Yamaha SXV60ERK Owner'S Manual Download Page 38

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6-5

ESU00093

Brake fluid leakage

Apply the brake for a few minutes. Check to see if any
brake fluid leaks out from the brake hose joints or the
master cylinder.

WARNING

If brake fluid leakage is found, ask a Yamaha dealer
for immediate repairs.

CAUTION:

Brake fluid may deteriorate painted surfaces or plas-
tic parts. Never spill any brake fluid. If any is spilled,
clean it up immediately.

ESU00941

V-belt

Open the shroud and remove the drive guard.
Check the V-belt for wear and damage. Replace if neces-
sary.

WARNING

●

Make sure that the drive guard is tightened
securely before operating the snowmobile.

●

Never run the engine without the V-belt or with
the drive guard removed.

ESU00096

Drive guard

Check the drive guard mounts for damage. Make sure
that the drive guard is firmly in place.

Wear limit

32.5 mm (1.28 in)

U8EX11.book Page 5 Thursday, May 13, 2004 10:56 AM

Summary of Contents for SXV60ERK

Page 1: ...OWNER S MANUAL SNOWMOBILE ...

Page 2: ......

Page 3: ...y ID and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer 1 The frame number is the seventeen digit number stamped on the frame of the snowmobile See fig È 2 The engine number is stamped in the location as shown See fig É 3 Key number See fig Ê Also record and keep the ID numbers in a separate place in case the snowmobile is stolen A B C ...

Page 4: ...you have any questions concerning the operation or maintenance of your snowmobile please consult a Yamaha dealer To maintain the high quality and performance of this snowmobile it is important that you and your Yamaha dealer pay close attention to the recommended mainte nance schedules and operating instructions contained within this manual SXV60K SXV60ERK VT60K OWNER S MANUAL 2004 by Yamaha Motor...

Page 5: ...nual should be considered a permanent part of this snowmobile and should remain with the snow mobile when resold Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator a b...

Page 6: ...witch 5 12 Shroud latches 5 13 Drive guard 5 13 V belt holders 5 14 Spark plug holders 5 14 Carburetor coolant shut off lever 5 14 Backrest 5 15 Storage compartment 5 15 PRE OPERATION CHECKS 6 1 Fuel 6 1 Engine oil 6 2 Coolant 6 2 Throttle lever 6 3 Recoil starter 6 3 Throttle override system T O R S 6 3 Brake 6 4 Brake fluid leakage 6 5 V belt 6 5 Drive guard 6 5 Drive track 6 6 Slide runners 6 6...

Page 7: ...ustments 8 10 Cooling system 8 11 V belt replacement 8 13 Checking the drive chain housing oil level and the drive chain tension 8 15 Checking the brake pads 8 17 Checking the parking brake pads 8 17 Checking the brake fluid level 8 18 Brake fluid replacement 8 18 Suspension 8 19 Drive track adjustment 8 23 Ski alignment 8 25 Lubrication 8 26 Headlight bulb replacement 8 27 Headlight beam adjustme...

Page 8: ...1 1 ESU00004 1 YAMAHA MOTOR CORPORATION U S A SNOWMOBILE LIMITED WARRANTY CW 01E ...

Page 9: ...1 2 CW 02E ...

Page 10: ...1 3 CW 03E ...

Page 11: ...1 4 ESU04280 YAMAHA EXTENDED SERVICE Y E S CW 06E ...

Page 12: ...0007 2 LOCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operat ing this snowmobile NOTE Maintain or replace safety and instruction labels as nec essary 1 SXV60 1 SXV60ER 1 VT60 ...

Page 13: ...2 2 2 3 VT60 ...

Page 14: ...0 and SXV60ER are designed to carry the OPERATOR ONLY Passengers are prohibited Carrying a passenger can cause loss of control 4 Do not operate the snowmobile after drinking alcohol or taking drugs Your ability to operate the snowmo bile is reduced by the influence of alcohol or drugs 5 For safety and proper care of the snowmobile always perform the pre operation checks on pages 6 1 6 9 before sta...

Page 15: ... inhale a lot of gasoline vapor or get some gasoline into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash your skin with soap and water and change your clothes 10 Wear protective clothing Wear an approved helmet and a face shield or goggles Also wear a good qual ity snowmobile suit boots and a pair of gloves or mit tens that will permit use of...

Page 16: ...n most surfaces is to release the throttle and apply the brake gently not suddenly Maintenance and storage 1 Do not leave the snowmobile on its left side for an extended period of time Fuel may leak out from the fuel breather hose 2 Modifications made to the snowmobile not approved by Yamaha or the removal of original equipment may render your snowmobile unsafe for use that may cause severe person...

Page 17: ...4 1 ESU00012 4 DESCRIPTION 1 Windshield 2 Steering handlebar 3 Seat 4 Passenger grip warmer switch VT60 5 Frame 6 Slide rail suspension 7 Drive track 8 Skis 9 Headlight 0 Shroud VT60 SXV60 SXV60ER ...

Page 18: ... Shift lever SXV60ER VT60 M Starter handle N Shroud latch O Main switch P Starter lever Q Tachometer R High beam indicator light S Warning light T Self diagnosis warning indicator U Coolant temperature warning indicator V Fuel level warning indicator W Oil level warning indicator X Speedometer Y Grip warmer indicator Z Select reset button Thumb warmer indicator Fuel meter and grip thumb warmer hea...

Page 19: ...e removed only in this position 2 ON The ignition circuit is switched on The engine can be started NOTE The headlight meter lights and taillight will come on after the engine starts For SXV60ER VT60 3 START The starting circuit is switched on The starter motor starts CAUTION Release the switch immediately after the engine starts È SXV60 É SXV60ER VT60 A B ...

Page 20: ...e the speed of the snowmobile by varying the throttle position Because the throttle is spring loaded the snowmobile will deceler ate and the engine will return to idle when it is released b WARNING Check the throttle brake and steering for proper operation before starting the engine ESU00231 Throttle override system T O R S If the carburetor or throttle cable should malfunction dur ing operation t...

Page 21: ...ngine Be sure to use the specified spark plug and spark plug cap Otherwise the T O R S will not work properly CA 01E È Idling starting É Running Ê Trouble 1 Carburetor switch 2 Throttle switch 3 Throttle cable 4 Throttle valve a On b Off A B C Mode Item Idling starting Running Trouble Throttle switch Off On Off Carburetor switch On Off Off Engine Run Run T O R S will operate A B C ...

Page 22: ...level After the engine is started the tachometer 1 makes one sweep and the warning light 2 and all segments of the meter 3 turn on and off once The grip warmer level is initially displayed for 5 seconds then switches to the fuel meter display Odometer and tripmeter modes Pushing the select reset button 4 switches the display between the odometer mode ODO and the tripmeter mode TRIP To reset the tr...

Page 23: ...es down to the last segment E Empty When this occurs the fuel level warning indicator 2 and the warning light 3 come on If the fuel level warning indicator and the warning light come on fill the fuel tank at the first opportunity NOTE The snowmobile must be stopped on a level surface to obtain an accurate fuel meter reading The fuel meter reading changes as the snowmobile moves and depend ing on t...

Page 24: ...tinually pressed at the mini mum level When the engine is started the grip thumb warmer levels are set to the levels saved when the engine was stopped ESU00287 Fuel level warning indicator The fuel level warning indicator indicates a malfunction ing sensor disconnected coupler broken lead or short circuit when detected by the self diagnosis device of the snowmobile The fuel level warning indicator...

Page 25: ...ant level in the coolant reservoir See page 6 2 CAUTION Do not operate the engine if it overheats The coolant temperature warning indicator indicates a malfunctioning sensor disconnected coupler broken lead or short circuit when detected by the self diagnosis device of the snowmobile The coolant temperature warning indicator and warning light warn the rider of the above problems by flashing contin...

Page 26: ...cator and warning light flash patterns WARNING If the self diagnosis warning indicator and warn ing light flash continuously during operation there may be some problem with the electrical circuit lead couplers etc See page 5 9 for warn ing indicator and warning light flash pattern num bers 1 5 Stop the engine and allow it to cool off Then check that the wire harness couplers are con nected properl...

Page 27: ... warning light flash continuously in this pattern 3 Warning indicator and warning light flash continuously in this pattern 4 Warning indicator and warning light flash continuously in this pattern 5 Warning indicator and warning light flash continuously in this pattern On Off s Second 0 75 s 2 5 s 0 75 s 0 25 s 3 5 s 0 75 s 0 25 s 4 5 s 0 75 s 0 25 s 5 5 s 0 75 s 0 25 s 6 5 s ...

Page 28: ...ver towards the handlebar grip to stop the snowmobile 1 Brake lever 2 Brake lever end 3 Handlebar end NOTE When the brake lever is operated the brake light will illu minate CAUTION Make sure that the brake lever end does not project out over the handlebar end This will help prevent brake lever damage when the snowmobile is placed on its side for service The brake lever is equipped with a position ...

Page 29: ...ne Never run the snowmobile with the parking brake applied This may overheat the brake disc and reduce braking ability ESU00321 Shift lever For SXV60ER VT60 The shift lever is used to put the snowmobile into forward or reverse After coming to a complete stop push the shift lever down and move it to the desired direction 1 Shift lever 2 Push down 3 Move to FWD 4 Move to REV CA 02E CAUTION Do not sh...

Page 30: ...ge the headlight beam to high or low 1 Headlight beam switch 2 Push 3 High beam 4 Low beam ESU00440 Passenger grip warmer switch For VT60 The passenger grip warmer switch controls the electri cally heated passenger grips 1 Passenger grip warmer switch 2 OFF 3 HI High 4 LO Low ...

Page 31: ...shroud WARNING Do not drive the snowmobile with the shroud open unlatched or removed Keep your body and clothing away from rotating parts when servicing with the shroud open Do not touch the hot muffler and engine during or immediately after operation ESU00521 Drive guard The drive guard is designed to cover the V belt clutch and V belt in case parts break or come loose WARNING Make sure that the ...

Page 32: ... coolant shut off lever The carburetor coolant shut off lever controls the flow of coolant through the carburetor Make sure that the lever is in the ON position to allow the coolant to flow and warm the carburetor while the ambient temperature is below 0 C 32 F 1 Carburetor coolant shut off lever 2 ON open 3 OFF closed CAUTION When operating the snowmobile in temperatures above 0 C 32 F move the c...

Page 33: ...d for the rider as shown in the illustration To adjust the passenger grip position remove the pas senger grip adjusting knobs 3 on both sides of the seat and change the position of the passenger grip to any one of the three positions shown WARNING Make sure that the passenger grip adjusting knobs are tightened securely after adjusting the passenger grip position ESU02420 Storage compartment Open t...

Page 34: ...ck the SAFETY INFORMATION section carefully before refueling See page 3 2 Do not fill the fuel tank above the bottom of the filler tube 1 Fuel could overflow if the snowmo bile is tilted on its side or if the ambient tempera ture rises causing the fuel to warm up and expand Make sure that the fuel tank cap is closed securely after refueling Leaking fuel can catch fire 2 Fuel level CAUTION Oxygenat...

Page 35: ...imilar be careful not to mistake the caps ESU00086 Coolant Check the coolant level in the coolant reservoir when the engine is cold If the coolant level is below the COLD LEVEL mark add soft water until it reaches the COLD LEVEL mark See pages 8 11 8 12 for more details 1 COLD LEVEL mark WARNING Do not remove the coolant reservoir cap when the engine is hot CAUTION Hard water or salt water is harm...

Page 36: ...ine up to clutch engagement r min Otherwise the snowmobile could start moving forward unexpectedly which could cause an accident 1 Start the engine NOTE Refer to the Starting the engine section 2 Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb above and forefinger below between the throttle lever pivot 1 and the engine stop switch housing 2 While hold...

Page 37: ...cates a failure in the brake system Do not operate the snowmobile if you find any problems in the brake system You could lose braking ability which could lead to an accident Ask a Yamaha dealer to inspect and repair the brake system CAUTION Make sure that the brake lever end does not project out over the handlebar end This is to prevent brake lever damage when the snowmobile is placed on its side ...

Page 38: ... tic parts Never spill any brake fluid If any is spilled clean it up immediately ESU00941 V belt Open the shroud and remove the drive guard Check the V belt for wear and damage Replace if neces sary WARNING Make sure that the drive guard is tightened securely before operating the snowmobile Never run the engine without the V belt or with the drive guard removed ESU00096 Drive guard Check the drive...

Page 39: ... maladjusted Drive track damage or failure could result in loss of brak ing ability and snowmobile control which could cause an accident ESU00981 Slide runners Check the slide runners for wear and damage If the slide runners reach the wear limit they should be replaced 1 Slide runners a Wear limit CAUTION Ride on fresh snow frequently Operating on ice or hard packed snow will rapidly wear the slid...

Page 40: ... for excessive free play 1 Push the handlebar up and down and back and forth 2 Turn the handlebar slightly to the right and left If excessive free play is noticed consult a Yamaha dealer ESU00105 Lights Check the lights Replace any burned out bulbs CAUTION Avoid using a scraper or hot water for cleaning the plastics lens 1 ESU00106 Battery For SXV60ER VT60 Check the fluid level and fill if necessa...

Page 41: ... and remove the snow Then reinstall the air filter element beneath the holding guides on the case After riding the snowmobile make sure there is no snow on the air filter element NOTE The air filter element can be removed when the ambi ent temperature is 5 C 41 5 F or higher Before removing the air filter element consult a Yamaha dealer ...

Page 42: ...ce to carry the tool kit spare parts and other necessary equipment with you while riding the snowmobile so that minor repairs can be done if neces sary The following should be carried at all times Tool kit Flashlight Roll of plastic tape Steel wire Tow rope Emergency starter rope V belt Light bulbs Spark plugs When you start out for a long distance trip extra fuel and oil should be carried as well...

Page 43: ...ting 3 Half open warm engine up 4 Closed warm engine starting NOTE The starter lever choke is not required when the engine is warm Put the starter lever choke in the closed posi tion Manual starting model For SXV60 2 Turn the main switch to the ON position 1 ON 3 Pull slowly on the recoil starter until it is engaged then pull it briskly After the engine starts put the starter lever choke in the ha...

Page 44: ...hen try again Each attempt should be as short as possible to preserve the battery Do not crank the engine more than 10 seconds on any one attempt ESU00248 Emergency engine starting Manual starting model For SXV60 If the recoil starter system should fail take the emer gency starter rope and the screwdriver handle out of the tool kit and proceed as follows NOTE The emergency starter rope and a screw...

Page 45: ...emergency starter rope around your hand 6 After the engine starts put the starter lever choke in the half open position Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the closed position 7 Install the drive guard and shroud WARNING Avoid contact with the moving primary sheave assembly Electric starting model For SXV60ER VT60 Follow the proc...

Page 46: ...oid lugging the engine such as laborious opera tion in wet snow If any abnormal condition is noticed such as excessive vibration or noise consult a Yamaha dealer NOTE To ensure proper engine break in use a 50 1 gasoline oil mixture when filling the fuel tank of a new snowmobile for the first time For example 10 L of gasoline per 0 2 L of oil 1 gal of gasoline per 2 6 oz of oil equals a 50 1 mixing...

Page 47: ...ded with added safety and a more reliable snowmobile Always wear the proper cloth ing for both warmth and to help protect you from injury if an accident occurs Become familiar with operating your snow mobile at low speeds even if you are an experienced rider Do not attempt to oper ate at maximum performance until you are totally familiar with the snowmobile s han dling and performance characterist...

Page 48: ... thor oughly familiar with the operation of your snowmobile Riding uphill You should practice first on gentle slopes Try more difficult climbs only after you have developed your skill As you approach a hill accelerate before you start the climb and then reduce the throttle to prevent track slippage It is also important to keep your weight on the uphill side at all times On climbs straight up the h...

Page 49: ...our downhill leg on the seat and the foot of your uphill leg on the running board This position will make it easier for you to shift your body weight as needed Snow and ice are slippery so be prepared for the possibility that your snowmobile could begin to slip sideways on the slope If this happens steer in the direction of the slide if there are no obstacles in your path As you regain proper bala...

Page 50: ...es 2 Snow mixed with a lot of dirt and sand All of the above surfaces have one thing in common in regard to drive track and slide runners little or no lubricating ability Drive track and all slide rail systems require lubrication snow or water between the slide runners and the slide metal In the absence of lubrication the slide runners will rapidly wear and in severe cases liter ally melt away and...

Page 51: ...erheating avoid sustained high speed usage in areas such as icy trails frozen lakes and rivers that have minimal snow coverage An overheated track will be weakened internally which may cause fail ure or damage Off trail riding Avoid off trail riding until there is sufficient snow cover age It generally takes several feet of snow to provide a good overall base to properly cover debris such as rocks...

Page 52: ...le 5 Apply the parking brake by moving the parking brake lever to the left For SXV60ER VT60 1 Select the desirable operating position by moving the shift lever 1 Push down 2 FWD Forward 3 REV Reverse WARNING Make sure that the throttle lever is fully released and the snowmobile is at a full stop before shift ing Be sure to move the shift lever to forward or reverse until it stops completely while ...

Page 53: ...p the snowmobile 6 Apply the parking brake by moving the parking brake lever to the left ESU00137 Stopping the engine Turn the main switch to the OFF position to stop the engine 1 OFF È SXV60 É SXV60ER VT60 WARNING Push down the engine stop switch to stop the engine in an emergency Make sure that the key is removed from the main switch whenever the operator leaves the snow mobile to prevent accide...

Page 54: ... hydrostatic lock When possible the fuel tank should be empty during transportation especially if the trip will be longer than 30 minutes If transporting the snowmobile in an open trailer or truck put a tight fitting cover on the snowmobile A cover specifically designed for your snowmobile is best This will help keep foreign objects out of the cooling vents in the shroud and also help protect the ...

Page 55: ...r cracks or damage Replace if necessary Oil line Check oil hose for cracks or damage Replace if necessary Engine coolant Check coolant level 6 2 8 11 8 12 Air bleed the cooling system if necessary 8 11 Carburetor Check throttle lever operation 5 2 6 3 Adjust the jets Whenever operating condition elevation temperature is changed Recoil starter Check operation and rope damage Replace if necessary 6 ...

Page 56: ... play Lubricate shaft with specified grease as required Every 1 600 km 1 000 mi Drive chain oil Check oil level 8 15 8 16 Replace Drive chain Check deflection Adjust if necessary Initial at 500 km 300 mi and every 800 km 500 mi thereafter 8 16 Skis and ski runners Check for wear and damage 6 7 Replace if necessary Steering system Check operation 6 7 Adjust toe out if necessary Lights Check operati...

Page 57: ... bushings for wear for secondary Replace if necessary Lubricate with specified grease Steering column bearing Lubricate with specified grease 8 26 Ski and front suspension Lubricate with specified grease 8 26 Suspension component Lubricate with specified grease 8 26 Parking brake cable end and lever end throttle cable end Lubricate with specified grease 8 26 Check cable damage Replace if necessary...

Page 58: ...condition of the spark plug can indi cate the condition of the engine Check the coloration on the white porcelain insulator around the center electrode The ideal coloration at this point is a medium to a light tan color for a snowmobile that is being ridden normally If a spark plug shows a distinctly different color there could be something wrong with the engine For example a very white center ele...

Page 59: ...rm on the exposed threads resulting in combustion chamber hot spots and thread damage Always use a spark plug with the speci fied reach Before installing any spark plug measure the electrode gap with a wire thickness gauge and adjust to specifica tion When installing the spark plug always clean the gasket surface Wipe off any grime from the threads and tighten the spark plug to the specified torqu...

Page 60: ...efer to the Starting the engine section 2 Turn the throttle stop screw 1 in or out to adjust the engine idle speed ESU01471 Throttle cable adjustment CAUTION Be sure to adjust the engine idle speed first 1 Loosen the locknut 2 Turn the adjuster in or out until the proper throttle lever free play is achieved 1 Locknut 2 Adjuster 3 Tighten the locknut Standard engine idle speed 1 600 100 r min Throt...

Page 61: ...re to have a Yamaha dealer make this adjustment Make sure that the carburetor silencer is installed during running to prevent engine damage Under some operating conditions the carburetor setting may have to be changed due to air temperature changes elevation changes use of alcohol oxygenated fuels etc and should be set by a Yamaha dealer CAUTION The drive chain gears and V belt clutch should be ad...

Page 62: ...is in place below the clip WARNING Make sure that the throttle outer cable is firmly seated in the holder and the throttle operates smoothly after assembling the carburetor 3 Assemble by reversing the removal steps Standard pilot screw position 2 0 turns out from the seated position Pilot screw 1 Mixture Condition Turn in Lean Warm weather High altitude Turn out Rich Cold weather Low altitude Stan...

Page 63: ...are it is HIGHLY FLAMMABLE CD 04E 1 Loosen the carburetor clamps and remove the carbu retor 2 Pinch the fuel hose to prevent fuel flowing 3 Remove the drain plug and install the proper main jet 4 Assemble by reversing the removal steps WARNING Make sure that the throttle outer cable is firmly seated in the holder and throttle operates smoothly after assembling the carburetor Standard main jet 1 No...

Page 64: ...amaha dealer carefully Proper carburetion adjustments will correct the air fuel ratio Remember less air at higher altitude means there is less horsepower available even with proper carburetion Expect acceleration and top speed to be reduced at higher altitudes To overcome operating with less power at high altitudes your snowmobile may also require different settings for the drive chain gears and V...

Page 65: ...cap slowly rotate the cap counterclockwise to the detent This pro cedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it The cooling system must be bled of air if the coolant reservoir becomes empty if air can be seen in the cooling system or if there is a cooling system leak Consult a Yamaha dealer CAUTIO...

Page 66: ...then stop the engine 3 Fill the coolant reservoir with coolant to the COLD LEVEL mark 4 Install the coolant reservoir cap Check for any cool ant leakage NOTE If you find any leaks consult a Yamaha dealer Recommended coolant High quality ethylene glycol antifreeze containing corro sion inhibitors Coolant and water mixed ratio 60 40 Total amount For SXV60 SXV60ER 3 8 L 3 34 Imp qt 4 02 US qt For VT6...

Page 67: ...ng bolt Have a Yamaha dealer make this adjustment CAUTION As the V belt wears adjustment may be necessary To ensure proper clutch performance the V belt position should be adjusted by adding a spacer on each adjusting bolt when the V belt position reaches 1 5 mm 0 06 in below the edge Have a Yamaha dealer make this adjustment CD 05E NOTE Apply the parking brake before replacing the V belt 1 Remove...

Page 68: ...position is incorrect adjust the V belt position by removing or adding a spacer 4 on each adjusting bolt 5 CD 06E 7 Tighten each adjusting bolt Standard V belt position a From 1 5 mm 0 06 in above the edge of the second ary sheave to 0 5 mm 0 02 in below the edge V belt position Adjustment More than 1 5 mm 0 06 in above the edge Remove spacer From 1 5 mm 0 06 in above the edge to 0 5 mm 0 02 in be...

Page 69: ...e very hot after the engine has been run Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair 1 Place the snowmobile on a level surface 2 Remove the dipstick 1 and wipe it off with a clean rag Then put the dipstick in the hole CAUTION There is a magnet attached to the end of the dipstick It is used to remove any metal par...

Page 70: ...ns SXV60ER VT60 CAUTION Make sure that no foreign material enters the drive chain housing 4 Install the dipstick and fit the loop 4 of the dipstick handle onto the projection 5 of the drive chain hous ing Chain tension adjustment 1 Loosen the locknut 2 Turn the adjusting bolt clockwise until it is finger tight 3 Hold the adjusting bolt in place while tightening the locknut 1 Locknut 2 Adjusting bo...

Page 71: ...djustment As the parking brake pads wear adjustment may be nec essary to ensure proper brake performance WARNING Be sure to have a Yamaha dealer make this adjust ment 1 Loosen the locknut 1 2 Turn the parking brake adjuster 2 in or out to adjust the clearance between the parking brake pad 3 and brake disc 4 3 Turn the cable adjuster 5 in or out to adjust the clear ance between the parking brake pa...

Page 72: ...rake fluid level goes down consult a Yamaha dealer CAUTION Brake fluid may deteriorate painted surfaces or plas tic parts Never spill any fluid If any is spilled clean it up immediately ESU00181 Brake fluid replacement Brake fluid replacement is necessary when the following components are replaced during the periodic mainte nance or if they are damaged or leaking a All oil seals of the master cyli...

Page 73: ...pes of terrain or riding conditions WARNING Be sure to have a Yamaha dealer make this adjust ment ESU03040 Ski spring preload adjustment The spring preload can be adjusted by turning the spring preload adjuster 1 CD 10E CAUTION The left and right ski spring preload must be set to the same pressure Uneven settings can cause poor handling and loss of stability Spring adjuster position 5 4 3 2 1 Prel...

Page 74: ...er is in the rear 2 of the rear suspension assembly The spring preload can be adjusted by turning the spring preload adjuster 3 on the front and rear shock absorb ers CD 13E For SXV60 SXV60ER CD 14E A Spring adjuster position 1 2 3 4 5 Preload Soft Hard È Standard front 3 B Spring adjuster position 1 2 3 4 5 6 7 Preload Soft Hard É Standard rear 2 ...

Page 75: ...erty damage Do not tamper with or attempt to open the shock absorber Do not subject the shock absorber to an open flame or other high heat sources which could cause it to explode Do not deform or damage the shock absorber in any way Do not dispose of a worn or damaged shock absorber by yourself Take the unit to a Yamaha dealer B Spring adjuster position 1 2 3 4 5 6 7 Preload Soft Hard É Standard r...

Page 76: ...turn while holding the adjusting bolt 2 securely with a wrench so it does not move CAUTION Never allow the adjusting bolt 2 to move while loos ening the nut 2 Turn the adjusting bolt 2 to the desired position CAUTION Make sure that the adjusting bolt ends are set at the same position on each side 3 While holding the adjusting bolt securely tighten the full rate adjusting nut 1 CAUTION Never allow ...

Page 77: ...he drive track condition frequently Replace damaged slide metal Replace the drive track if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken Otherwise track damage or failure could result in loss of braking ability and snow mobile control which could cause an accident Drive track deflection measurement 1 Lay the snowmobile on its side 2 Measure th...

Page 78: ...he drive track one or two turns Stop the engine 4 Check the drive track alignment with the slide runners 2 If the alignment is incorrect align the drive track by turning the left and right adjusters CD 08E 7 Slide runners 8 Drive track 9 Slide metal a Gap b Forward 5 Adjust the drive track deflection to specification CD 09E 5 6 Drive track alignment 5 Shifted to right 6 Shifted to left 3 Left adju...

Page 79: ...ent is achieved 7 Tighten the rear axle nut ESU00200 Ski alignment 1 Turn the handlebar so the skis face straight ahead 2 Check the following for ski alignment a Skis are facing forward b Ski toe out 1 2 is within specification 3 If the alignment is not correct consult a Yamaha dealer Rear axle tightening torque 75 Nm 7 5 m kgf 54 ft lb Ski toe out 1 2 0 15 mm 0 0 59 in ...

Page 80: ...ble end WARNING Apply a dab of grease onto the cable end only Do not grease the brake or throttle cable themselves because they could become frozen which could cause loss of control 2 Steering 3 Front suspension 4 Rear suspension 2 2 3 Lubricant Low temperature grease 3 4 ...

Page 81: ...ucts or your hands away from the hot bulb until it cools down 6 Install the new bulb CAUTION Keep oil or your hands away from the glass part of the bulb or its life and illumination will be affected If the glass is oil stained thoroughly clean it with a cloth moistened with alcohol or lacquer thinner ESU00293 Headlight beam adjustment 1 Turn the headlight beam adjuster 1 in or out to adjust the he...

Page 82: ...is poisonous and dangerous It contains sulfuric acid and can cause severe burns Avoid contact with skin eyes or clothing ANTIDOTE EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sp...

Page 83: ...negative battery lead to prevent accidental short circuiting 1 Lift up the shroud 2 Disconnect the negative battery lead 3 Replace the blown fuse with one of proper amperage 4 Connect the negative battery lead NOTE If the fuse immediately blows again ask a Yamaha dealer to inspect the snowmobile 5 Spare fuses 20 A 10 A 6 Spare main fuse Specified fuses 1 Main fuse 30A 2 HEAD fuse 20A 3 TAIL fuse 1...

Page 84: ...g the T O R S make sure that the throttle returns prop erly to the fully closed position The T O R S is an important safety device in the case of a malfunction take the snowmobile to a Yamaha dealer immediately for repair For SXV60 Short circuit in the lighting system sig nal system and meter system except for the ignition system Disconnect the relay with the white coupler not the black coupler to...

Page 85: ...ient coolant Add coolant 2 Air in cooling system Bleed air or ask a Yamaha dealer to inspect 3 Leaking coolant Ask a Yamaha dealer to inspect G Snowmobile does not move 1 Malfunctioning V belt clutch Ask a Yamaha dealer to inspect 2 Drive track does not move Foreign object is caught in the drive track or slide runners have melted to the slide metal due to lack of lubrication 3 Tight loose or broke...

Page 86: ...tch components Ask a Yamaha dealer to inspect 2 Worn or damaged bearings Ask a Yamaha dealer to inspect 3 Worn or damaged V belt with flat spots Replace 4 Worn or damaged idler wheels or shafts Ask a Yamaha dealer to inspect 5 Worn or damaged drive track Ask a Yamaha dealer to inspect ...

Page 87: ...ts This is more important in areas where oxygenated fuel gasohol is used because the alcohol content in the fuel increases the chance for water to enter the engine Use Yamaha Stor Rite Engine Fogging Oil or an equiva lent fogging oil to protect both the com bustion chamber and crankshaft from corrosion An alternate method is to remove the carburetor silencer and squirt oil into the carburetor thro...

Page 88: ...t of direct sunlight Put a fab ric cover over the snowmobile preferably one that is designed for it Do not use a plastic or vinyl cover condensation could be trapped underneath which could increase the chances of rusting Returning to service after storage When returning your snowmobile to ser vice reinstall the V belt and adjust the drive track Before installing the battery have a Yamaha dealer in...

Page 89: ... kg 516 lb SXV60ER 258 kg 569 lb VT60 Ski stance 1 070 mm 42 1 in SXV60 SXV60ER VT60 Type Liquid cooled 2 stroke 7 port Cylinder arrangement Parallel 3 cylinder Displacement 593 cm3 Bore Stroke 65 0 59 6 mm 2 56 2 35 in Idle speed 1 600 100 r min Engine oil type YAMALUBE 2 cycle oil Carburetor type MIKUNI TM31 3 Fuel Unleaded gasoline Pump octane 88 or higher Starting system Manual with recoil sta...

Page 90: ...ly variable 3 8 1 1 1 Sheave distance Approx 268 5 mm 10 57 in Sheave offset Approx 15 mm 0 59 in SXV60 Approx 20 mm 0 79 in SXV60ER VT60 Engagement speed Approx 4 300 r min SXV60 SXV60ER Approx 4 100 r min VT60 Shift speed Approx 8 500 r min Drive chain Silent chain enclosed in oil bath Reduction ratio 39 20 1 95 Fuel tank Tank capacity 44 3 L 9 7 lmp gal 11 7 US gal Oil tank Tank capacity 3 0 L ...

Page 91: ...8 0 031 in Battery Capacity GM18Z 3A 12 V 20A h SXV60ER VT60 Maximum charge rate 2 0 Amperes hr for 10 hrs SXV60ER VT60 Headlight Bulb Quantity 12 V 60 55 W 2 Tail brake light Bulb Quantity 12 V 5 21 W 2 SXV60 SXV60ER 12 V 8 23 W 1 VT60 Meter light Bulb Quantity 14 V 50 mA 6 Indicator light Bulb Quantity 14 V 80 mA 2 ...

Page 92: ... G Y L W Y B L Y G B B G G R B G B G G B L R G Y G Y L R L R R B R B W L Y W B B P P R R R R R B B B B B R W Br L Lg W Lg L W B Y W Y L Y W Y L W B Lg W Lg L W B G Y Y B Y G Lg B G R L G Ch W Gy O Ch B D W Gy O W Gy O O B B Gy W B B B B B B Lg Y R D D D A B B G G B L W L W B Y B Y B B L Y L Y A G B G B A G R G R A R B R B B W W Y Y A B G B G E E BLACK BLACK Lg W Lg L W B Lg L Lg W B L Y W Y L W B ...

Page 93: ...il level switch X High beam indicator light Y Warning light Z Multi function meter Meter light Tachometer Meter assembly _ Headlight a Headlight relay with the black coupler b Headlight beam switch c IGNITION fuse SXV60ER VT60 d TAIL fuse SXV60ER VT60 e HEAD fuse SXV60ER VT60 f Load control relay with the white coupler È SXV60 É SXV60 SXV60ER Ê VT60 COLOR CODE B Black Br Brown Ch Chocolate G Green...

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