspect Drive V belt Cracks damage wear Replace Oil or grease on the V belt Check the pri mary and secondary sheaves 5 Inspect Primary sheave Secondary sheave Oil or grease on the primary and secondary sheaves Use a rag soaked in lacquer thin ner or solvent to remove the oil or grease Check the prima...

Page 19: ...Out of specification Adjust the primary sheave Engagement speed 3 800 200 r min 500 3 600 X 4 000 r min 4 200 200 r min 600 4 000 X 4 400 r min 3 900 200 r min 700 3 700 X 4 100 r min BRAKE PAD INSPECTION 1 Apply the brake lever 2 Inspect Brake pad Wear indicator 1 nearly contacts the brake disc Replace the brake pads as a set Wear limit a 4 2 mm 0 17 in SLIDE RUNNER INSPECTION 1 Inspect Slide run...

Page 20: ...15 mm 0 0 59 in Ski stance b center to center 1 040 mm 40 9 in 3 Adjust Ski toe out Adjustment steps Loosen the locknuts tie rod 1 at inside and outside tie rod ball joint Turn the relay rod 2 in or out until the speci fied toe out is obtained After tightening the inside and outside ball joint locknut 1 make sure the tie rod 2 can be rotated freely through the ball joint travel If not loosen the l...

Page 21: ... TM31 TM33 Manufacturer MIKUNI z z I D Mark 8CJ10 8DG100 8CH10 Main jet M J 151 3 1 136 3 2 3 133 8 1 145 2 3 143 8 Pilot jet P J 45 42 5 45 Main air jet M A J ø2 5 Pilot screw P S 1 3 4 turns out 2 0 turns out 1 1 2 turns out Float height 21 3 X 23 3 mm 0 839 X 0 917 in 11 3 X 15 3 mm 0 45 X 0 60 in z Idle speed 1 600 100 r min 1 500 X 1 700 r min z z ...

Page 22: ...9 68L 18 39 68L Primary spring Color Length Preload rate 90501 551L3 B P B 88 4 mm 30 kg 2 0 z z z z 90501 583L5 W P W 86 7 mm 30 kg 2 25 z z z z Preload rate Wire diameter Outside diameter 30 kg 2 0 kg mm ø5 5 mm ø60 mm z z z 30 kg 2 25 kg mm ø5 8 mm z z z z Weight 1D Weight rivet Weight bushing 8DJ00 Steel 13 9 OUT Steel 10 3 IN Duralon z Steel 10 3 OUT z z z Aluminum 10 3 OUT z z z None OUT Alu...

Page 23: ...9 68L 18 39 68L 18 39 68L Primary spring Color Length Preload rate Wire diameter Outside diameter 90501 582L7 Y G Y 89 4 mm 40 kg 2 5 kg mm ø5 8 mm ø60 mm z z z z z z 90501 602L3 P S P 85 1 mm 35 kg 3 0 kg mm ø6 0 mm z z z z z z z Weight 1D Weight rivet Weight bushing 8DG00 Steel 10 3 OUT Steel 13 9 IN Duralon z Aluminum 10 3 OUT z z z z Steel 10 3 IN z z z Aluminum 10 3 IN z Roller outer dia Roll...

Page 24: ...Gearing 22 39 70L z z 21 39 68L Primary spring Color Length Preload rate Wire diameter Outside diameter 90501 582L7 Y G Y 89 4 mm 40 kg 2 5 kg mm ø5 8 mm ø60 0 mm z z z z z z 90501 602L8 G G G 87 9 mm 40 kg 2 75 kg mm ø6 0 mm z z z z z z z Weight 1D Weight rivet Weight bushing 8DF00 Steel 13 9 OUT Steel 13 9 IN Duralon z Steel 10 3 OUT z z z Aluminum 10 3 OUT z z z None OUT z z Roller outer dia Ro...

Page 25: ... the machine has been started at full throttle from a dead stop and has travelled 200 300 m 650 1 000 ft Normally when a machine reaches shifting speed the vehicle speed increases but the en gine speed remains nearly constant Under un favorable conditions wet snow icy snow hills or rough terrain however engine speed may decrease after the shifting speed has been reached A Engine speed B Good condi...

Page 26: ...ear ratios while the number on the following line followed by an L designates the number of chain links Do not set the gearing to any of the indicated settings 1 Chain and sprocket parts number Parts name Teeth Links Parts No Standard 18T 89J 17682 80 19T 89J 17682 91 Drive sprocket 20T 89J 17682 00 600 Drive s rocket 21T 89J 17682 10 500 22T 89J 17682 20 700 23T 89J 17682 30 39T 89J 47587 90 500 ...

Page 27: ... 6003 613 5 2 BROWN 5 0 75 90508 536A9 7147 729 5 5 RED 5 3 75 500 600 90508 556A2 8314 848 5 5 GREEN 5 5 75 700 90508 556A7 9460 965 4 8 SILVER 5 5 75 4 Secondary spring twist angle 0 3 6 9 1 10 40 70 100 2 20 50 80 110 3 30 60 90 120 5 Torque cam secondary spring seat Parts No Cam angle Standard 8BV 17604 11 41 8BV 17604 31 43 500 8BV 17604 51 45 700 8BV 17604 71 47 600 8BV 17604 91 39 ...

Page 28: ...501 553G6 22 2 25 245 25 W Y W 5 5 60 4 61 76 5 90501 555J9 22 2 25 343 35 W S W 5 5 48 4 66 81 0 90501 556G5 22 2 25 196 1 20 W B W 5 5 60 4 62 74 3 90501 557G6 22 2 25 147 15 W G W 5 5 60 4 62 72 1 90501 551L3 24 5 2 5 294 30 B P B 5 5 60 4 91 88 4 500 90501 556G7 24 5 2 5 196 1 20 Y G Y 5 5 60 4 36 73 4 90501 581J7 24 5 2 5 245 25 Y 5 8 60 4 96 75 4 90501 582J1 24 5 2 5 294 30 Y P Y 5 8 60 4 96...

Page 29: ...onger Preload Harder Softer Length Max Min 251 5 mm 261 5 mm 268 0 mm 9 81 in 10 20 in 10 45 in Be sure that the left and right spring preload is the same This shock absorber contains highly pres surized nitrogen gas Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock absorber assem bly to an open flame or high temperature as this could cause it to explode ...

Page 30: ...er Preload Harder Softer Length front Max Min 203 mm 213 mm 215 mm 7 92 in 8 31 in 8 39 in Length rear Max Min 358 5 mm 368 5 mm 370 5 mm 14 11 in 14 51 in 14 45 in This shock absorber contains highly pres surized nitrogen gas Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock absorber assem bly to an open flame or high heat which could cause it to explode ...

Page 31: ... bracket Ski stopper Collar Washers Ski Ski runner Washers Ski handle 1 1 1 1 6 1 1 6 1 Remove the parts in the order below For installation reverse the removal procedure 11 Nm 1 1 m kg 8 ft lb A 21 Nm 2 1 m kg 15 ft lb B 48 Nm 4 8 m kg 35 ft lb C ESSO beacon 325 grease or Aeroshell grease 7A CHASSIS SKI 700 ...

Page 32: ... 28 SKI CHAS INSPECTION 1 Inspect Ski 1 Ski runner 2 Ski column lower bracket 3 Ski handle 4 Ski Stopper 5 Wear cracks damage Replace Mounting bolt 6 Collar 7 Wear damage Replace ...

Page 33: ...ds Collars Bushings Connecting rod Collars Front arm 1 1 1 1 1 2 1 2 2 4 1 2 1 Remove the parts in the order below Refer to SKI For installation reverse the removal procedure 23 Nm 2 3 m kg 17 ft lb A 43 Nm 4 3 m kg 31 ft lb B 48 Nm 4 8 m kg 35 ft lb C 78 Nm 7 8 m kg 56 ft lb D 50 Nm 5 0 m kg 36 ft lb E 56 Nm 5 6 m kg 40 ft lb F ESSO beacon 325 grease or Aeroshell grease 7A FRONT SUSPENSION 600 70...

Page 34: ...ength mm Set angle Color Upper 475 5 0 5 mm 18 545 0 0197 in 93 1 Blue Lower 472 6 0 5 mm 18 431 0 0197 in 93 1 Blue Right hand Set length mm Set angle Color Upper 475 5 0 5 mm 18 545 0 0197 in 87 1 Yellow Lower 472 6 0 5 mm 18 431 0 0197 in 87 1 Yellow b 12 mm 48 64 Nm 4 8 6 4 m kg 35 46 ft lb 14 mm 62 84 Nm 6 2 8 4 m kg 45 60 ft lb ...

Page 35: ...ty Remarks 1 2 3 Primary sheave removal V belt Blind cap Primary sheave assembly 1 1 1 Remove the parts in the order below For installation reverse the removal procedure 120 Nm 12 0 m kg 87 ft lb 1st 2nd 60 Nm 6 0 m kg 43 ft lb A POWER TRAIN PRIMARY SHEAVE AND DRIVE V BELT ...

Page 36: ...e Bushing Spider Sliders 1 1 3 3 6 3 3 6 1 1 1 1 1 6 Disassemble the parts in the order below For assembly reverse the disassembly procedure 6 Nm 0 6 mSkg 4 3 ftSlb A 14 Nm 1 4 mSkg 10 ftSlb B 200 Nm 20 mSkg 145 ftSlb C 1 10 2 3 4 5 6 7 8 9 11 12 13 14 S Clean the threads S Apply LOCTITER 648 as illustrated in And then tighten the spider The spider must turn counter clockwise to be tighten D E a b...

Page 37: ...0 3 Inspect Weight 1 Roller 2 Bushing 3 Slider 4 Rivet 5 Collar Wear scratches damage Replace Slider inside clearance Min 0 10 mm 0 0039 in Max 0 45 mm 0 0177 in Rivet replacement steps Remove old rivet with the appropriate drill Insert the rivet 1 from the ID mark 2 side Press or peen the rivet head so that the diame ter a of rivet head measures to 8 2 mm 0 32 in or larger 4 Measure Bushing insid...

Page 38: ...d sheave Stopper Sliding sheave Secondary sheave plate 2 1 1 1 1 1 1 1 Remove the parts in the order listed below 600 600 For assembly reverse the disassembly procedure 4 Nm 0 4 m kg 2 9 ft lb A 6 5 Nm 0 65 m kg 4 6 ft lb B 10 Nm 1 0 m kg 7 2 ft lb C 23 Nm 2 3 m kg 17 ft lb D ESSO beacon 325 grease or Aeroshell grease 7A 1 1 2 3 4 5 6 7 SECONDARY SHEAVE 600 700 ...

Page 39: ...dard spring position 2 6 600 3 3 700 Installation steps Attach the sheave compressor Turn the sliding sheave counterclockwise to the specified angle a Hold the sliding sheave and fixed sheave in this position Standard twist angle a 80 600 60 700 a sheave side hole number spring seat side hole number 10 Turn in the sheave compressor screw so that the spring seat engages with the fixed sheave ...

Page 40: ...er Chain tensioner Roller Drive sprocket Collar Drive chain Driven sprocket Collar Drive chain housing 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order below Refer to BRAKE Loosen Refer to SLIDE RAIL SUSPENSION Oil drain For installation reverse the removal procedure 12 Nm 1 2 m kg 8 7 ft lb A 24 Nm 2 4 m kg 17 ft lb B 48 Nm 4 8 m kg 35 ft lb C 60 Nm 6 0 m kg 43 ft lb D DRIVE CHAIN HOUSING ...

Page 41: ...ent is necessary always replace the chain and the sprockets as a set 2 Inspect Drive chain 1 Stiffness Clean and lubricate or replace Drive chain plates 2 Damage wear Replace the drive chain Cracks Replace the drive chain INSTALLATION During installation pay attention to the following point A Make sure that the bearing seals face to wards the drive chain as shown B Properly install the rubber seal...

Page 42: ...name Q ty Remarks 1 2 3 4 Brake pad removal Cap bolt Retaining pin Pad spring Brake pad 1 1 1 2 Remove the parts in the order below For installation reverse the removal procedure 6 Nm 0 6 m kg 4 3 ft lb A 48 Nm 4 8 m kg 35 ft lb B BRAKE 700 ...

Page 43: ... damage may occur Disconnect any hydraulic connection of herwise the entie system must be disas sembled drained cleaned and then prop erly filled and bled after reassembly BRAKE PAD REPLACEMENT It is not necessary to disassemble the brake cal iper and brake hose to replace the brake pads 1 Remove Brake pads 1 Do not depress the brake lever when the cali per or disc is off the machine otherwise the...

Page 44: ...ontainer Loosen the caliper bleed screw and push the pistons into the caliper with the 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 The tangs a of the pad spring must point in the direction of the disc rotation 3 Inspect Brake fluid level 4 Check Brake lever operation A soft or spongy feeling Bleed brake sys tem ...

Page 45: ... ty Remarks 1 2 3 4 Slide rail suspension removal Tension abjuster Blind caps Bolts Washer Slide rail suspension 2 6 2 1 Remove the parts in the order below Loosen For installation reverse the removal procedure 71 Nm 7 1 m kg 51 ft lb A SLIDE RAIL SUSPENSION 700 ...

Page 46: ...acket Front pivot arm Bracket Bushings Shaft Bushings Collars Suspension wheels Collar Wheel brackets Front pivot arm brackets 2 2 4 2 1 2 1 1 2 2 1 4 2 2 2 2 2 Disassemble the parts in the order below 1 2 3 4 5 6 7 8 9 10 4 Nm 0 4 m kg 2 9 ft lb A 16 Nm 1 6 m kg 11 ft lb B 30 Nm 3 0 m kg 22 ft lb C 49 Nm 4 9 m kg 35 ft lb D 72 Nm 7 2 m kg 52 ft lb E 24 Nm 2 4 m kg 17 ft lb F 11 12 13 14 15 16 17 ...

Page 47: ...heel brackets Circlips Suspension wheels Bushings Shaft Rear suspension bracket Spacers Washer plate Collar 2 2 2 2 2 2 1 1 2 2 1 18 24 Nm 2 4 m kg 17 ft lb A 49 Nm 4 9 m kg 35 ft lb B 72 Nm 7 2 m kg 52 ft lb C 19 20 21 22 23 24 25 26 27 28 SLIDE RAIL SUSPENSION POWR TR ...

Page 48: ...absorber Bushings Collar Pull rod Collars Bushings Collars Suspension wheels Control rods Bushings Screw Bushings 1 2 1 2 4 4 2 2 2 2 2 2 29 30 49 Nm 4 9 m kg 35 ft lb A 72 Nm 7 2 m kg 52 ft lb B 31 32 33 34 35 36 37 38 39 40 SLIDE RAIL SUSPENSION POWR TR ...

Page 49: ...heels Wheel bracket Rear axle Guide wheels Collars Tension adjusters Collar Collar Sliding frames 1 2 1 1 1 1 2 2 1 1 3 2 2 1 1 2 For assembly reverse the disassembly procedure 41 24 Nm 2 4 m kg 17 ft lb A 72 Nm 7 2 m kg 52 ft lb B 75 Nm 7 5 m kg 54 ft lb C 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 SLIDE RAIL SUSPENSION POWR TR ...

Page 50: ... roughly 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 ...

Page 51: ...dary sheave Speedometer gear assembly Cable joint Set bolt Front axle assembly Bearing Track 1 1 2 1 1 1 Remove the parts in the order listed below Refer to DRIVE CHAIN HOUSING Refer to SLIDE RAIL SUSPENSION Refer to SECONDARY SHEAVE For installation reverse the removal procedure 9 Nm 0 9 m kg 6 5 ft lb A 20 Nm 2 0 m kg 14 ft lb B FRONT AXLE AND TRACK 600 700 ...

Page 52: ...Bends scratches excessive damage Replace INSTALLATION 1 Install Sprocket wheels Guide wheels When pressing the sprocket wheels onto the front axle align the lugs on each sprocket wheel Position each sprocket wheel on the axle as shown in the illustration A 600 700 2 Place the track in the chassis Be sure it is positioned as shown in the illustra tion A Turning direction B Forward ...

Page 53: ...e seats Reed valve stoppers Reed valves Gaskets Piston rings Piston pins Pistons Bearings 2 1 1 2 1 2 2 2 4 4 2 4 2 2 2 Remove the parts in the order below Make sure its projection comes to the exhaust side For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb A 13 Nm 1 3 m kg 9 4 ft lb 1st 2nd 23 Nm 2 3 m kg 17 ft lb B 20 Nm 2 0 m kg 14 ft lb C 13 Nm 1 3 m kg 9 4 ft lb D ENGINE ...

Page 54: ...SPECTION 1 Measure Valve stopper height a Out of specification Replace Valve stopper height a 10 4 10 8 mm 0 41 0 42 in 2 Measure Reed valve bending limit a Out of specification Replace Reed valve bending limit a less than 0 3 mm 0 012 in ...

Page 55: ...eed valve seat Reed valve stopper Reed valve Gasket Piston ring Piston pin Piston Bearing 3 1 3 3 1 1 3 3 3 6 6 3 6 3 3 3 Remove the parts in the order listed below Refer to ENGINE ASSEMBLY For installation reverse the removal procedure 14 Nm 1 4 m kg 10 ft lb A 1st B 28 Nm 2 8 m kg 20 ft lb D 2nd 11 Nm 1 1 m kg 8 0 ft lb 23 Nm 2 3 m kg 17 ft lb 20 Nm 2 0 m kg 14 ft lb C CYLINDER HEAD AND CYLINDER...

Page 56: ...000 65 014 mm 2 5591 2 5596 in 700 70 50 70 52 mm 2 775 2 776 in 65 1 mm 2 563 in 70 6 mm 2 780 in Taper T 0 05 mm 0 0019 in Out of round R 0 01 mm 0 0004 in C Maximum D T Maximum D1 or D2 Maximum D5 or D6 R Maximum D1 D3 or D5 Minimum D2 D4 or D6 If out of specification replace cylinder and replace piston and piston rings as a set 2nd step Measure the piston skirt diameter P with a micrometer a 1...

Page 57: ...in der and replace piston and piston rings as a set Piston to cylinder clearance 600 0 065 0 070 mm 0 0026 0 0028 in Limit 0 1 mm 0 004 in 700 0 070 0 075 mm 0 0028 0 0030 in Limit 0 1 mm 0 004 in 2 Measure Side clearance piston rings Out of specification Replace piston and or rings Use a feeler gauge 1 Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side ...

Page 58: ...ton Piston pin to piston clearance Bore size piston pin b Outside diameter piston pin a Piston pin to piston clearance 0 004 0 020 mm 0 00016 0 0008 in 5 Inspect Reed valves 1 Bends cracks damage Replace 6 Measure Valve stopper height a Out of specification Replace the valve stopper Valve stopper height a 10 4 10 8 mm 0 41 0 42 in 7 Measure Reed valve bending limit a Out of specification Replace t...

Page 59: ...er cap body Clamp Coolant hose 2 Coolant hose 3 Heat exchanger right Coolant hose 4 Coolant hose 5 Heat exchanger left Joint pipe Coolant hose 6 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order below Drain Refer to COOLANT REPLACEMENT For installation reverse the removal procedure HEAT EXCHANGER COOL COOLING SYSTEM HEAT EXCHANGER 500 ...

Page 60: ...re below the specified pressure Replace Cap opening at pressure 80 100 kPa 0 8 1 0 kg cm2 11 44 14 30 psi Measurement steps Attach the cooling system tester 1 90890 01325 YU 24460 01 to the coolant filler cap 2 Apply the specified pressure for 10 seconds and make sure there is no pressure drop ...

Page 61: ... parts in the order below Loosen For installation reverse the removal procedure 1 2 6 7 3 4 5 2 Intake silencer First remove the throttle cable from the cable guide on the steering column Adjust the throttle cable free play while the cable is in the cable guide After adjusting the throttle cable free play properly install the upper and lower intake silencer plates and seal CARBURETORS CARB CARBURE...

Page 62: ...embly 2 5 Nm 0 25 m kg 1 8 ft lb 2 Measure Float height a Out of specification Adjust Float height a 21 3 23 3 mm 0 839 0 917 in Measurement and adjustment steps Hold the carburetor in an upside down posi tion Measure the distance between the carburetor body and top of the floats The float arm should be resting on the valve but no compressing the needle valve If the float height is not within spec...

Page 63: ...ce the machine on a level place Attach the fuel level gauge 90890 01312 YM 01312 A 1 to the float chamber nozzle 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 gauge If the fuel level is incorrect adjust the fuel level Remove the c...

Page 64: ...rs 3 6 2 1 3 1 1 3 1 Remove the parts in the order below Loosen For installation reverse the removal procedure Intake silencer First remove the throttle cable from the cable guide on the steering column Adjust the throttle cable free play while the cable is in the cable guide After adjusting the throttle cable free play properly install the upper and lower intake silencer plates and seal CARBURETO...

Page 65: ...r Collar Spring Screw Starter rod Spring Starter levers Breather hoses Top covers Gaskets Throttle shaft connecting screws Connecting plate upper Connecting plate lower 4 1 1 1 3 1 1 3 3 3 3 3 1 1 Separation the parts in the order below Loosen For assembly reverse the separation procedure 1 2 3 4 5 6 7 8 9 11 12 13 14 ...

Page 66: ...sembly 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 45 0 60 in Measurement and adjustment steps Hold the carburetor in an upside down posi tion Measure the distance between the carburetor body and top of the floats The float arm should be resting on the valve but no compressing the needle valve If the float height is not within speci...

Page 67: ...ce the machine on a level place Attach the fuel level gauge 90890 01312 YM 01312 A 1 to the float chamber nozzle 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 gauge If the fuel level is incorrect adjust the fuel level Remove the c...

Page 68: ...0 1 cu in 68 68 mm 2 68 2 68 in 6 5 1 7 750 250 r min 7 750 250 r min Recoil hand starter Crankcase reed valve Forward indined parallel 3 cylinder 593 cm3 36 2 cu in 65 0 59 6 mm 2 56 2 35 in 6 6 1 8 500 250 r min 8 250 250 r min Forward indined parallel 3 cylinder 698 cm3 42 6 cu in 70 5 59 6 mm 2 78 2 35 in 6 7 1 8 500 250 r min 8 250 250 r min Lubrication system Separate lubrication YAMAHA YAMA...

Page 69: ...e 22 5 1 070 mm 42 1 in Suspension Front suspension type Rear suspension type Leading arm Slide rail suspension Track Track type Track width Length on ground Track deflection mm 10 kg 22 lb Internal drive type 381 mm 15 0 in 752 mm 29 6 in 25 X 30 mm 0 98 X 1 18 in Brake Brake type Operation method Caliper type disc brake Handle lever left hand operated Electrical Ignition system manufacturer Gene...

Page 70: ...0 7880 in 64 930 X 64 935 mm 2 5563 X 2 5565 in 10 mm 0 39 in 0 65 X 0 70 mm 0 0026 X 0 0028 in 70 425 X 70 430 mm 2 7727 X 2 7728 in 15 mm 0 59 in 0 070 X 0 075 mm 0 0028 X 0 0030 in Piston pin Piston pin outside diameter Piston pin length 19 995 X 20 000 mm 0 7872 X 0 7874 in 55 7 X 56 0 mm 2 193 X 2 205 in Piston ring Sectional sketch Top Ring 2nd Ring End gap installed Top Ring 2nd Ring Side c...

Page 71: ...0016 in Below 0 03 mm 0 0012 in 90 mm 3 54 in 85 mm 3 35 in 55 95 X 56 00 mm 2 203 X 2 205 in 291 75 X 292 30 mm 11 486 X 11 508 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 Big end bearing Type Needle bearing Small end bearing Type Needle bearing Crank pin Crank pin outside diameter Connecting rod Small end diameter Big end diameter 24 987 X 25 000 mm 0 9838 X 0 ...

Page 72: ...HN50 3 1 Q 4 2 3 Q 2 1 0 ø0 8 0 9 2 ø1 3 ø1 5 11 3 X 15 3 mm 0 45 X 0 60 in 36 X 38 mm 1 42 X 1 50 in TM33 3 pcs 8CH10 1 145 2 3 143 8 45 6DGM05 3 Q 8 Q 4 0 8 1 1 2 3 5 ø1 2 ø1 1 Fuel pump Type Manufacturer DIAPHRAM TAIYO GIKEN Oil pump Pump cable adjusting length Align the marks 22 X 24 mm 0 87 X 0 94 in 21 X 23 mm 0 83 X 0 90 in Cooling system Water pump drive belt tension New belt Filler cap op...

Page 73: ...e circumference Width A Wear limit B 8CJ 17641 00 DAYCO 1 124 mm 44 25 in 35 0 mm 1 39 in 33 0 mm 1 30 in 8DN 17641 00 MITSUBOSHI 1 133 mm 44 6 in 34 5 mm 1 36 in 32 5 mm 1 28 in MITSUBOSHI 32 5 mm 1 28 in Primary sheave spring Part number Color code Diameter Wire diameter Preload Spring rate Number of coils Free length 90501 551L3 Blue Pink Blue 60 mm 2 36 in 5 5 mm 0 21 in 294 N 30 kg 66 lb 19 6...

Page 74: ... 40 in 90261 06034 13 9 mm 0 55 in 90261 06034 13 9 mm 0 55 in Secondary sheave spring Part number Color code Outside diameter Wire diameter Hole position Sheave side spring side twist angle 90508 536A9 Red 69 5 mm 2 736 in 5 3 mm 0 208 in 3 6 90 2 6 80 90508 556A2 Green 5 5 mm 0 216 in 3 3 60 Spring rate Number of coils Free length Torque cam angle 7 3 N mm 0 74 kg mm 40 49 lb in 5 53 75 mm 2 95 ...

Page 75: ... 98 X 1 18 in 8EA 47110 10 8EA 47110 10 19 mm 0 75 in Slide rail suspension Front travel Rear travel Suspension spring rate Front Rear 230 mm 9 in 290 mm 11 5 in 15 X 25 N mm 1 5 X 2 5 kg mm 87 5 X 148 lb in 27 X 47 N mm 2 8 X 4 8 kg mm 160 X 273 lb in Spring wire diameter Front Rear 7 8 mm 0 30 in 11 4 mm 0 44 in Suspension setting position Stopper band hole position F Hook setting length Full ra...

Page 76: ...0 N 0 3 m s 970 N 0 3 m s Slide runner Thickness Wear limit 17 8 mm 0 70 in 10 mm 0 4 in Track sprocket wheel Material Number of teeth Polyethylene 9T Rear guide wheel Material Outside diameter High molecular weight polyethylene with rubber 178 mm 7 in Brake Pad thickness Pad wear limit Disc outside diameter Disc thickness 10 2 mm 0 40 in 4 7 mm 0 185 in 220 mm 8 66 in 10 mm 0 39 in ...

Page 77: ...4 R ski 34 7 L ski 34 7 R ski 29 4 L ski Toe out 0 X 15 mm 0 X 0 59 in 22 5 Ski Ski material Length Width Thickness Plastic 1 000 mm 39 4 in 130 mm 5 12 in 7 6 mm 0 3 in 131 mm 5 16 in 130 mm 5 12 in Ski suspension Type Travel Spring type Spring rate Wire diameter Proaction system 221 mm 8 7 in Coil spring 22 5 N mm 1 3 2 1 2 5 kg mm 7 8 mm 0 307 in Shock absorber damping force Extension Compressi...

Page 78: ...gneto CDI Magneto model Manufacturer Pickup coil resistance color code Source coil resistance color code Charging current Minimum Charging current Maximum Charging coil resistance color code Lighting voltage Minimum Lighting voltage Maximum Lighting coil resistance color code Grip warmer coil resistance color code CDI unit manufacturer F4T 324 MITSUBISHI 189 X 231 Ω at 20 C 68 F White Red White Gr...

Page 79: ...IONS SPEC Model SX500D SX600D SX700D Rectifier regulator Model manufacturer 8CR 00 EHU0TR140 Model manufacturer 8CR 00 MATSUSHITA EHU0TR140 MATSUSHITA No load regulated voltage AC 13 8 X 14 8 V AC DC 13 8 X 14 8 V 14 0 X 15 0 V ...

Page 80: ... 1 5 MJ 146 3 JN 1 5 MJ 145 JN 1 5 MJ 143 8 JN 1 5 1 500 X 2 000 m 4 900 X 6 600 ft MJ 146 3 JN 1 5 MJ 145 JN 1 5 MJ 143 8 JN 1 5 MJ 142 5 JN 1 5 MJ 141 3 JN 1 5 2 000 X 2 500 m 6 600 X 8 200 ft MJ 143 8 JN 1 0 MJ 142 5 JN 1 0 MJ 141 3 JN 1 0 MJ 140 JN 1 0 PJ 50 PS 2 1 2 MJ 138 8 JN 1 0 PJ 50 PS 2 1 2 2 500 X 3 000 m 8 200 X 9 800 ft MJ 142 5 JN 1 0 MJ 141 3 JN 1 0 MJ 140 JN 1 0 MJ 138 8 JN 0 5 PA...

Page 81: ... 5 PS 2 5 JN 6DHN50 2 5 MJ 1 131 3 MJ 2 3 128 8 PJ 42 5 PS 2 5 JN 6DHN50 2 5 MJ 1 128 8 MJ 2 3 126 3 PJ 42 5 PS 3 0 JN 6DHN50 2 0 MJ 1 126 3 MJ 2 3 123 8 PJ 45 PS 3 0 JN 6DHN50 2 0 1 500 X 2 000 m 4 900 X 6 600 ft MJ 1 136 3 MJ 2 3 133 8 PJ 42 5 PS 2 0 JN 6DHN50 2 5 MJ 1 133 8 MJ 2 3 131 3 PJ 42 5 PS 2 5 JN 6DHN50 2 5 MJ 1 131 3 MJ 2 3 128 8 PJ 42 5 PS 2 5 JN 6DHN50 2 0 MJ 1 128 8 MJ 2 3 126 3 PJ ...

Page 82: ...2 5 PS 1 5 8 MJ 1 140 0 MJ 2 3 138 8 PJ 52 5 JN 2 0 PS 1 5 8 MJ 1 138 8 MJ 2 3 137 5 PJ 52 5 JN 2 0 PS 1 5 8 MJ 1 137 5 MJ 2 3 136 3 PJ 52 5 JN 2 0 PS 1 1 2 1 500 X 2 000 m 4 900 X 6 600 ft MJ 1 140 0 MJ 2 3 138 8 PJ 55 0 JN 2 0 PS 2 0 MJ 1 138 8 MJ 2 3 137 5 PJ 55 0 JN 2 0 PS 1 7 8 MJ 1 137 5 MJ 2 3 136 3 PJ 55 0 JN 2 0 PS 1 7 8 MJ 1 136 3 MJ 2 3 135 0 PJ 55 0 JN 2 0 PS 1 7 8 MJ 1 135 0 MJ 2 3 13...

Page 83: ...der and sliding sheave Primary sheave cap and sliding sheave Roller and weight primary sheave Bolt Screw Ring gear Secondary sheave Drive sprocket Lock nut chain tensioner Chain housing and frame Driven sprocket Drain bolt Chain housing cover Chain housing and brake caliper Bearing holder jackshaft Suspension wheel Guide wheel 13 27 40 90 90 27 60 40 27 13 23 13 25 13 28 20 7 23 14 10 8 10 12 0 7 ...

Page 84: ... column and relay rod Relay rod and relay arm Relay arm and tie rod Tie rod and steering arm Locknut relay rod Ski runner Ski Shock absorber upper Shock absorber lower Steering arm and ski column Lower control arm and frame Upper control arm and frame Control arm and front arm Front arm pivot bolt Stabilizer bar and connecting rod Connecting rod and front arm Hood Seat and frame nut Front cowling ...

Page 85: ... 81 CABLE ROUTING SPEC CABLE ROUTING 500 ...

Page 86: ...11 To battery negative terminal 12 Battery negative lead 13 To starter relay 14 To reverse gear 15 Gear position switch lead for model with reverse 16 Route the main switch harness along the under of the oil and fuel breather hose 17 Route the parking brake cable along the under of the oil breath er hose 18 Main switch assembly 19 Starter cable assembly 20 Oil pump cable 21 Throttle cable 22 Varia...

Page 87: ... 83 CABLE ROUTING SPEC ...

Page 88: ...he 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 adhe sive tape below the fuel tank as shown 8 50 mm 1 97 in 9 To tail brake light 10 Adhesive tapes 11 Pass the wire harness and fuel tank breather hose through the cable hlder 12 Clip 13 Fuel sender coupler 14 Oil level switch coupler 15 Install the metal clip...

Page 89: ... 85 CABLE ROUTING SPEC ...

Page 90: ...4 Install the smoothing condenser so it is flush with the inner edge of the tab 5 Clamp 6 Speedometer cable 7 Headlight lead 8 Fasten the headlight lead and speedometer cable at the white tape mark with a plastic clamp 9 Route the headlight lead and speedometer cable over the shroud s stopper wire ...

Page 91: ... 87 CABLE ROUTING SPEC ...

Page 92: ...Fasten the oil breather hose with a plastic clamp 14 Fasten the wire harness and oil breather hose behind the steer ing colum with a plastic band Do not fasten the parking brake cable and brake hose 15 Grip warmer control knob 16 Fasten the wire harness and fuel breather hose with a plastic clamp 17 Ground lead 18 Fuel sender coupler 19 Oil level switch coupler 20 Fuel switch coupler 21 Bolt 22 Fu...

Page 93: ... 89 CABLE ROUTING SPEC ...

Page 94: ...Gear position switch for model without reverse 43 Brake hose holder 44 Fasten the wire harness with a plastic clamp 45 To the reverse gear 46 Gear position switch for model with reverse 47 Dose not kink 48 Fasten the wire harness fuel breather hose and oil breather hose with a plastic clamp 49 Main switch assembly 50 Starter choke lever assembly 51 Install the starter lever to the position as illu...

Page 95: ... 91 CABLE ROUTING SPEC ...

Page 96: ...the wire harness through the slot on the intake silencer 5 Carburetor switch coupler 6 Water temperature sensor coupler 7 Starter relay coupler 8 CDI unit 9 Make sure a plastic locking tie is routed through wire harnesses as shown 10 Fasten the fuel hose at the white paint mark 11 To the carburetor 12 CDI unit coupler 13 To the carburetor 14 CDI magneto coupler 15 CDI unit coupler CABLE ROUTING SP...

Page 97: ... 93 CABLE ROUTING SPEC CABLE ROUTING 600 700 ...

Page 98: ...1 Wire lead electric starter model 12 Wire negative lead electric starter model 13 Brake hose 14 To battery negative terminal 15 To starter relay electric starter model 16 To reverse gear 17 Gear position switch coupler electric starter model 18 Route the main switch harness along the under of the oil and fuel breather hose 19 Route the parking brake cable along the under of the oil breath er hose...

Page 99: ... 95 CABLE ROUTING SPEC ...

Page 100: ... 96 33 Water temperature sensor coupler 34 Oil pump cable 35 Throttle cable 36 35 45 mm 1 37 1 76 in 37 Clamp 38 Silencer Air box 39 Ignition coil 3 CABLE ROUTING SPEC ...

Page 101: ... 97 CABLE ROUTING SPEC ...

Page 102: ...her 8 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 adhe sive tape below the fuel tank as shown 9 50 mm 1 97 in 10 To tail brake light 11 Fuel tank 12 Compression spring 13 Clip 14 Fuel sender coupler 15 Oil level switch coupler 16 Install the metal clip facing down...

Page 103: ... 99 CABLE ROUTING SPEC ...

Page 104: ...hing condenser so it is flush with the inner edge of the tab 5 Clamp 6 Headlight lead 7 Speedometer cable 8 Fasten the headlight lead and speedometer cable at the white tape mark with a plastic clamp 9 Route the headlight lead and speedometer cable over the shroud s stopper wire CABLE ROUTING SPEC ...

Page 105: ... 101 CABLE ROUTING SPEC ...

Page 106: ...mp 14 Fasten the wire harness and oil breather hose behind the steer ing colum with a plastic band Do not fasten the parking brake cable and brake hose 15 Grip warmer control knob 16 Fasten the wire harness and fuel breather hose with a plastic clamp 17 Ground lead 18 Fuel sender coupler 19 Oil level switch coupler 20 Bolt 21 Fuel breather hose 22 Spring compression 23 Clip 24 Fuel pipe 25 To the ...

Page 107: ... 103 CABLE ROUTING SPEC ...

Page 108: ...h for model without reverse 43 Brake hose holder 44 Fasten the wire harness with a plastic clamp 45 To the reverse gear 46 Gear position switch for model with reverse 47 Dose not kink 48 Fasten the wire harness fuel breather hose and oil breather hose with a plastic clamp 49 Main switch assembly 50 Starter choke lever assembly 51 Install the starter lever to the position as illustrated 52 Mark CAB...

Page 109: ... 105 CABLE ROUTING SPEC ...

Page 110: ... relay coupler 6 CDI unit 7 Make sure a plastic locking tie is routed through wire harnesses as shown 8 CDI unit coupler 9 Fasten the wire harness with a plastic clamp Route the wire harness through the slot on the intake silencer 10 Clamp Does no kink 11 CDI magneto coupler 12 Starter relay coupler without electric starter model 13 Clamp 14 Coolant breather hose 15 To the coolant reservoir tank 1...

Page 111: ... 26 High beam indicator light 27 Speedometer light 28 Tachometer assembly 29 Tachometer light 30 Tachometer 31 Fuelmeter 32 DC back buzzer 33 Gear position switch 34 Passenger grip warmer switch 35 Passenger grip warmer 36 Passenger grip warmer switch 37 Passenger grip warmer resistor 38 Fuel sender 1 CDI magneto 2 Rectifier regulator 3 Starter relay fuse 4 Battery 5 Starter motor 6 Main switch 7 ...

Page 112: ...WIRING DIAGRAM ...

Page 113: ...te B Y Black Yellow G B Green Black G R Green Red G Y Green Yellow L R Blue Red R B Red Black R W Red White W G White Green W R White Red Y B Yellow Black Y L Yellow Blue Y R Yellow Red Y W Yellow White Br R Brown Red 20 Oil level switch 21 Brake light switch 22 Tail brake light 23 Speedometer assembly 24 Oil level indicator light 25 Water temp indicator light 26 High beam indicator light 27 Speed...

Page 114: ...WIRING DIAGRAM ...

Page 115: ...99 06 1 E ITP PRINTED ON RECYCLED PAPER ...

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Yamaha SX500D, Supplementary Service Manual

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