Yamaha SXV70ERG Supplementary Service Manual Download Page 97

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–91–

OIL PUMP, CRANKCASE AND CRANKSHAFT

ENG

NOTE:

CAUTION:

INSTALLATION

1. Install:

Stopper rings

(onto the lower crankcase bearing

shown)

Knock pin

2. Install:

Crankshaft assembly
(onto the upper crankcase

)

Turn the bearings and labyrinth seal to set the
knock pins

on the bearings and labyrinth seal

into the pin holes

in the upper crankcase

Bearing

Turn bearing

to set the knock pin

on the

upper crankcase

into the pin hole

in the

bearing.

The oil seal lip must fit into the crankcase
groove.

Summary of Contents for SXV70ERG

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

Page 2: ...a Motor Corporation U S A 1st Edition June 2001 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 P N LIT 12618 02 22 HOW TO USE THIS MANUAL Particularly important information is distin guished in this manual by the following nota tions The Safety Alert Symbol means ATTENTION BE ALERT YOU...

Page 3: ... Electrical 9 Specifications Illustrated symbols 10 to 16 are used to identify the specifications which appear 10 Filling fluid 11 Lubricant 12 Tightening 13 Wear limit clearance 14 Engine speed 15 Special tool 16 Ω V A Illustrated symbols 17 to 25 in the exploded dia gram indicate grade of lubricant and location of lubrication point 17 Apply locking agent LOCTITE 18 Apply Yamabond No 5 19 Apply e...

Page 4: ... 5 4 INSP ADJ GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS POWER TRAIN ENGINE COLLING SYSTEM ELECTRICAL SPECIFICATIONS GEN INFO 2 3 POWR TR ENG COOL ELEC SPEC CHASSIS CHAS 7 CARBURETION CARB INDEX ...

Page 5: ...KI RUNNER 20 STEERING SYSTEM 20 ELECTRICAL 21 HEADLIGHT BEAM ADJUSTMENT 21 FUSE INSPECTION SXV70ER 21 SPEEDOMETER UNIT INSPECTION 23 TUNING 24 CARBURETOR TUNING 24 CLUTCH 31 GEAR SELECTION 32 HIGH ALTITUDE TUNING 38 FRONT SUSPENSION 39 REAR SUSPENSION 40 CHASSIS STEERING 44 INSTALLATION 46 FRONT SUSPENSION 49 HANDLING NOTES 50 INSPECTION 50 INSTALLATION 51 POWER TRAIN PRIMARY SHEAVE AND DRIVE V BE...

Page 6: ... 115 ELECTRICAL SWITCH INSPECTION 116 SWITCH INSPECTION 116 INSPECTING A SWITCH SHOWN IN THE MANUAL 116 COMBINATION METER FUNCTION 117 LIGHTING SYSTEM 118 CIRCUIT DIAGRAM 118 TROUBLESHOOTING 119 BULB S 120 HEADLIGHT BEAM SWITCH 120 HEADLIGHT RELAY 121 YAMAHA POWER VALVE SYSTEM Y P V S 122 CIRCUIT DIAGRAM 122 TROUBLE SHOOTING 123 SERVOMOTOR 124 SELF DIAGNOSIS 125 FUEL METER FUEL LEVEL WARNING INDIC...

Page 7: ...AME SERIAL NUMBER The frame serial number 1 is located on the right hand side of the frame just below the front of the seat ENGINE SERIAL NUMBER The engine serial number 1 is located on the right hand side of the crankcase Designs and specifications are subject to change without notice ...

Page 8: ...et This gauge is used to measure the sheave distance and for offset ad justment SSheave gauge for SXV70ER P N YS 45472 This gauge is used to measure the sheave distance and for offset ad justment SDial gauge P N YU 03097 for U S A Canada 90890 03097 for Europe This gauge is used for run out measurement SFuel level gauge P N YM 01312 A for U S A Canada 90890 01312 for Europe This gauge is used to m...

Page 9: ...ve holder P N YS 01880 for U S A Canada 90890 01701 for Europe This tool is used to hold the primary sheave SPrimary sheave puller 18 mm P N YS 01881 1 1 YS 01882 1 2 This tool is used for removing the primary sheave SClutch spider separator P N YS 28890 B for U S A Canada 90890 01711 for Europe This tool is used when disassembling and assembling the primary sheave SClutch separator adapter P N YS...

Page 10: ...ETION SERVICE SMity vac P N YB 35956 for U S A Canada 90890 06756 for Europe This tool is used to check the fuel pump FOR ELECTRICAL SERVICE SPocket tester P N YU 03112 for U S A Canada 90890 03112 for Europe This instrument is necessary for checking the electrical components SElectro tester P N YU 33260 A for U S A Canada 90890 03021 for Europe This instrument is invaluable for checking the elect...

Page 11: ...heck condition Replace if necessary F Fuel line Check fuel hose for cracks or damage Replace if necessary F Oil line Check oil hose for cracks or damage Replace if necessary F Engine coolant Check coolant level F Engine coolant Air bleed the cooling system if necessary F Check throttle lever operation F Carburetor Adjust the jets Whenever operating condition elevation temperature is changed Y P V ...

Page 12: ...ary F Check engagement and shift speed F g g Adjust if necessary Whenever operating elevation is changed Primary and secondary clutches Inspect sheaves for wear damage Inspect weights rollers and bushings for wearfor primary Inspect ramp shoes bushings for wear for second ary Replace if necessary F Lubricate with specified grease F Steering column bearing Lubricate with specified grease F Ski and ...

Page 13: ...qt 2 Remove SCarburetors Refer to CARBURETORS in CHAPTER 7 3 Remove SRear bracket right 1 4 Place a rag under the oil pump assembly to soak up any spilled oil 5 Disconnect SOil hose 6 Drain the oil until no more air bubbles appear in the oil hose 7 Connect SOil hose 8 Disconnect SOil delivery hose 9 Feed the YAMALUBE 2 cycle oil into the oil delivery hose using an oil can for complete air bleeding...

Page 14: ...CARBURETORS in CHAPTER 7 Cable adjustment Before adjusting the oil pump cable the throttle cable free play should be adjusted Adjustment steps SSlide back the adjuster cover SLoosen the locknut 1 STurn the adjuster 2 in or out until the specified distance a is obtained Distance 20 5 1 mm 0 807 0 039 in Turning in Distance a is increased Turning out Distance a is decreased STighten the locknut and ...

Page 15: ...ver 1 is turned to ON 4 Remove SCoolant 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 hissin...

Page 16: ...0 Drain the coolant Lift up the tail of the machine to drain the coolant completely Coolant is poisonous It is harmful or fatal if swallowed SIf coolant is swallowed induce vomiting immediately and get immediate medical attention SIf coolant splashes in your eyes thorough ly wash them with water and consult a doc tor SIf coolant splashes on your skin or clothes quickly wash it away with soap and w...

Page 17: ...mSkg 10 ftSlb 16 Fill SCooling system Recommended coolant High quality silicate free ethylene glycol antifreeze containing corrosion inhibitors Coolant mixing ratio coolant water 3 2 60 40 Total amount 4 5 L 3 96 Imp qt 4 76 US qt SHard water or salt water is harmful to en gine parts If soft water is not available use boiled or distilled water SDo not use water containing impurities or oil 17 Blee...

Page 18: ...anger SWhile slowly adding coolant to the coolant fill er drain the coolant until no more air bubbles appear STighten the bleed bolt 1 Bleed bolt 12 5 Nm 1 3 mSkg 9 4 ftSlb SAdd coolant to the coolant cold level a SLoosen the bleed bolt 2 SDrain the coolant until no more air bubbles ap pear STighten the bleed bolt 2 Bleed bolt 3 5 Nm 0 4 mSkg 2 9 ftSlb SInstall the coolant filler cap Apply and loc...

Page 19: ...ell ventilated area SRemove the coolant filler cap and bleed the cooling system again as described above No air bubbles OK SAdd coolant to the specified level 3 Install SSide cover SSeat HEAT SHIELD CLAMP REPLACEMENT Clamps on the exhaust pipe heat shields may become loose and cause a ratting noise which is due to the deformation of the heat shields These clamps are not adjustable and must be repl...

Page 20: ... follows STurn the main switch to ON Y P V S adjustment coupler lead 4 Battery terminal 5 Y P V S adjustment coupler lead 6 Battery terminal 7 Y P V S adjustment coupler YS 43092 1 SWhen battery power is applied the Y P V S valve should fully open SIf the valve does not fully open check the Ser vo motor Refer to YAMAHA POWER VALVE SYSTEM Y P V S Failure to use the proper Y P V S adjustment coupler...

Page 21: ...e adjuster cover Y P V S valve housing bolt 8 Nm 0 8 mSkg 5 8 ftSlb Locknut 7 Nm 0 7 mSkg 5 1 ftSlb SDisconnect the Y P V S adjustment coupler from the Y P V S check coupler SInstall the Y P V S check coupler cap YAMAHA POWER VALVE SYSTEM Y P V S PRE SEASON CHECKS There may be excessive amounts of carbon on the Y P V S valve which will cause the valve to stick to the cylinder In this case the valv...

Page 22: ...on or reassemble the valve refer to the YAMAHA POWER VALVE SYSTEM Y P V S in CHAPTER 5 S If the valve is not stuck but the warning light and self diagnosis warning indicator remains lit refer to the SELF DIAGNOSIS in CHAPTER 8 Freeplay There is freeplay because the valve is either stuck in the half or fully opened position Check that the warning light and self diagnosis warning indicator lights up...

Page 23: ...easure SSheave distance a Use the distance gauge Out of specification Adjust Sheave distance 268 X 271 mm 10 55 X 10 67 in Distance gauge 90890 01702 YS 91047 3 4 Measure SSheave offset a Out of specification Adjust Sheave offset SXV70 A Approx 14 mm 0 55 in SXV70ER B Approx 12 mm 0 47 in Sheave gauge YS 42421 1 For SXV70 YS 45472 For SXV70ER 1 Starter motor driven gear ...

Page 24: ... 18 SHEAVE DISTANCE AND OFFSET ADJUSTMENT INSP ADJ A B SSheave clearance c Use the sheave gauge Out of specification Adjust Sheave clearance 0 X 1 mm 0 X 0 04 in A SXV70 B SXV70ER ...

Page 25: ...o stand behind the machine when the engine is running SWhen the rear of the machine is raised to allow the track to spin a suitable stand must be used to support the rear of the ma chine Never allow anyone to hold the rear of the machine off the ground to allow the track to spin Never allow anyone near a ro tating track SInspect the condition of the track frequent ly Replace the track if it is dam...

Page 26: ...1 in To avoid scratching wearing and damaging the plastic skis be careful when loading and unloading the snowmobile and avoid riding in areas with little or no snow and on sur faces with sharp edges such as concrete curbs etc STEERING SYSTEM Toe out adjustment 1 Place the machine on a level surface 2 Check SSki toe out a c SSki stance b Point the skis forward Out of specification Adjust Ski toe ou...

Page 27: ... adjusting screw 1 counter clockwise FUSE INSPECTION SXV70ER The following procedure applies to all of the fuses To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Check SContinuity Checking steps S Connect the pocket tester to the fuse and check the continuity Set the pocket tester selector to Ω 1 Pocket tester 90890 03112 YU 03112 S If the pocket teste...

Page 28: ...diately blows again check the electrical circuit Item Amperage Q ty Main fuse 30 A 1 HEAD fuse 20 A 1 TAIL fuse 10 A 1 IGNITION fuse 10 A 1 Reserve fuse 20 A 10 A 1 Reserve fuse 30 A 1 Never use a fuse with an amperage other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the lighting ignition grip warmer sign...

Page 29: ...oupler and headlight coupler SConnect the speedometer unit test coupler leads as follows Speedometer unit test coupler lead red 4 Battery terminal Speedometer unit test coupler lead black 5 Battery terminal Speedometer unit test coupler YS 45686 SCheck that the light and LCD in the speedome ter light up SIf the light does not light up Check the bulbs Refer to BULB S in CHAPTER 8 SIf the LCD is not...

Page 30: ... possible to supply the optimum fuel oil mix ture depending on the throttle opening Therefore after the carburetors have been tuned or maintained or after the float cham bers are removed for cleaning or jet replace ment be sure to idle the engine for about three minutes in order to avoid engine trouble Before performing the carburetor tuning make sure that the following items are set to specificat...

Page 31: ... plugs 3 Check SSpark plug insulator 1 color A medium to light tan color indicates normal conditions Distinctly different color Replace the main jet 4 The main jet should be adjusted on the basis of the Main jet selection chart By checking the condition of the spark plugs it is easy to get some idea of the condition of the engine This may diagnose potential problems before engine damage occurs Hig...

Page 32: ...NING INSP ADJ B Throttle valve opening Mid range speed tuning High speed tuning Fully opened Closed Low speed tuning Throttle valve opening Fully opened Closed Fuel flow rate 1 hr A B C D E F A D E Guide for carburetion ...

Page 33: ...larger than stan dard A No 2 position B No 1 position C No 3 position If the air silencer box is removed from the carburetors the change in pressure in the intake will create a lean mixture that may cause severe engine damage The air silenc er box has no effect on performance charac teristics and must be secured to the carbu retors during carburetor tuning and adjustment Also it must always be in ...

Page 34: ...number of turns Pilot mixture screw 1 1 7 8 turns out Pilot mixture screw effects Turn in STD setting Turn out Leaner Mixture Richer Mixture 2 Set the engine idle speed by turning the throttle stop screw in to increase engine speed or out to decrease engine speed Engine idle speed 1 800 100 r min 3 If low speed performance is still poor at high er elevations under extreme conditions the standard p...

Page 35: ... Adjustment Hard starting Insufficient fuel Add gasoline Excessive use of the starter or choke Return the starter lever to its seated posi tion so that the starter valve is fully closed Fuel passage is clogged or frozen S Check and if necessary clean the fuel tank air vent the fuel filter and all of the fuel passages S Check and if necessary clean the carburetor air vents fuel passages and the flo...

Page 36: ...an it with compressed air and then install it S Make sure that the main jet is fully tightened Clogged fuel line Clean or replace the fuel line Dirty fuel tank Clean the fuel tank Air leaks into the fuel line Tighten or replace the fuel line joint Low fuel pump performance Repair or replace the fuel pump Clogged fuel filter Replace the fuel filter Clogged intake Remove any obstructions e g ice Abn...

Page 37: ...heave spring 90501 603L2 z z z z Color Y W Y z z z z Free length 91 4 mm 3 60 in z z z z Preload 441 N 45 kg 99 lb z z z z Spring rate 24 5 N mm 2 5 kg mm 140 lb in z z z z Wire diameter 6 0 mm 0 236 in z z z z Outside diameter 60 mm 2 36 in z z z z Weight ID 8EK 17605 00 8EK00 z z z z Weight rivet Steel 17 2 OUT Steel 13 9 IN Steel 13 9 OUT Steel 13 9 IN Steel 10 3 OUT Steel 13 9 IN Aluminum 10 3...

Page 38: ...itions 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 condition C Bad condition D Clutch shifting speed E Clutch engagement speed F Starting position G 200 X 300 m 650 X 1 000 ft H Distance travelled GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow co...

Page 39: ...nks 1 68 68 links 1 61 68 links 38 teeth 1 90 68 links 1 81 68 links 1 73 68 links 1 65 70 links 3 Secondary sheave spring Part no Spring rate NSmm rad kgSmm rad Preload N m kg mm lb in Color Wire gauge mm in No of coils Free length mm in Outside diameter mm in Standard 90508 500B1 6003 613 6 2 0 63 35 28 Brown 5 0 0 196 5 19 75 2 95 69 5 2 736 90508 536A9 7147 729 7 3 0 74 41 44 Red 5 3 0 209 5 5...

Page 40: ... secondary spring seat Effects Part no Cam angle Identification mark Standard Quicker upshifting during acceleration 8BV 17604 71 47_ 8BV71 SXV70 SXV70ER 8BV 17604 51 45_ 8BV51 8BV 17604 31 43_ 8BV31 Quicker 8BV 17604 11 41_ 8BV11 backshifting under load 8BV 17604 91 39_ 8BV91 ...

Page 41: ...0 2 36 5 25 91 2 3 59 90501 582L7 24 5 2 50 392 40 Yellow Green Yellow 5 8 0 228 60 2 36 4 92 89 4 3 52 90501 583L0 19 6 2 00 441 45 Blue White Blue 5 8 0 228 60 2 36 5 65 95 9 3 78 90501 583L1 22 1 2 25 441 45 White White White 5 8 0 228 60 2 36 5 25 93 4 3 68 90501 583L4 22 1 2 25 343 35 White Silver White 5 8 0 228 60 2 36 5 25 89 0 3 50 90501 583L5 22 1 2 25 294 30 White Pink White 5 8 0 228 6...

Page 42: ...tch weight Parts no Weight g oz without bush and rivets Shape ID mark Standard 8CH 17605 10 35 32 1 247 8CR 17605 10 38 09 1 345 8DG 17605 00 34 26 1 209 8DJ 17605 00 37 77 1 333 8DN 17605 20 42 09 1 486 8EK 17605 00 39 00 1 376 SXV70 SXV70ER ...

Page 43: ... 2 7 0 095 90261 06015 Steel 10 3 0 406 2 4 0 085 Decreased 90261 06028 Aluminum 10 3 0 406 0 8 0 028 Force 9 Rollers I D 9 mm 0 354 in Roller with bushing part number Outside diameter mm in Bushing type P N Identification mark Width Standard Effects 8CR 17624 00 14 5 0 57 Duralon 90380 09245 Grooved Machined 14 6 mm SXV70 SXV70ER Increased force 8CR 17624 10 15 0 0 59 Duralon 90380 09245 Grooved ...

Page 44: ...g Check to see if the gearing is too high or low Try high altitude settings Decide if the problem is with the pilot jet and adjust accordingly Check the engagement speed and shift performance Adjust the primary clutch as required Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK OK OK OK OK OK OK OK OK OK HIGH ALTITUDE TUNING INSP ADJ HIGH ALTITUDE TUNING To attain the best performance in hi...

Page 45: ...ter z Longer Preload Harder z Softer Min Max Length 250 mm 260 mm 263 5 mm g 9 84 in 10 24 in 10 37 in Be sure that the left and right spring pre loads are 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 flames or high heat which could cause it to explode ...

Page 46: ...cts the handling character istics of the machine Adjustment steps SLoosen the locknut 1 STurn the adjusting nut 2 in or out to adjust the stopper band tension Adjuster thread length Standard 25 0 5 mm 0 98 0 02 in Longer Shorter Maximum Minimum 35 mm 10 mm 1 37 in 0 40 in Effects More weight Less weight on skis on skis Less weight More weight transfer transfer STighten the locknut 1 Locknut 16 Nm ...

Page 47: ...load Harder z Softer Front length Min Max 203 mm 213 mm 215 mm 7 99 in 8 39 in 8 46 in Rear length Min Max 358 5 mm 368 5 mm 370 5 mm 14 11 in 14 51 in 14 59 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 flames or high heat which could cause it to explode ...

Page 48: ... STurn the adjusting bolt 2 to the desired posi tion Be sure the adjusting bolt ends are set at the same position on each side SWhile holding the adjusting bolt securely tighten the nut 1 Nut shock absorber 49 Nm 4 9 mSkg 35 ftSlb Never allow the adjusting bolt to move while tightening the nut SThis model has a Easy adjust system for the Full rate adjuster The bolt has teeth on it So when the bolt...

Page 49: ...steps SLoosen the lock nut 1 STurn the adjusting nut 2 in or out to adjust the control rod stroke Adjusting position 1 2 3 4 Effect Increase Decrease weight transfer pitching Standard 3 Never adjust the control rods beyond the maximum range indicated on the rods with red paint 3 SWhile holding the adjusting bolt securely tight en the locknut 1 Locknut 25 Nm 2 5 mSkg 18 ftSlb ...

Page 50: ...able Oil pump cable Brake lever holder Master cylinder assembly Handlebar holder upper Cable holder Handlebar Handlebar holder lower 1 3 1 1 1 1 1 4 1 1 1 1 1 2 1 1 1 Remove the parts in the order listed below Disconnect Disconnect Disconnect Disconnect Disconnect After installing all parts refer to CABLE ROUTING in CHAPTER 9 to check the cable lead and hose routings For installation reverse the r...

Page 51: ...Collar Steering column Cotter pin Tie rod Washer Washer Bushing Collar Relay arm 1 1 1 2 3 4 4 1 4 2 2 2 2 1 1 Remove the parts in the order listed below Refer to ENGINE ASSEMBLY in CHAPTER 5 For installation reverse the removal procedure A 23 Nm 2 3 mSkg 17 ftSlb 25 Nm 2 5 mSkg 18 ftSlb 35 Nm 3 5 mSkg 25 ftSlb 42 Nm 4 2 mSkg 30 ftSlb B C D 67 Nm 6 7 mSkg 48 ftSlb E ESSO beacon 325 grease or Aeros...

Page 52: ...s 3 Tie rod part number Set length Tie rod length 8CR 23831 00 517 2 mm 20 3622 in 454 2 mm 17 8819 in 3 Install STie rods 1 SMake sure that the indentation a on the tie rod faces out SThe threads on both rod ends must be the same length Always use new cotter pins Locknut rod end 25 Nm 2 5 mSkg 18 ftSlb LOCTITE Nut tie rod relay arm 35 Nm 3 5 mSkg 25 ftSlb Nut tie rod steering arm 42 Nm 4 2 mSkg 3...

Page 53: ... check that the skis are at right angles to the handlebar SLoosen the locknuts relay rod 1 SPosition the skis parallel in the riding direction SWith the skis in this position turn the relay rod 2 in either direction until the handlebars at right angles with respect to the direction of movement Turning the relay rod in direction Turning the handle bar in direction Turning the relay rod in direction...

Page 54: ...he area a shown SBe sure the side of the holder with the small gap b faces forward SCenter the match mark c on the handlebar 1 between the lower handlebar holders 2 Bolt handlebar holder 15 Nm 1 5 mSkg 11 ftSlb First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side ...

Page 55: ...r Bushing Connecting rod Collar Front arm 1 1 1 1 1 2 1 2 2 4 1 2 1 Remove the parts in the order listed below Refer to SKI For installation reverse the removal procedure A 23 Nm 2 3 mSkg 17 ftSlb 42 Nm 4 2 mSkg 30 ftSlb 48 Nm 4 8 mSkg 35 ftSlb 50 Nm 5 0 mSkg 36 ftSlb B C D 78 Nm 7 8 mSkg 56 ftSlb F ESSO beacon 325 grease or Aeroshell grease 7A 1 35 Nm 3 5 mSkg 25 ftSlb G FRONT SUSPENSION CHAS FRO...

Page 56: ...open the gas chamber SDo not subject the shock absorber to flames or any other source of high heat This may cause the unit to explode due to excessive gas pressure SDo not deform or damage the gas chamber in any way Gas chamber damage will re sult in poor damping performance INSPECTION 1 Inspect SShock absorber 1 Oil gas leaks bends damage Replace 2 Inspect SSki column 1 SSteering arm 2 Cracks ben...

Page 57: ...ALLATION 1 Install SControl rod 1 SLocknut 2 SJoint 3 a Set length Left hand Set length Set angle color Upper 469 6 0 5 mm 18 4882 0 0197 in 94 1_ Blue Lower 466 4 0 5 mm 18 3622 0 0197 in 92 1_ Blue Right hand Set length Set angle color Upper 469 6 0 5 mm 18 4882 0 0197 in 86 1_ Yellow Lower 466 4 0 5 mm 18 3622 0 0197 in 88 1_ Yellow Locknut control rod 12 mm 56 Nm 5 6 mSkg 40 ftSlb 14 mm 73 Nm ...

Page 58: ...T SUSPENSION CHAS NOTE 2 Install SSteering arm 1 SAlign the punch mark a on the ski column with the punch mark b on the steering arm SInstall sections c without any gaps Nut steering arm 35 Nm 3 5 mSkg 25 ftSlb ...

Page 59: ...rber bracket angle ID mark 8DM 2382E 10 L H 8DM 2382F 10 R H 25 5_ 3_ 10_ M Stabilizer part number Part number Size length bar diameter ID color 8CR 2386E 00 896 16 mm 35 2755 0 6299 in Purple Control rod part number Part Number Length Angle Upper Lower 8EK 2384E 00 8EK 2384F 00 432 1 mm 17 0079 in 0 0394 in 421 1 mm 16 5748 0 0394 in 3 0 5_ 9 0 5_ ...

Page 60: ...elt Blind cap Primary sheave assembly 1 1 1 Remove the parts in the order listed below For installation reverse the removal procedure A 1st 60 Nm 6 0 mSkg 43 ftSlb 2nd 120 Nm 12 0 mSkg 85 ftSlb PRIMARY SHEAVE AND DRIVE V BELT POWR TR POWER TRAIN PRIMARY SHEAVE AND DRIVE V BELT ...

Page 61: ...ve the parts in the order listed below SXV70ER Left handed thread For assembly reverse the disassembly procedure A 6 Nm 0 6 mSkg 4 3 ftSlb 14 Nm 1 4 mSkg 10 ftSlb 19 Nm 1 9 mSkg 13 ftSlb 200 Nm 20 0 mSkg 145 ftSlb B C E Clean the threads Apply LOCTITE 648 as illustrated in And then tighten the spider The spider must be turned counterclockwise to be tightened a 16 mm 0 63 in b 30 mm 1 18 in 1 2 3 4...

Page 62: ...heave spring 1 Cracks damage Replace 3 Measure SPrimary sheave spring free length a Out of specification Replace the primary sheave spring Primary sheave spring free length 91 4 mm 3 60 in When changing the primary sheave springs re fer to GEAR SELECTION in CHAPTER 2 4 Inspect SPrimary sheave cap bush 1 SSliding sheave bush 2 Cracks damage Replace Clutch bushing press YS 42424 ...

Page 63: ... V belt Washer Shim Collar Secondary sheave assembly 1 1 1 1 Remove the parts in the order listed below Refer to SHEAVE DISTANCE AND OFFSET ADJUSTMENT in CHAPTER 2 For installation reverse the removal procedure A 64 Nm 6 4 mSkg 46 ftSlb SECONDARY SHEAVE POWR TR SECONDARY SHEAVE ...

Page 64: ...ave plate 1 Fixed sheave Stopper Sliding sheave Secondary sheave plate 2 1 1 1 1 1 1 1 Remove the parts in the order listed below For assembly reverse the disassembly procedure A 4 Nm 0 4 mSkg 2 9 ftSlb 6 5 Nm 0 65 mSkg 4 6 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 23 Nm 2 3 mSkg 17 ftSlb B C D ESSO beacon 325 grease or Aeroshell grease 7A 1 1 2 3 4 5 6 7 ...

Page 65: ... Replace SSliding bushing 3 Unsymmetrical wear damage Replace 3 Inspect SSecondary sheave spring 1 Cracks damage Replace 4 Measure SSecondary sheave spring free length a Below specification Replace the second ary sheave spring Free length limit 69 5 mm 2 736 in 5 Measure SRamp shoe thickness a Out of specification Replace the ramp shoe Wear limit 1 0 mm 0 04 in ASSEMBLY 1 Install SStopper SSliding...

Page 66: ...in the spring seat Standard spring position 1 6 Installation steps S Hold the spring seat 1 and turn the fixed sheave 2 counterclockwise to the specified angle a The holes in the spring seat should align with the bolts on the sliding sheave a sheave hole number spring seat hole number 10 Twist angle 70_ S Push down on the spring seat until the bolts come through the holes S While pushing down on t...

Page 67: ...so the clearance is 35 5 mm 1 40 in 6 Adjust SSecondary sheave clearance Adjustment steps S Disassemble the secondary sheave S Remove the bolts and original shims 1 S Install new shims of the proper thickness and reassemble the secondary sheave S Measure the secondary sheave clearance again Repeat these steps until the clearance is with in specification Yamaha recommends keeping the original shims...

Page 68: ... 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 listed below Refer to BRAKE Refer to BRAKE Loosen Drain the oil For installation reverse the removal procedure A 16 Nm 1 6 mSkg 11 ftSlb 24 Nm 2 4 mSkg 17 ftSlb 48 Nm 4 8 mSkg 35 ftSlb 60 Nm 6 0 mSkg 43 ftSlb B C D DRIVE CHAIN HOUSING POWR TR DRIVE CHAIN HOUSING SXV70 ...

Page 69: ...the bearing and the inner race holder as a set Replacement steps S Remove the circlip 5 drive chain housing S Remove the bearing s 3 using a general bearing puller S Install the new bearing s Use a socket 6 that is the same size as the out side diameter of the bearing race Do not strike the inner race 7 or ball bear ings 8 Contact only the outer race 9 S Install a new circlip drive chain housing A...

Page 70: ...ive chain section length 133 35 mm 5 25 in Limit 137 35 mm 5 41 in SMeasure the length between drive chain pin 1 and 15 as shown SPerform this measurement at two or three dif ferent places If replacement is necessary always replace the chain and the sprockets as a set 4 Inspect SDrive chain 1 Stiffness Clean and lubricate or replace SDrive chain plates 2 Damage wear Replace the drive chain Cracks ...

Page 71: ...n housing making sure that there are no gaps C1 C2 Be sure to install the spacers in their origi nal positions otherwise the brake disc and jackshaft will stick D 0 3 mm 0 012 in ESSO beacon 325 grease or Aeroshell grease 7A For the jackshaft and drive chain housing instal lation refer to JACKSHAFT 2 Fill SDrive chain housing oil Refer to DRIVE CHAIN in CHAPTER 2 3 Adjust SDrive chain slack Refer ...

Page 72: ...ver assembly Lever Bolt Drive chain housing cover Joint Lever rod Washer Reverse drive gear Spring 2 1 1 1 1 1 2 1 1 1 1 Remove the parts in the order listed below Refer to BRAKE Refer to BRAKE Loosen Disconnect the gear position switch leads Drain the oil A 10 Nm 1 0 mSkg 7 2 ftSlb 13 Nm 1 3 mSkg 9 4 ftSlb 16 Nm 1 6 mSkg 11 ftSlb 24 Nm 2 4 mSkg 17 ftSlb B C D 48 Nm 4 8 mSkg 35 ftSlb E 60 Nm 6 0 m...

Page 73: ... driven gear Washer Forward driven sprocket Collar Counter gear Drive sprocket Drive chain Collar Washer Plate Shaft Drive chain housing 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure A 10 Nm 1 0 mSkg 7 2 ftSlb 13 Nm 1 3 mSkg 9 4 ftSlb 16 Nm 1 6 mSkg 11 ftSlb 24 Nm 2 4 mSkg 17 ftSlb B C D 48 Nm 4 8 mSkg 35 ftSlb E 60 Nm 6 0 mSkg 43 ftSlb F ...

Page 74: ...Rear axle nut Tension adjuster Blind cap Suspension rear plate Slide rail suspension Collar 2 2 1 2 Remove the parts in the order listed below Loosen Loosen For installation reverse the removal procedure A 72 Nm 7 2 mSkg 52 ftSlb SLIDE RAIL SUSPENSION POWR TR SLIDE RAIL SUSPENSION ...

Page 75: ...t arm Bushing Shaft Bushing Collar Suspension wheel Collar Wheel bracket Front pivot arm bracket 2 2 4 2 1 2 1 2 1 2 1 4 2 2 2 2 2 Remove the parts in the order listed below A 4 Nm 0 4 mSkg 2 9 ftSlb 16 Nm 1 6 mSkg 11 ftSlb 24 Nm 2 4 mSkg 17 ftSlb 30 Nm 3 0 mSkg 22 ftSlb B C D 49 Nm 4 9 mSkg 35 ftSlb E 72 Nm 7 2 mSkg 52 ftSlb F ESSO beacon 325 grease or Aeroshell grease 7A 1 1 2 3 4 5 6 7 8 9 10 1...

Page 76: ...ar Wheel bracket Circlip Suspension wheel Collar Bushing Shaft Rear suspension bracket Spacer Bearing Collar 2 2 2 2 2 2 2 1 1 2 1 1 A 24 Nm 2 4 mSkg 17 ftSlb 49 Nm 4 9 mSkg 35 ftSlb 72 Nm 7 2 mSkg 52 ftSlb B C ESSO beacon 325 grease or Aeroshell grease 7A 1 19 20 21 22 23 24 25 26 27 28 18 29 ...

Page 77: ...Part name Q ty Remarks Rear shock absorber Collar Pull rod Collar Suspension wheel Control rod Bushing Bushing 1 1 2 4 2 2 2 2 A 49 Nm 4 9 mSkg 35 ftSlb 72 Nm 7 2 mSkg 52 ftSlb B ESSO beacon 325 grease or Aeroshell grease 7A 1 30 31 32 33 34 35 36 37 ...

Page 78: ...ar axle Guide wheel Collar Tension adjuster Collar Collar Sliding frame 1 2 1 1 1 1 2 2 1 1 3 2 2 1 1 2 For assembly reverse the disassembly procedure A 24 Nm 2 4 mSkg 17 ftSlb 72 Nm 7 2 mSkg 52 ftSlb 75 Nm 7 5 mSkg 54 ftSlb B C 40 41 42 43 44 45 46 47 48 49 50 51 52 53 ESSO beacon 325 grease or Aeroshell grease 7A 1 39 38 SLIDE RAIL SUSPENSION POWR TR ...

Page 79: ...amage Replace SShock absorber 3 Oil leaks damage Replace SBushings Wear cracks damage Replace SFront pivot arm 4 SRear pivot arm 5 SRear pivot arm bracket 6 SSuspension wheel bracket 7 SSliding frame 8 Cracks damage Replace SSlide runner 9 Wear damage Replace ASSEMBLY 1 Install SStopper band 1 Install the stopper band with a toward the hook and b toward the front suspension bracket Nut stopper ban...

Page 80: ...gth mm in Length mm in Control rod 1 303 5 11 95 150 0 5 91 2 5P 3 7 5 0 098P 3 0 295 Control rod 1 parts number Control rod 2 parts number Washer plate parts number Washer plate thickness mm in parts number parts number Upper Lower 8EK 4745A 00 8CR 4745B 00 90202 16229 2 5 0 098 90202 16229 2 5 0 098 ...

Page 81: ...r Gear unit Set bolt Front axle assembly Bearing Track 1 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 A 8 Nm 0 8 mSkg 5 8 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 40 Nm 4 0 mSkg 29 ftSlb B C FRONT AXLE AND TRACK POWR TR FRONT AXLE AND TRACK ...

Page 82: ...age Replace INSTALLATION 1 Install SSprocket wheels SGuide wheels SWhen pressing the sprocket wheels onto the front axle align the lugs on each sprocket wheel SPosition each sprocket wheel on the axle as shown in the illustration 2 Place the track in the chassis For track with a direction of rotation mark a Install the track with the mark pointing in the direction of track rotation A For U S A Can...

Page 83: ...topper wire Spring 1 Spring 2 Spring 3 Exhaust pipe Gasket 1 Gasket 2 Exhaust joint Gasket 3 Spring 4 Exhaust silencer 2 2 1 1 1 1 1 1 2 1 Remove the parts in the order listed below Open For installation reverse the removal procedure A 14 5 Nm 1 5 mSkg 10 ftSlb EXHAUST ASSEMBLY ENG ENGINE EXHAUST ASSEMBLY ...

Page 84: ...SExhaust joint SInstall the gasket with its projection a facing the primary sheave side STighten the nuts 1 X 12 in a crisscross pat tern Nut exhaust joint 14 5 Nm 1 5 mSkg 10 ftSlb 2 Install SSpring 4 1 SSprings 3 2 SSpring 2 3 SSprings 1 4 Install the springs as shown ...

Page 85: ... 1 1 1 1 1 3 1 1 1 1 Remove the parts in the order listed below Refer to EXHAUST ASSEMBLY Refer to CARBURETORS in CHAPTER 7 Refer to YAMAHA POWER VALVE SYSTEM Y P V S Refer to RECOIL STARTER Refer to AC MAGNETO Refer to PRIMARY SHEAVE AND DRIVE V BELT in CHAPTER 4 Drain Refer to COOLANT REPLACEMENT in CHAPTER 2 Disconnect Disconnect Disconnect Disconnect Disconnect Disconnect SXV70ER SXV70ER For i...

Page 86: ...e routings 1 Be sure to fasten the oil pump cable 1 with the cable holder 2 on the ignition coil brack et 2 Install SStarter motor lead 1 SXV70ER Route the starter motor lead as shown in the il lustration 3 Bleed SOil system Refer to OIL PUMP in CHAPTER 2 SCooling system Refer to COOLING SYSTEM in CHAPTER 2 4 Adjust SOil pump cable distance a Refer to OIL PUMP in CHAPTER 2 Distance 20 5 1 mm 0 807...

Page 87: ...Spark plug cap Clamp Sub wire harness 2 Bracket Plastic band Ignition coil 3 Spacer 1 Ignition coil 2 Spacer 2 Ignition coil 1 3 1 1 1 3 1 2 1 1 1 Remove the parts in the order listed below A 10 Nm 1 0 mSkg 7 2 ftSlb 14 Nm 1 4 mSkg 10 ftSlb B CYLINDER HEAD AND CYLINDER ENG CYLINDER HEAD AND CYLINDER ...

Page 88: ...on pin Piston Bearing Clamp Oil pump breather hose Intake manifold Gasket Spacer Reed valve seat Reed valve stopper Reed valve 3 1 1 3 1 6 6 3 3 3 2 1 3 3 3 3 6 6 For installation reverse the removal procedure A 14 Nm 1 4 mSkg 10 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 33 Nm 3 3 mSkg 24 ftSlb B C D 1st 28 Nm 2 8 mSkg 20 ftSlb 2nd 13 Nm 1 3 mSkg 9 4 ftSlb CYLINDER HEAD AND CYLINDER ENG ...

Page 89: ...X 69 014 mm 2 7165 X 2 7171 in 69 100 mm 2 7205 in Taper T 0 05 mm 0 002 in Out of round R 0 01 mm 0 0004 in C Maximum D T Maximum of D1 or D2 Maximum of D5 or D6 R Maximum of D1 D3 or D5 Minimum of D2 D4 or D6 SIf out of specification replace cylinder and replace piston and piston rings as a set 2nd step SMeasure the piston skirt diameter P with a micrometer a 10 mm 0 39 in from the bottom edge o...

Page 90: ...a set Piston to cylinder clearance 0 070 X 0 075 mm 0 0028 X 0 0030 in Limit 0 25 mm 0 010 in 2 Measure SOutside diameter piston pin a Out of specification Replace the piston pin Outside diameter piston pin 19 995 X 20 000 mm 0 7872 X 0 7874 in 3 Measure SPiston pin to piston clearance Out of specification Replace the piston Piston pin to piston clearance Bore size piston pin b Outside diameter pi...

Page 91: ...valve 1 Nm 0 1 mSkg 0 7 ftSlb LOCTITE Tighten each screw gradually to avoid warping 3 Install SGasket reed valve Install the gasket so that the projection a is positioned as seen from the intake side in the il lustration 4 Check SPiston ring position SMake sure that the ring ends are properly fitted around the ring locating pins in the piston grooves SBe sure to check that the manufacturer s marks...

Page 92: ...aces upward SThe edge with the notch a should be between cylinders 1 and 2 Always use new gasket 6 Install SCylinder Install the cylinder with one hand while com pressing the piston rings with the other hand 7 Tighten SNuts cylinder Nut cylinder 33 Nm 3 3 mSkg 24 ftSlb 8 Install SGaskets cylinder head Install with the mark a facing upwards ...

Page 93: ...il leads Ignition coil 1 Black White lead Sub wire harness Orange lead Ignition coil 2 Black White lead Sub wire harness Gray lead Ignition coil 3 Black White lead Sub wire harness White lead Ignition coil 1 2 3 Black lead Sub wire harness Black lead Connect the black leads of the sub wire har ness to the ignition coils as follows the longest lead to ignition coil 1 the medium size lead to ignitio...

Page 94: ...kcase Crankshaft assembly Stopper ring Oil seal Upper crankcase 1 1 1 2 2 2 1 1 1 1 1 1 1 1 Remove the parts in the order listed below For installation reverse the removal procedure A 8 Nm 0 8 mSkg 5 8 ftSlb 13 Nm 1 3 mSkg 9 4 ftSlb 15 Nm 1 5 mSkg 11 ftSlb 33 Nm 3 3 mSkg 24 ftSlb B C D F 1st 27 Nm 2 7 mSkg 19 ftSlb 2nd 13 Nm 1 3 mSkg 9 4 ftSlb 40 Nm 4 0 mSkg 29 ftSlb E OIL PUMP CRANKCASE AND CRANK...

Page 95: ...ll end free play a Use the dial gauge Out of specification Replace the defective parts Small end free play 0 8 X 1 0 mm 0 03 X 0 04 in SBig end side clearance b Use the thickness gauge Out of specification Replace the defective parts Big end side clearance 0 25 X 0 75 mm 0 01 X 0 03 in 3 Inspect SCrankshaft bearing 1 Pitting damage Replace SStopper ring 2 Bends damage Replace SCrankshaft oil seals...

Page 96: ...t lower brackets 3 SFront upper brackets 4 SRear bracket 5 SDampers 6 Cracks damage Replace 5 Inspect SImpeller driven gear teeth 1 Wear damage Replace the impeller shaft SImpeller shaft 2 SBearing 3 Pitting damage Replace 6 Inspect SOil pump Cracks damage Replace SOil hoses Clogs damage Replace ...

Page 97: ... Install SCrankshaft assembly onto the upper crankcase A Turn the bearings and labyrinth seal to set the knock pins 1 on the bearings and labyrinth seal into the pin holes 2 in the upper crankcase A 3 Bearing Turn bearing 3 to set the knock pin 4 on the upper crankcase A into the pin hole 5 in the bearing The oil seal lip must fit into the crankcase groove ...

Page 98: ...4 Tighten SCrankcase bolts 1 X 16 M8 80 Tighten the bolts in order starting with the low est number and torque the bolts in two stages Bolt crankcase First 13 Nm 1 3 mSkg 9 4 ftSlb Final 27 Nm 2 7 mSkg 19 ftSlb 5 Tighten SCrankcase bolts 1 X 6 M8 35 STighten the bolts in order starting with the low est number SInstall the hose holder with bolt 4 Bolt crankcase 15 Nm 1 5 mSkg 11 ftSlb 6 Install SOi...

Page 99: ...neto coupler Starter pulley Magneto rotor Woodruff key Holder Plate Stator coil 2 1 1 1 1 1 1 Remove the parts in the order listed below Refer to RECOIL STARTER Disconnect For installation reverse the removal procedure A 23 Nm 2 3 mSkg 17 ftSlb 110 Nm 11 0 mSkg 80 ftSlb B AC MAGNETO ENG AC MAGNETO ...

Page 100: ...s a faces outward 2 Install SWoodruff key 1 Be sure to remove any oil or grease from the tapered portion of the crankshaft using a cloth dampened with thinner Pass the magneto leads through the hole and install the grommet in the crankcase 3 Install SMagneto rotor SWasher SNut magneto rotor Be sure to remove any oil or grease from the tapered portion of the magneto rotor using a cloth dampened wit...

Page 101: ... SStarter pulley bolt 1 SMagneto rotor nut 2 Starter pulley bolt 23 Nm 2 3 mSkg 17 ftSlb Magneto rotor nut 110 Nm 11 mSkg 80 ftSlb Attach the primary sheave holder to hold the pri mary sheave Primary sheave holder 90890 01701 YS 01880 ...

Page 102: ...Drive plate Drive pawl Return spring Cam guide Drive plate spring Collar Sheave drum Starter rope Starter spring 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed below Refer to EXHAUST ASSEMBLY For installation reverse the removal procedure A 18 Nm 1 8 mSkg 13 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 48 Nm 4 8 mSkg 35 ftSlb B C RECOIL STARTER ENG RECOIL STARTER ...

Page 103: ...ends damage Replace SDrive pawl 2 SReturn spring 3 SCam guide 4 Wear cracks damage Replace SDrive plate spring 5 Wear damage Replace SSheave drum 6 Cracks damage Replace SStarter spring 7 Cracks bends damage Replace SCollar 8 SStarter rope 9 Wear breaks damage Replace ...

Page 104: ... larger to a smaller diameter SMesh the sheave drum hook 4 with the spring hook 5 3 Install SDrive pawl 1 SCam guide 2 SDrive plate 3 The cam guide 2 should not be on top of the drive pawl 1 4 Pull about four inches of starter rope out of the cutout portion in the sheave drum and ro tate the sheave drum 4 1 2 times counter clockwise to preload the starter spring Pass the rope through the case hole...

Page 105: ...oupler Cable holder Servo motor assembly Collar Y P V S valve housing Dowel pin 1 1 1 1 1 2 3 6 Remove the parts in the order listed below Disconnect Disconnect For installation reverse the removal procedure A 6 5 Nm 0 65 mSkg 4 7 ftSlb 7 5 Nm 0 75 mSkg 5 4 ftSlb B YAMAHA POWER VALVE SYSTEM Y P V S ENG YAMAHA POWER VALVE SYSTEM Y P V S ...

Page 106: ...rip Washer Gasket Valve housing 2 O ring Puller Servo motor assembly 1 3 3 3 3 3 3 3 3 3 3 3 3 3 1 1 Remove the parts in the order listed below For assembly reverse the disassembly procedure A 7 Nm 0 7 mSkg 5 1 ftSlb 7 5 Nm 0 75 mSkg 5 4 ftSlb B ESSO beacon 325 grease or Aeroshell grease 7A 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 YAMAHA POWER VALVE SYSTEM Y P V S ENG ...

Page 107: ...rp instrument Avoid dam aging or scratching the surface 2 Eliminate SCarbon deposit from the cylinder Use the rounded scraper 1 Do not use a sharp instrument Avoid dam aging or scratching the surface ASSEMBLY 1 Install SOil seal 1 Install the oil seal so that there is a distance a between its end and the end of valve housing 1 2 a 0 X 0 5 mm 0 X 0 02 in 2 Install SY P V S cable pulley 1 Install th...

Page 108: ...housing 2 4 Install SY P V S cables Refer to the illustrations Cable Installation Position 1Cable Lower notch 2Cable Upper notch 3Cable Center notch SBefore installing the Y P V S cable onto the Y P V S cable pulley check that the Y P V S cable moves smoothly SAfter installing the cables turn the Y P V S cable pulley 4 counterclockwise to remove any freeplay ...

Page 109: ...lve very carefully in its original place SThe projection a on the Y P V S valve assem bly should face upward SRefer to page 14 X 15 for proper Y P V S ad justing procedure 2 Install SCable holder 1 SMake sure that the cables are properly posi tioned in the holder as shown SThe opened side of the cable holder should face in SPosition the cable holder as close to the spark plug as possible 2 1Cable ...

Page 110: ...nt hose 2 Joint pipe Coolant hose 3 Coolant hose 4 Heat exchanger right Coolant hose 5 Coolant hose 6 Heat exchanger left Joint pipe Coolant hose 7 Coolant hose 8 Heat exchanger front 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed below Drain Refer to COOLING SYSTEM in CHAPTER 2 For installation reverse the removal procedure HEAT EXCHANGER COOL COOLING SYSTEM HEAT EXCHANGER ...

Page 111: ... 105 HEAT EXCHANGER COOL INSPECTION 1 Inspect SCoolant hoses 1 SHeat exchangers 2 SJoint pipe 3 SCoolant reservoir tank 4 SCarburetor heating hoses 5 Cracks damage Replace ...

Page 112: ...g knob O ring Thermostat cover Thermostatic valve Thermostat housing Water temperature sensor 2 1 1 1 1 1 1 Remove the parts in the order listed below For assembly reverse the disassembly procedure A 10 Nm 1 0 mSkg 7 2 ftSlb 23 Nm 2 3 mSkg 17 ftSlb B 1 2 3 4 5 6 7 THERMOSTAT COOL THERMOSTAT ...

Page 113: ...lve 1 Valve does not open at 48 X 52_C 119 X 126_F Replace Inspection steps SSuspend thermostatic valve in a vessel SPlace reliable thermometer in a water SObserve thermometer while stirring water continually 1 Thermometer 2 Water 3 Thermostatic valve 4 Vessel A CLOSE B OPEN Thermostatic valve is sealed and its setting is calibrated If its accuracy is in doubt replace it A faulty unit could cause ...

Page 114: ...e hole a in the thermostat with to mark b in the thermostat housing 2 Install SThermo sensor 1 Water temperature sensor 23 Nm 2 3 mSkg 17 ftSlb Be very careful when handling the water temperature sensor and thermo unit Re place parts that were subjected to impacts or were dropped ...

Page 115: ...upler Clamp screw Carburetor heating hose Throttle cable Starter cable Fuel hose Carburetor 1 2 1 6 2 1 1 3 3 Remove the parts in the order listed below Refer to FUEL PUMP Before removing the carburetors make sure that the carburetor heating knob is turned to OFF Disconnect Loosen Disconnect For installation reverse the removal procedure CARBURETORS CARB CARBURETION CARBURETORS ...

Page 116: ...r Throttle position sensor 2 1 1 1 3 1 1 3 6 3 3 3 1 1 1 Remove the parts in the order listed below Loosen S Since the oil seal remains on the carburetor body when the T P S is removed fit it back on the T P S when reinstalling it S Measure the resistance and adjust the position of the T P S as needed then securely install it For assembly reverse the separation procedure NOTE A 3 5 Nm 0 35 mSkg 2 ...

Page 117: ...r throttle lever assembly Boot Starter plunger assembly Pilot mixture screw Spring Washer O ring Float chamber 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed below Turn clockwise A 0 7 Nm 0 07 mSkg 0 51 ftSlb 1 Nm 0 1 mSkg 0 7 ftSlb 1 8 Nm 0 18 mSkg 1 3 ftSlb B C D 1 ESSO beacon 325 grease or Aeroshell grease 7A 2 5 Nm 0 25 mSkg 1 8 ftSlb 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 118: ... valve Screw valve seat Valve seat assembly O ring 1 1 1 1 1 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure A 0 7 Nm 0 07 mSkg 0 51 ftSlb 1 Nm 0 1 mSkg 0 7 ftSlb 1 8 Nm 0 18 mSkg 1 3 ftSlb 2 5 Nm 0 25 mSkg 1 8 ftSlb B C D ESSO beacon 325 grease or Aeroshell grease 7A 1 13 14 15 16 17 18 19 20 21 22 23 24 CARBURETORS CARB ...

Page 119: ...y Black terminal 1 Tester lead Red Yellow terminal 2 SCheck the T P S resistance T P S resistance R1 4 X 6 kΩ at 20_C 68_F Gray Black Red Yellow Out of specification Replace the T P S SConnect the pocket tester Ω 1k to the T P S coupler Tester lead Gray Black terminal 1 Tester lead Green Yellow terminal 3 SWhile slowly pushing the throttle check the T P S resistance T P S resistance R2 0 X 4 kΩ at...

Page 120: ...imeter lead 1 Digital multimeter lead 2 SMeasure the voltage A When measuring the voltage A be sure that the test coupler is connected to the T P S SCalculate the specified voltage B Specified voltage B Voltage A 0 136 SLoosen the T P S bolts 4 SConnect the digital multimeter to the test cou pler Digital multimeter lead 1 Digital multimeter lead 3 SAdjust the T P S position to obtain the speci fie...

Page 121: ...installing all parts refer to CABLE ROUT ING in chapter 9 to check the cable lead and hose routings 1 Adjust SStarter cable freeplay Refer to STARTER CHOKE CABLE AD JUSTMENT in CHAPTER 2 2 Bleed SCooling system Refer to COOLING SYSTEM in CHAPTER 2 ...

Page 122: ...h turn it on and off a few times INSPECTING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the col umn and the switch lead colors in the top row For each switch position indicates the terminals with continuity The example ...

Page 123: ...e kilometers to miles To switch the speedometer odometer and trip meter displays between kilometers and miles select the odometer mode ODO and then push the select reset button 1 for at least 10 seconds This operation should be done when vehicle is stopped with the engine running ...

Page 124: ... 35 32 32 29 29 28 44 44 3 R W W W W W R B B R Br L R L L R Y L R L W L W L W B G L R R B G B B G B G B B P P L R L R G Y Y B L Y W G B L Y W B G G R R B L R L W G B Y G Y B B G Y Y Lg Lg Br W B R R R Y Br B B W B W B Y B Y Ch Ch Lg Y R B B B B W W W G R W B W B Y Y R Lg Br Br W Y B G R G Ch W G O Gy W W R W B Y L B L B R W R W B Y L B L B R W B L W W B Y W G Y L W Y W R Y G Y Gy B B B B Gy B O B ...

Page 125: ... IGNITION SYSTEM OUT OF SPECIFICATION Replace the condenser Check the stator coil and pickup coil Refer to IGNITION SYSTEM OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM FAULTY Replace the main switch Check the headlight beam switch FAULTY Replace the headlight beam switch Check the headlight relay FAULTY Replace the headlight relay Check the l...

Page 126: ...e products and your hands away from the bulb while it is on it will be hot Do not touch the bulb until it cools down 3 Check SBulb s Terminal Continuity Yes Yes HEADLIGHT BEAM SWITCH 1 Disconnect SHeadlight beam switch coupler 2 Connect SPocket tester to the headlight beam switch coupler 3 Check SHeadlight beam switch continuity Faulty Replace Switch position Continuity HI Yes LO No ...

Page 127: ...ou pler SConnect the pocket tester Ω 1 and battery 12 V to the headlight relay terminals as shown Low beam Positive tester probe Blue White 1 Negative tester probe Green 2 High beam Positive battery terminal Light green 3 Negative battery terminal Black 4 Positive tester probe Blue White 1 Negative tester probe Yellow 5 SFaulty Replace ...

Page 128: ...37 39 40 46 45 41 42 43 38 21 10 9 8 22 20 15 14 13 18 19 17 16 17 16 17 12 11 16 29 29 28 44 44 3 R W W W W W R B B R Br L R L L R Y L R L W L W L W B G L R R B G B B G B G B B P P L R L R G Y Y B L Y W G B L Y W B G G R R B L R L W G B Y G Y B B G Y Y Lg Lg Br W B R R R Y Br B B W B W B Y B Y Ch Ch Lg Y R B B B B W W W G R W B W B Y Y R Lg Br Br W Y B G R G Ch W G O Gy W W R W B Y L B L B R W R ...

Page 129: ... coupler OUT OF SPECIFICATION Correct connection and or replace the DC regulator Check the condenser OUT OF SPECIFICATION Replace the condenser Check the stator coil INCORRECT Replace the AC magneto Correct connection and or replace CDI unit and or rectifier regulator SERVOMOTOR DOES NOT MOVE OK OK OK OK CORRECT YAMAHA POWER VALVE SYSTEM Y P V S ELEC TROUBLESHOOTING ...

Page 130: ...Connect the Y P V S adjustment coupler 1 to the Y P V S check coupler 2 and apply bat tery voltage 12 V to the Y P V S adjustment coupler lead Y P V S test lead 3 Battery terminal Y P V S test lead 4 Battery terminal STurn the main switch to ON Y P V S adjustment coupler YS 43092 1 SXV70ER STurn the main switch to ON Do not operate the engine SIf servomotor does not move replace it 4 Connect SY P ...

Page 131: ...FUEL METER FUEL LEVEL WARNING INDICATOR AND THE WANING LIGHT The fuel meter fuel level warning indicator and the warning light faults are displayed as follows SFuel sender Item Fuel sender Condition Disconnected Short circuit 2 COOLANT TEMPERATURE WARNING LIGHT AND THE WARNING LIGHT The coolant temperature warning light and the warning light faults are displayed as follows SThermo sensor Item Ther...

Page 132: ...nsor T P S SYamaha Power Valve System Y P V S SVariable resistor grip and thumb warmer SGrip and thumb warmer SVoltage Item T P S Condition Disconnected Short circuit Locked Item Y P V S Condition Disconnected Short circuit Locked Item Variable resistor grip warmer gri warmer Condition Disconnected Item Grip warmer Condition Short circuit ON Warning light ON OFF Warning light OFF s Time second ...

Page 133: ... SELF DIAGNOSIS ELEC Item Variable resistor thumb warmer Condition Disconnected Item Thumb warmer Condition Short circuit Item Voltage Condition Wrong ON Warning light ON OFF Warning light OFF s Time second ...

Page 134: ...orse power r min Maximum torque r min Starting system Liquid cooled 2 stroke 7 port Crankcase reed valve Forward inclined parallel 3 cylinder 696 cm3 42 5 cu in 69 62 mm 2 72 2 44 in 1 5 8 1 2 3 6 6 1 8 500 r min 8 000 r min Recoil hand starter SXV70 Electric and recoil hand starter SXV70ER Lubrication system Separate lubrication YAMAHA AUTOLUBE Engine oil Type Tank capacity YAMALUBE 2 cycle oil 3...

Page 135: ...2_ 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 Generato...

Page 136: ...ton offset direction Piston pin bore inside diameter 68 927 X 68 930 mm 2 7137 X 2 7138 in 10 mm 0 39 in 0 070 X 0 075 mm 0 0028 X 0 0030 in 0 25 mm 0 010 in 0 75 mm 0 0295 in EX side 20 004 X 20 015 mm 0 7876 X 0 7880 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 ...

Page 137: ...016 in 0 03 mm 0 0012 in 89 5 mm 3 52 in 84 5 mm 3 33 in 0 25 X 0 75 mm 0 01 X 0 03 in 0 026 X 0 040 mm 0 0010 X 0 0016 in 0 8 X 1 0 mm 0 03 X 0 04 in Big end bearing Type Needle bearing Small end bearing Type Needle bearing Crank pin Crank pin outside diameter 26 991 X 27 000 mm 1 0626 X 1 0630 in Connecting rod Small end diameter Big end diameter 24 995 X 25 005 mm 0 9841 X 0 9844 in 34 020 X 34...

Page 138: ...00 156 3 45 6HEY2 59 3 P 8 1 0 ø0 9 ø0 8 1 7 8 turns out C A 1 5 ø1 3 ø1 5 11 3 X 15 3 mm 0 44 X 0 60 in 36 X 38 mm 1 42 X 1 50 in 1 800 100 r min Fuel pump Type Manufacturer Diaphragm TAIYO GIKEN Oil pump Pump cable adjusting distance 20 5 1 mm 0 807 0 039 in Cooling system Filler cap opening pressure Water pump type Coolant type Coolant mixing ratio coolant water Coolant total amount 95 X 125 kP...

Page 139: ... 4 X 44 7 in 34 5 mm 1 36 in 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 603L2 Yellow White Yellow 60 mm 2 36 in 6 0 mm 0 236 in 441 N 45 kg 99 lb 24 5 N mm 2 50 kg mm 140 lb in 5 39 91 4 mm 3 60 in Primary sheave weight arm Part number with bush Weight without bush and rivets 8EK 17605 00 39 00 g 1 376 o...

Page 140: ... mm 41 66 lb in 5 53 75 mm 2 95 in 47_ Drive chain Type Number of links Borg Warner Automotive 23RH303 70A SM 68L Track Part number Width Length Pitch Number of links Thickness A Height B Track deflection at 10 kg 22 lb 8EK 47110 00 for U S A Canada SXV70 8EK 47110 00 for Canada SXV70ER 8DN 47110 01 for Europe 8EA 47110 00 for U S A SXV70ER 381 mm 15 0 in 3 072 mm 120 9 in 64 mm 2 52 in 48 5 5 mm ...

Page 141: ...0 in B Shock absorber Damping force Front Extension Compression Rear Extension Compression 1 830 N 0 3 m s 187 kg 0 3 m s 412 lb 0 3 m s 1 800 N 0 3 m s 184 kg 0 3 m s 406 lb 0 3 m s 2 900 N 0 3 m s 296 kg 0 3 m s 653 lb 0 3 m s 970 N 0 3 m s 99 kg 0 3 m s 218 lb 0 3 m s Slide runner Thickness Wear limit 17 8 mm 0 70 in 10 mm 0 39 in Track sprocket wheel Material Number of teeth Polyethylene 9 T R...

Page 142: ...34 7_ L ski 34 7_ R ski 29 4_ L ski Toe out 0 X 15 mm 0 X 0 59 in 22_ Ski Ski material Length Width Plastic 1 020 mm 40 2 in 132 0 mm 5 20 in Ski suspension Front suspension Type Travel Spring type Spring rate Wire diameter Proaction system 221 mm 8 70 in Coil spring 12 7 N mm 1 3 kg mm 72 8 lb in 7 8 mm 0 307 in Shock absorber damping force Extension Compression 1 270 N 0 3 m s 130 kg 0 3 m s 287...

Page 143: ...l resistance color code Stator coil resistance color code CDI unit model Manufacturer F4T36971 MITSUBISHI 14 V 20 A 280 W at 5 000 r min 189 X 231 Ω at 20_C 68_F White Red White Green 0 36 X 0 44 Ω at 20_C 68_F White White F8T37574 MITSUBISHI Rectifier regulator Type Model Manufacturer No load regulated voltage DC Capacity DC Withstand voltage Short circuit type SH650D 11 SHINDENGEN 14 1 X 14 9 V ...

Page 144: ...Full Empty 8CW NIPPON SEIKI 4 X 10 Ω at 20_C 68_F 90 X 100 Ω at 20_C 68_F Load control relay Model Manufacturer Coil resistance 8DM MATSUSHITA 76 X 93 Ω at 20_C 68_F Headlight relay Model Manufacturer Coil resistance 5DM OMRON 95 X 116 Ω at 20_C 68_F Grip warmer Heater resistance left right 1 53 X 1 87 Ω at 20_C 68_F 1 53 X 1 87 Ω at 20_C 68_F Thumb warmer Heater resistance 37 0 X 45 2 Ω at 20_C 6...

Page 145: ...0 PS 2 3 8 MJ 151 3 PJ 47 5 JN 3 0 PS 2 3 8 MJ 150 PJ 47 5 JN 3 0 PS 2 3 8 MJ 148 8 PJ 47 5 JN 2 5 PS 2 3 8 MJ 147 5 PJ 47 5 JN 2 5 PS 2 1 8 1 500 X 2 000 m 5 000 X 6 700 ft MJ 151 3 PJ 50 JN 2 5 PS 2 7 8 MJ 150 PJ 50 JN 2 5 PS 2 5 8 MJ 148 8 PJ 50 JN 2 5 PS 2 5 8 MJ 147 5 PJ 50 JN 2 5 PS 2 5 8 MJ 146 3 PJ 50 JN 2 5 PS 2 5 8 MJ 145 PJ 50 JN 2 5 PS 2 3 8 2 000 X 2 500 m 6 700 X 8 300 ft MJ 148 8 PJ...

Page 146: ...y Y P V S locknut Y P V S puller Y P V S valve housing Throttle position sensor Carburetor Pilot jet Valve seat Main jet Pilot air jet Starter plunger assembly Clamp coolant hose 2 Impeller Carburetor heating lever assembly Coolant drain bolt Bleed bolt front cooling system Bleed bolt rear cooling system Magneto rotor Starter motor Starter motor assembly 13 27 15 50 40 33 33 33 50 14 5 13 13 28 33...

Page 147: ...nt pivot arm bracket and sliding frame Suspension wheel Rear axle Slide rail suspension mounting bolt M10 Rear pivot arm and bracket Shock absorber and rear pivot arm Rear pivot arm and rod Rear suspension bracket and rod Shock absorber and rear suspension bracket Control rod and sliding frame Shock absorber and front pivot arm Shock absorber and front suspension bracket Rear pivot arm bracket Rea...

Page 148: ...arks Wheel bracket shaft and sliding frame Set bolt front axle Speed sensor Gear unit speed sensor 72 8 20 40 7 2 0 8 2 0 4 0 52 5 8 14 29 Apply LOCTITE Tightening steps 1 Tighten the bolt to a torque at 120 Nm 12 mSkg 85 ftSlb 2 Loosen the bolt completely 3 Retighten the bolt to a torque of 60 Nm 6 0 mSkg 43 ftSlb ...

Page 149: ...teering arm locknut Lower control rod and frame Upper control rod and frame Control rod and front arm Front arm pivot bolt Stabilizer bar and connecting rod Connecting rod and front arm Frame cross member M10 20 Master cylinder assembly Brake lever adjuster locknut Side cover Seat and frame nut Shroud 15 23 23 35 35 35 42 67 25 48 21 11 11 48 48 35 50 50 56 78 23 23 48 10 6 3 9 3 1 5 2 3 2 3 3 5 3...

Page 150: ...L TORQUE SPECIFICATIONS DEFINITION OF UNITS SPEC A nut B bolt General torque specifications nut bolt Nm mSkg ftSlb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 A Distance across flats B Outside thread diameter DEFINITION OF UNITS Unit Read Definition Measurement mm cm Millimeter Centimeter 10 3 meter 10 2 meter ...

Page 151: ... 145 CABLE ROUTING SPEC ...

Page 152: ...ument panel Route the main switch harness behind the instrument panel at taching screw Pass the parking brake cable under the oil tank breather hose Main switch First the main switch lead shall be looped and then route it ac cordingly Starter choke lever Brake hose Throttle cable Oil pump cable Thumb warmer resistor Grip warmer resistance Oil level gauge Variable resistor coupler Speed sensor Cool...

Page 153: ... 147 CABLE ROUTING SPEC ...

Page 154: ...harness starter relay lead wire harness and side frame Route the harness so that it will not get contact with the rectifi er regulator Rectifier regulator Bracket for model without re verse Condensor for model without reverse Rivet for model without re verse Y P V S check coupler for model without reverse Sub lead coupler for model with reverse 27 28 29 30 31 32 33 34 CABLE ROUTING SPEC ...

Page 155: ... 149 CABLE ROUTING SPEC ...

Page 156: ...ther hose do not interfere with each other Band them beside the instru ment panel attaching bolt Make sure to pass the tail light lead between the fuel tank and panel without being caught and secure the lead in the groove of fuel tank bottom surface using the adhesive tape at 3 posi tions 50 mm 1 97 in To tail light unit Adhesive tape Pass the fuel tank breather hose through the holder Fuel sender...

Page 157: ... 151 CABLE ROUTING SPEC ...

Page 158: ...er Frame directly attached clamp Fuel hose Pulser hose Oil delivery hose Headlight relay dimmer black Load control relay white DC back buzzer Situate the C D I unit coupler in the footrest CDI unit 19 20 21 22 23 24 25 26 27 28 29 CABLE ROUTING SPEC ...

Page 159: ... 153 CABLE ROUTING SPEC ...

Page 160: ...dlight harness Align the clamp with the white tape on the harness Clamp the headlight harness Route it behind the shroud stopper Stay Hook Assemble the starter lever so that it will be in this range 2 3 4 5 6 7 8 CABLE ROUTING SPEC ...

Page 161: ... 155 CABLE ROUTING SPEC ...

Page 162: ...ke hose Thumb warmer resistor Color red Grip warmer resistor Color black Clamp the fuel tank breather hose Variable resistor coupler Fuel sender coupler Fuel tank breather hose Oil level gauge coupler Y P V S lead coupler Ground lead Clamp the fuel tank breather hose CDI unit harness and Y P V S lead Clamp the CDI unit harness and speed sensor lead Speed sensor lead Pay attention to the fuel pipe ...

Page 163: ... 157 CABLE ROUTING SPEC ...

Page 164: ...Condenser For model withoutl reverse Rectifier regulator Clamp the tail light lead and rectifier regulator lead For model with reverse Clamp the coupler For model without reverse Hose To coolant reservoir tank Clamp the wire harness Clamp the tail light lead rectifi er regulator lead and gear position switch lead For model with reverse Fold back and clamp it For model without reverse To reverse ge...

Page 165: ... 159 CABLE ROUTING SPEC ...

Page 166: ...ump cables through Throttle cable Collar Oil tank Grommet Fuel tank Flange bolt Screw Flange nut Nut Hexagon bolt Bracket Sub frame Clamp the harness and steer ing gate Clamp the harness and fuel sender lead Clamlp them at the position of 30 X 40 mm 1 18 X 1 57 in from the end of the lead wire cover 30 X 40 mm 1 18 X 1 57 in Harness Starter relay lead Wire harness 58 59 60 61 62 63 64 65 66 67 68 ...

Page 167: ... 161 CABLE ROUTING SPEC ...

Page 168: ...nt hose T O R S lead coupler and igni tion coil lead Clamp them between ignition coil lead coupler and position behind the thermo sensor cou pler However the leads should be routed without excessive force loaded such as sharp bending Thermo sensor coupler Wire harness For model with reverse Starter motor For model with reverse Clamp the wire harness and coolant hose Battery For model with reverse ...

Page 169: ... 163 CABLE ROUTING SPEC ...

Page 170: ...eed sensor lead Coolant hose Frame directly attached clamp Pass the wire harness under the carburetor heater hose Clamp the wire harness and the metal section of the brake hose Coolant reservoir tank Joint Wire harness Pass the wire harness under the coolant hose Coolant pipe 22 23 24 25 26 27 28 29 30 31 32 33 34 35 CABLE ROUTING SPEC ...

Page 171: ...B R L Br W Br O Gy W B RUN IDLE L Y B L R G Y B G Y B Gy B G Y R Y G Y B Y L R Y B L Y G R L W R B W G B B G A B D E F 1 2 23 5 7 6 4 24 25 26 27 30 31 33 33 36 37 39 40 46 45 41 42 43 38 21 10 9 8 22 20 15 14 13 18 19 17 16 17 16 17 12 11 16 35 34 32 32 29 29 28 44 44 3 R W W W W W R B B R Br L R L L R Y L R L W L W L W B G L R R B G B B G B G B B P P L R L R G Y Y B L Y W G B L Y W B G G R R B L...

Page 172: ...3 Main relay 24 Fuse HEAD 1 25 Fuse TAIL 1 26 Fuse IGN 1 27 Hi beam switch 28 Headlight dimmer relay 29 Headlight 30 Meter assembly 31 Tachometer 32 Meter light 33 Multi function meter 34 Warning light 35 Hi beam indicator light 36 Water temperature sensor 37 Oil level switch 38 Speed sensor 39 Fuel sender 40 Tail brake light 41 Brake light switch 42 Back buzzer 1 43 Gear position switch 1 44 Smoo...

Page 173: ... ੑ 01 06 0 8E ITP PRINTED ON RECYCLED PAPER ...

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