Yamaha SXV70SJ Supplementary Service Manual Download | Manualshive

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D

E

F

G

H

I

J

K

L

Spring identification color code

A

Spring rate color

B

Preload color

C

GEAR SELECTION

INSP

ADJ

6 Primary spring

Parts No.

Spring rate

N / mm

(kg / mm)

Preload

N (kg)

Color

Wire

gauge

mm (in)

Outside

diameter

mm (in)

No. of

coils

Free

length

mm (in)

Standard

90501-551L3

19.6 (2.00)

294 (30)

Blue-Pink-Blue

5.5 (0.216)

60 (2.36)

4.91

88.4 (3.48)

VT70J (U.S.A, CAN)

90501-551L9

19.6 (2.00)

343 (35)

Blue-Silver-Blue

5.5 (0.216)

60 (2.36)

4.91

90.9 (3.58)

90501-552L5

19.6 (2.00)

392 (40)

Blue-Green-Blue

5.5 (0.216)

60 (2.36)

4.91

93.4 (3.68)

90501-581L5

24.5 (2.50)

294 (30)

Yellow-Pink-Yellow

5.8 (0.228)

60 (2.36)

4.92

85.4 (3.36)

90501-581L6

27 (2.75)

294 (30)

Green-Pink-Green

5.8 (0.228)

60 (2.36)

4.66

84.3 (3.32)

90501-582L1

24.5 (2.50)

343 (35)

Yellow-Gold-Yellow

5.8 (0.228)

60 (2.36)

4.92

87.4 (3.44)

90501-582L2

27 (2.75)

343 (35)

Green-Silver-Green

5.8 (0.228)

60 (2.36)

4.66

86.1 (3.39)

90501-582L6

22.1 (2.25)

392 (40)

White-Green-White

5.8 (0.228)

60 (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)

60 (2.36)

5.25

86.7 (3.41)

90501-601L7

29.4 (3.00)

294 (30)

Pink-Pink-Pink

6.0 (0.236)

60 (2.36)

4.82

83.4 (3.28)

VT70J (EUR)

90501-601L8

31.9 (3.25)

294 (30)

Orange-Pink-Orange

6.0 (0.236)

60 (2.36)

4.60

82.6 (3.25)

90501-602L3

29.4 (3.00)

343 (35)

Pink-Silver-Pink

6.0 (0.236)

60 (2.36)

4.82

85.1 (3.35)

90501-602L8

27.0 (2.75)

392 (40)

Green-Green-Green

6.0 (0.236)

60 (2.36)

5.08

87.9 (3.46)

90501-602L9

29.4 (3.00)

392 (40)

Pink-Green-Pink

6.0 (0.236)

60 (2.36)

4.82

86.7 (3.41)

90501-603L2

24.5 (2.50)

441 (45)

Yellow-White-Yellow

6.0 (0.236)

60 (2.36)

5.39

91.4 (3.60)

SXV70SJ

90501-603L3

27.0 (2.75)

441 (45)

Green-White-Green

6.0 (0.236)

60 (2.36)

5.08

89.8 (3.54)

90501-624L8

31.9 (3.25)

343 (35)

Orange-Silver-Orange

6.2 (0.244)

60 (2.36)

5.00

84.2 (3.31)

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Summary of Contents for SXV70SJ

Page 1: ......

Page 2: ...LEMENTARY SERVICE MANUAL 2003 by Yamaha Motor Corporation U S A 1st Edition April 2003 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 31 HOW TO USE THIS MANUAL Particularly important information is distin guished in this manual by the following nota tions The Safety Al...

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 COOLING SYSTEM ELECTRICAL SPECIFICATIONS GEN INFO 2 3 POWR TR ENG COOL ELEC SPEC CHASSIS CHAS 7 CARBURETION CARB INDEX ...

Page 5: ...INSTALLATION 30 CHAPTER 4 POWER TRAIN BRAKE 31 INSPECTION 32 BRAKE MASTER CYLINDER ASSEMBLY 32 INSTALLATION 32 SLIDE RAIL SUSPENSION 33 INSTALLATION 38 CHAPTER 5 ENGINE ENGINE ASSEMBLY 39 CYLINDER HEAD AND CYLINDER 41 CHAPTER 6 COOLING SYSTEM HEAT EXCHANGER 43 THERMOSTAT 44 CHAPTER 7 CARBURETION CARBURETORS 45 CHAPTER 8 ELECTRICAL GRIP WARMER SYSTEM SXV70SJ 47 CIRCUIT DIAGRAM 47 GRIP WARMER SYSTEM...

Page 6: ... 60 COOLANT TEMPERATURE WARNING INDICATOR AND THE WARNING LIGHT 60 SELF DIAGNOSIS WARNING INDICATOR AND THE WARNING LIGHT 61 DETONATION CONTROL SYSTEM INDICATOR LIGHT 63 CHAPTER 9 SPECIFICATIONS GENERAL SPECIFICATIONS 65 MAINTENANCE SPECIFICATIONS 67 ENGINE 67 POWER TRAIN 70 CHASSIS 75 ELECTRICAL 76 HIGH ALTITUDE SETTINGS 78 TIGHTENING TORQUE 79 ENGINE 79 POWER TRAIN 80 CHASSIS 82 GENERAL TORQUE S...

Page 7: ...ry 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 S Check operation Adjust if neces...

Page 8: ...hift 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 wear for 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 front suspension Lubricate ...

Page 9: ...ing lever 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 ...

Page 10: ... Lift up the tail of the machine to drain the cool ant 8 Remove SLeft side cover 1 9 Disconnect SResister lead coupler 1 SPassenger grip warmer switch lead coupler 2 SPassenger grip warmer lead coupler 3 10 Remove SSeat SRear bumper cover 1 11 Disconnect SCoolant hoses left and right 1 12 Drain the coolant Lift up the tail of the machine to drain the coolant completely ...

Page 11: ...SRear bumper cover 1 Bolt rear bumper cover 3 Nm 0 3 mSkg 2 2 ftSlb 15 Inspect SGasket coolant drain bolt Damage Replace 16 Install SGasket SCoolant drain bolt 1 Coolant drain bolt 13 Nm 1 3 mSkg 9 4 ftSlb 17 Install SExhaust joint SExhaust pipe SExhaust joint nut 1 Refer to EXHAUST ASSEMBLY in CHAP TER 5 Nut exhaust joint 14 5 Nm 1 5 mSkg 10 ftSlb 18 Fill SCooling system Recommended coolant High ...

Page 12: ... SAttach the cooling system tester 1 to the cool ant filler 2 Cooling system tester 90890 01325 YU 24460 01 SApply 100 kPa 1 0 kg cm2 14 psi SMeasure the pressure with the gauge Air bleeding 1 Remove SSeat SRear bumper cover 1 2 Bleed air from the cooling system Air bleeding steps SLift up the tail of the machine SRemove the bleed bolt 1 on the heat ex changer SWhile slowly adding coolant to the c...

Page 13: ...machine is securely sup ported with a suitable stand SDo not exceed 3 000 r min Drive line dam age and excessive V belt wear could occur or the machine could unexpectedly move forward if the clutch engages SOperate the engine only in a well 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 In...

Page 14: ...ter adjusting the free play turn the handlebar to right and left and make sure that the engine idling does not run faster OIL PUMP 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 81 ...

Page 15: ...ch could cause an accident 1 Start the engine 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 stop switch hous ing 2 While holding as described above press the throttle lever 3 gradually The T O R S will operate and the engine should run between 2 800 and 3 000 r min If the engine doe...

Page 16: ...cylinder reservoir is horizontal Brake fluid may corrode painted surfaces or plastic parts Always clean up spilled fluid immediately SUse only the designated brake fluid Other fluids may deteriorate the rubber seals causing leakage and poor brake perfor mance SRefill with the same type of fluid Mixing fluids may result in a harmful chemical reaction leading to poor brake perfor mance SWhen refilli...

Page 17: ...earing 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 LUBRICATION Brake lever throttle lever and throttle cable end 1 Lubricate the brake lever pivot throttle lever and the ends of the throttle cables Recommended lubricant ESSO Beacon 325 Grease Apply a ...

Page 18: ...sheave 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 ...

Page 19: ...heave spring 90501 551L3 z z z z Color L P L z z z z Free length 88 4 mm 3 48 in z z z z Preload 294 N 30 kg 66 lb z z z z Spring rate 19 6 N mm 2 0 kg mm 112 lb in z z z z Wire diameter 5 5 mm 0 216 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 17 2 IN Steel 17 2 OUT Steel 13 9 IN Steel 17 2 OUT Steel 13 3 IN Steel 17 2 OU...

Page 20: ...n z Preload 294 N 30 kg 66 lb z Spring rate 29 4 N mm 3 0 kg mm 168 lb in z Wire diameter 6 0 mm 0 236 in z Outside diameter 60 mm 2 36 in z Weight ID 8BU 17605 10 8BU10 z Weight rivet Steel 17 2 OUT Steel 17 2 IN Steel 13 9 OUT Steel 13 9 IN Weight bushing Duralon z Roller outer dia 14 5 mm 0 57 in z Roller bushing Duralon z Pri clutch shim None z Secondary sheave spring 90508 556A2 z Color G z F...

Page 21: ...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 22: ...8 links 38 teeth 1 90 1 81 1 73 1 65 38 teeth 68 links 68 links 68 links 70 links 39 teeth 2 17 2 05 1 95 1 86 1 77 1 70 39 teeth 68 links 68 links 68 links 68 links 70 links 70 links 40 teeth 2 22 2 11 2 00 1 91 1 82 1 74 40 teeth 68 links 68 links 68 links 70 links 70 links 70 links 3 Secondary sheave spring Part no Spring rate torsion NSmm rad kgSmm rad Springrate compression N mm kg mm lb in C...

Page 23: ...spring seat Effects Part no Cam angle Identification mark Standard Quicker upshifting during acceleration 8BV 17604 71 47_ 8BV71 SXV70SJ g 8BV 17604 51 45_ 8BV51 VT70J U S A CAN 8BV 17604 31 43_ 8BV31 Quicker 8BV 17604 11 41_ 8BV11 backshifting under load 8BV 17604 91 39_ 8BV91 VT70J EUR ...

Page 24: ... 228 60 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...

Page 25: ...ight 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 SXV70SJ VT70J U S A CAN 8BU 17605 10 45 41 1 602 VT70J EUR ...

Page 26: ...261 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 SXV70SJ VT70J EUR Increased force 8CR 17624 10 15 0 0 59 Duralon 90380 09245 Grooved 14 6 mm 8...

Page 27: ... U S A CAN 276 mm 298 mm 301 mm U S A CAN 10 87 in 11 73 in 11 85 in Length EUR Min Max 250 mm 260 mm 262 mm 9 84 in 10 24 in 10 31 in A for U S A CAN B for EUR Be sure that the left and right spring pre loads are the same Spring preload VT70J 1 Adjust SSpring preload Adjustment steps STurn the adjusting ring 1 to the proper posi tion Spring adjuster position 1 2 3 4 5 Preload Softer z Harder Stan...

Page 28: ...djuster fully turned in direction b SNever attempt to turn an adjuster beyond the maximum or minimum setting SBe sure that left and right damping force 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 REAR SUS...

Page 29: ... 5 mm 1 18 0 02 in Maximum 35 mm 1 37 in Minimum 10 mm 0 40 in Effects Longer More weight on skis Less weight transfer Shorter Less weight on skis More weight transfer STighten the locknut 1 Locknut 16 Nm 1 6 mSkg 11 ftSlb A SXV70SJ B VT70J ESS00102 Spring preload 1 Adjust SSpring preload Adjustment steps STurn the adjusting ring 1 to the proper posi tion Spring adjuster position 1 2 3 4 5 Preload...

Page 30: ...ogen 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 Rear suspension position VT70J 1 Check SRear suspension position a Standard position Bolt slide rail suspension 72 Nm 7 2 mSkg 52 ftSlb Control rod 1 Check SControl rod bolt a Bolt control rod bolt 32 Nm 3 2 mSkg 23 ftSlb A SX...

Page 31: ... coupler Brake switch coupler High beam switch coupler Grip warmer lead coupler Grip warmer switch lead coupler Throttle cable holder Throttle cable Brake lever holder 1 2 1 1 1 1 1 4 1 1 1 1 Remove the parts in the order listed below Disconnect Disconnect Disconnect Disconnect Disconnect Disconnect Disconnect A 10 Nm 1 0 mSkg 7 2 ftSlb 15 Nm 1 5 mSkg 11 ftSlb B STEERING CHAS CHASSIS STEERING ...

Page 32: ...embly Handlebar holder upper Cable holder Handlebar Handlebar holder lower 1 2 2 1 1 After installing all parts refer to CABLE ROUTING in CHAPTER 9 to check the cable lead and hose routings For installation reverse the removal procedure NOTE A 10 Nm 1 0 mSkg 7 2 ftSlb 15 Nm 1 5 mSkg 11 ftSlb B ...

Page 33: ...ki runner Collar Ski Washer Ski handle 1 1 1 4 2 1 4 1 4 1 Remove the parts in the order listed below For installation reverse the removal procedure A 11 Nm 1 1 mSkg 8 0 ftSlb 17 Nm 1 7 mSkg 12 ftSlb 21 Nm 2 1 mSkg 15 ftSlb 48 Nm 4 8 mSkg 35 ftSlb B C D ESSO beacon 325 grease or Aeroshell grease 7A 1 SKI CHAS SKI SXV70SJ ...

Page 34: ...cket Ski runner Collar Collar Ski Washer Ski handle 1 1 1 6 1 1 2 2 1 4 1 Remove the parts in the order listed below Color Black Color Gold For installation reverse the removal procedure A 11 Nm 1 1 mSkg 8 0 ftSlb 17 Nm 1 7 mSkg 12 ftSlb 21 Nm 2 1 mSkg 15 ftSlb 48 Nm 4 8 mSkg 35 ftSlb B C D ESSO beacon 325 grease or Aeroshell grease 7A 1 VT70J ...

Page 35: ...r Bushing Connecting rod Collar Front arm 1 1 1 1 1 2 1 2 1 2 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 36: ...ON CHAS A B C b c a D E INSTALLATION Stabilizer part number Part number Size length bar diameter ID color 8CR 2386E 00 SXV70SJ 896 16 mm 35 2755 0 6299 in Purple 8CW 2386E 00 VT70J 896 18 mm 35 2755 0 7087 in Light green ...

Page 37: ...order listed below Drain For installation reverse the removal procedure 1 2 3 4 5 6 7 Brake master cylinder disassembly Reservoir cap set Diaphagm Master cylinder kit Master cylinder body 1 1 1 1 Disassemble the parts in the order listed below For assembly reverse the disassembly procedure 1 2 3 4 10 Nm 1 0 mSkg 7 2 ftSlb 30 Nm 3 0 mSkg 22 ftSlb A B ESSO beacon 325 grease or Aeroshell grease 7A 1 ...

Page 38: ...age Replace as a set BRAKE MASTER CYLINDER ASSEMBLY SAll internal parts should be cleaned only with new brake fluid SInternal parts should be lubricated with brake fluid when installed Recommended brake fluid DOT 4 SReplace the piston seals and dust seals whenever a caliper is disassembled INSTALLATION 1 Connect SBrake hose When installing the brake hose onto the brake master cylinder make sure th...

Page 39: ...sion adjuster Blind cap Suspension rear plate Slide rail suspension Collar 2 2 1 2 Remove the parts in the order listed below Loosen Loosen SXV70SJ For installation reverse the removal procedure 72 Nm 7 2 mSkg 52 ftSlb 24 Nm 2 4 mSkg 17 ftSlb A B SLIDE RAIL SUSPENSION POWR TR SLIDE RAIL SUSPENSION ...

Page 40: ...ing Collar Suspension wheel Collar Wheel bracket Front pivot arm bracket 2 2 4 2 1 2 1 1 2 1 2 1 4 2 2 2 2 2 Remove the parts in the order listed below SXV70SJ VT70J SXV70SJ 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ESSO beacon 325 grease or Ae...

Page 41: ...kg 52 ftSlb B C 19 20 21 22 23 24 25 26 27 28 29 ESSO beacon 325 grease or Aeroshell grease 7A 1 30 NOTE This model has a Easy adjust system for the full rate adjuster The bolt has teeth on it So when the bolt is turned it rides up and down the bracket SThe nut has to be loosened first while the bolt is held in place with a wrench SThen the bolt can be turned to adjust the shock position up or dow...

Page 42: ...absorber Collar Bushing Pull rod Collar Bushing Rear bracket Collar Suspension wheel Control rod Bushing Bushing 1 1 2 2 4 4 2 2 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 31 32 33 34 35 36 37 38 39 40 41 42 VT70J VT70J ...

Page 43: ...Guide wheel Collar Tension adjuster Collar Collar Guide wheel Sliding frame 1 2 1 1 1 1 2 2 1 1 2 2 2 1 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 45 46 47 48 49 50 51 52 53 54 55 56 57 58 ESSO beacon 325 grease or Aeroshell grease 7A 1 44 43 59 SLIDE RAIL SUSPENSION POWR TR ...

Page 44: ... Lower 8EK 4745A 00 SXV70SJ U S A CAN 8CR 4745B 00 90202 16229 2 5 mm 0 0984 in 90202 16230 5 0 mm 0 1969 in 8EK 4745A 00 SXV70SJ EUR 8CR 4745B 00 90202 16229 2 5 mm 0 0984 in 90202 16229 2 5 mm 0 0984 in Control rod parts number VT70J Parts number Length Length Control rod 1 8CR 4745A 01 310 5 mm 12 2244 in 220 0 mm 7 8740 in Control rod 1 parts number Control rod 2 parts number Washer plate part...

Page 45: ...in the order listed below Refer to EXHAUST ASSEMBLY in CHAPTER 5 Refer to CARBURETORS in CHAPTER 7 Refer to YAMAHA POWER VALVE SYSTEM Y P V S in CHAPTER 5 Refer to RECOIL STARTER in CHAPTER 5 Refer to AC MAGNETO in CHAPTER 5 Refer to PRIMARY SHEAVE AND DRIVE V BELT in CHAPTER 4 Drain Refer to COOLANT REPLACEMENT in CHAPTER 2 Disconnect Disconnect Disconnect Disconnect Disconnect A 33 Nm 3 3 mSkg 2...

Page 46: ...ose Oil pump cable Knock sensor lead Starter motor Starter motor lead 3 1 1 1 1 1 Disconnect Disconnect Disconnect For model with starter motor For model with starter motor For installation reverse the removal procedure A 33 Nm 3 3 mSkg 24 ftSlb 57 Nm 5 7 mSkg 41 ftSlb B 23 Nm 2 3 mSkg 17 ftSlb C ...

Page 47: ...val Spark plug cap Clamp Sub wire harness 2 Bracket Plastic band Ignition coil 3 Spacer 1 Ignition coil 2 Ignition coil 1 3 1 1 1 3 1 2 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 48: ...n 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 Disconnect 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 49: ...e 2 Joint pipe Coolant hose 3 Coolant hose 4 Heat exchanger right Coolant hose 5 Coolant hose 6 Heat exchanger left Heat exchanger rear 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 EXCHANGE...

Page 50: ...mostatic valve Thermostat housing Water temperature sensor Knock sensor 2 1 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 8 27 Nm 2 7 mSkg 20 ftSlb C 3 5 Nm 0 35 mSkg 2 5 ftSlb D THERMOSTAT COOL THERMOSTAT ...

Page 51: ...ensor coupler Clamp screw Carburetor heating hose Starter cable Fuel hose Carburetor 1 2 1 3 2 1 3 3 Remove the parts in the order listed below Before removing the carburetors make sure that the carburetor heating knob is turned to OFF Disconnect Loosen Disconnect For installation reverse the removal procedure Refer to FUEL PUMP in CHAPTER 7 CARBURETORS CARB CARBURETION CARBURETORS ...

Page 52: ... 46 CARBURETORS CARB 7 ...

Page 53: ... 36 38 34 35 34 37 B G Y B L Y W G B G R R B Y B G B G A Y B B Y B L Y B L Y W B W G B A G B G R A G R R B A R B 33 Lg B Lg B C Lg B Y G Y G C Y G Sb Sb A Sb Gy Br B R B 39 R B G B 40 G B G B B G P O R B W W L Y B G 41 L Y W B G L Y 42 L R G Y L R L R H G Y G Y H L R L R G G Y G Y G OFF ON G Y L G Y L R 43 G Y 187 187 Br P L R P 44 45 B P P L R RUN STOP OFF OPEN 6 5 Br Br W B Y W B B Y Br W B BrW ...

Page 54: ...R B 38 R B B G B 39 G B B G G B B G P O R B W W L Y B G 40 L Y W B G B L R G Y B B G B B H L R L R H G Y G Y H L R L R G G Y G Y G OFF ON G Y L G Y L R 42 G Y 187 187 Br P L R P 44 43 B P P L R RUN STOP OFF OPEN 5 4 Br Br W B Y W B B Y Br W B BrW B Y Br B Br W RUN IDLE 6 B Y W B B Lg B W 19 19 18 Lg Y R B B B B 7 Gy W Ch L B L B R O W R W R W B Dg G L G B Y Y R Y B Sb G R Lg R W W G Br L Y G Lg B ...

Page 55: ...PECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM NO CONTINUITY Replace the main switch Check the grip and thumb warmer NO CONTINUITY Replace the grip and or thumb warmer Check the grip warmer switch and thumb warmer switch INCORRECT Replace the left handlebar switch and or right handlebar switch Check the load control relay Refer to IGNITION SYSTEM FAULT...

Page 56: ...ip warmer Check the passenger grip warmer switch NO CONTINUITY Replace the passenger grip warmer switch Check the resistor INCORRECT Replace the resistor Check the passenger grip warmer relay FAULTY Replace the passenger grip warmer relay Check the load control relay Refer to IGNITION SYSTEM FAULTY Replace the load control relay Correct the connection and or replace the rectifier regulator and or ...

Page 57: ... continuity SThumb warmer 2 continuity No continuity Replace both grips together or separately and or the handlebar switch THUMB WARMER SWITCH 1 Disconnect SThumb warmer switch coupler 1 2 Connect SPocket tester to the switch coupler 3 Inspect SThumb warmer switch continuity Switch is operated Faulty Replace the handlebar switch right Thumb warmer switch position Continuity Switch is operated Yes ...

Page 58: ... operated Faulty Replace the handlebar switch left Grip warmer switch position Continuity Switch is operated Yes Switch is not operated No PASSENGER GRIP WARMER COIL VT70J 1 Disconnect SPassenger grip warmer coupler 1 2 Connect SPocket tester to the passenger grip warmer coupler 3 Inspect SPassenger grip warmer continuity No continuity Replace both passenger grips together or separately ...

Page 59: ...passenger grip warmer switch cou pler 3 Inspect SPassenger grip warmer switch continuity Faulty Replace Y L O B Y R LO OFF HI Continuity RESISTOR VT70J 1 Disconnect SResistor coupler 1 2 Connect SPocket tester to the resistor coupler 3 Measure SResistor resistance Out of specification Replace Resistor resistance Black Black 1 4 X 1 7 Ω at 20_C 68_F ...

Page 60: ...om the coupler S Connect the pocket tester Ω 1 and bat tery 12 V to the passenger grip warmer relay terminals as shown Positive battery terminal Yellow 1 Negative battery terminal Blue Red 2 Positive tester probe Blue Red 3 Negative tester probe Orange Black 4 S If load control relay does not have continuity between the blue red and orange black ter minals replace it ...

Page 61: ...Y B L Y W B W G B A G B G R A G R R B A R B 33 Lg B Lg B C Lg B Y G Y G C Y G Sb Sb A Sb Gy Br B R B 39 R B G B 40 G B G B B G P O R B W W L Y B G 41 L Y W B G 42 L R G Y L R L R H G Y G Y H L R L R G G Y G Y G OFF ON G Y L G Y L R 43 G Y 187 187 Br P L R P 44 45 P P L R RUN STOP OFF OPEN 6 5 Br Br W B Y W B B Y Br W B BrW B Y Br B Br W RUN IDLE 7 B Y W B B Lg B W 20 20 19 Lg Y R B B B B 8 Gy W Ch...

Page 62: ...P O R B W W L Y B G 40 L Y W B G L R G Y L R L R H G Y G Y H L R L R G G Y G Y G OFF ON G Y L G Y L R 42 G Y 187 187 Br P L R P 44 43 P P L R RUN STOP OFF OPEN 5 4 Br Br W B Y W B B Y Br W B BrW B Y Br B Br W RUN IDLE 6 B Y W B B Lg B W 19 19 18 Lg Y R B B B B 7 Gy W Ch L B L B R O W R W R W B Dg G L G B Y Y R Y B Sb G R Lg R W W G Br L Y G Lg B Gy B G Y R Y 8 R Y G Y Gy B R Y R Y D G Y G Y D Gy B...

Page 63: ...voltage on the smoothing condenser coupler SXV70SJ OUT OF SPECIFICATION Correct connection and or replace the rectifire regulator Check the stator coil and or connection NO CONTINUITY Replace the A C magneto and or connection Check the pick up coil and or connection NO CONTINUITY Replace the A C magneto and or connection Correct the connection and or replace the rectifier regulator and or CDI unit...

Page 64: ...K SENSOR 1 Disconnect SKnock sensor coupler 1 2 Connect SPocket tester to the knock sensor coupler 3 Measure SKnock sensor resistance Out of specification Replace the knock sensor Knock sensor resistance Black body 504 X 616 kΩ at 20_C 68_F ...

Page 65: ...kilometers and miles select the odometer mode ODO and then push the select reset button 1 for at least 10 seconds Switch the ODO meter to TRIP meter To switch the ODO meter display to TRIP meter display push the select reset button 1 for more than 0 1 second and for less than 0 7 se conds This operation should be done when vehicle is stopped with the engine running ...

Page 66: ... for one minute If the oil level warning indicator and the warning light go off the engine oil level is sufficient however it is getting low Add engine oil as soon as possible If the oil level warning indicator and the warning light do not go off check the engine oil level in the oil tank and add engine oil if necessary 1 FUEL METER FUEL LEVEL WARNING INDICATOR AND THE WARNING LIGHT The fuel meter...

Page 67: ...s SThrottle position sensor T P S SGrip and thumb warmer switch SGrip and thumb warmer SVoltage SKnock sensor Item T P S Condition Disconnected Short circuit Locked Item Y P V S Condition Disconnected Short circuit Locked Item Grip warmer switch switch Condition Disconnected Item Grip warmer Condition Short circuit ON Warning light ON OFF Warning light OFF s Time second ...

Page 68: ...em Thumb warmer switch Condition Disconnected Item Thumb warmer Condition Short circuit Item Voltage Condition Wrong Item Knock sensor Condition Disconnected Short circuit ON Warning light ON OFF Warning light OFF s Time second ...

Page 69: ...as follows SIf the detonation level increases the detonation control system indicator light flash pattern changes from pattern number 1 to pattern number 2 If excessive detonation levels continue maximum engine speed is reduced to protect the engine SEngine performance will decline according to the detonation level SIf the carburetor settings are not appropriate for the operating conditions detona...

Page 70: ... 64 SELF DIAGNOSIS ELEC ...

Page 71: ... 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 SXV70SJ Electric and recoil hand starter VT70J Lubrication system Separate lubrication YAMAHA AUTOLUBE Engine oil Type Tank capacity YAMALUBE 2 cycle oil 3 0 L 2 6 Imp...

Page 72: ...pension 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 SXV70SJ 944 mm 37 2 in VT70J 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 Ge...

Page 73: ...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 74: ...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 75: ...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 1 700 X 1 900 r min Fuel pump Type Manufacturer Diaphragm TAIYO GIKEN Oil pump Pump cable adjusting distance 20 5 1 mm 0 81 0 04 in Cooling system Filler cap opening pressure Water pump type Coolant type Coolant mixing ratio coolant water Coolant total amount 95 X 125 kPa 0 95 X 1 25...

Page 76: ...w SXV70SJ Blue Pink Blue VT70J for U S A CAN Pink Pink Pink VT70J for EUR 60 mm 2 36 in 6 0 mm 0 236 in SXV70SJ VT70J for EUR 5 5 mm 0 216 in VT70J for U S A CAN 441 N 45 kg 99 lb SXV70SJ 294 N 30 kg 66 lb VT70J 24 5 N mm 2 50 kg mm 140 lb in SXV70SJ 19 6 N mm 2 0 kg mm 112 lb in VT70J for U S A CAN 29 4 N mm 3 0 kg mm 168 lb in VT70J for EUR 5 39 SXV70SJ 4 91 VT70J for U S A CAN 4 82 VT70J for EU...

Page 77: ...mm 48 72 lb in VT70J 5 53 75 mm 2 95 in 47_ SXV70SJ 45_ VT70J for U S A CAN 39_ VT70J for EUR Drive chain Type Number of links Borg Warner Automotive 23RH303 68A SM 68 L Borg Warner Automotive 23RH303 70A SM 70 L 68 L SXV70SJ VT70J for EUR 70 L VT70J for U S A CAN Track Part number Width Length Pitch Number of links Thickness A Height B Track deflection at 10 kg 22 lb 8FA 47110 00 SXV70SJ for U S ...

Page 78: ... U S A CAN 14 7 N mm 1 47 kg mm 82 33 lb in VT70J for EUR 27 44 X 47 04 N mm 2 8 X 4 8 kg mm 157 X 269 lb in SXV70SJ 29 4 X 54 0 N mm 3 0 X 5 5 kg mm 164 66 X 302 44 lb in VT70J for U S A CAN 34 3 X 51 94 N mm 3 43 X 5 19 kg mm 192 10 X 290 90 lb in VT70J for EUR 7 5 mm 0 295 in SXV70SJ 7 8 mm 0 307 in VT70J 11 2 mm 0 441 in SXV70SJ 11 5 mm 0 452 in VT70J for U S A CAN 12 0 mm 0 472 in VT70J for E...

Page 79: ...kg 0 3 m s 202 lb 0 3 m s VT70J for U S A CAN 1 775 N 0 3 m s 181 kg 0 3 m s 399 lb 0 3 m s VT70J for EUR 1 480 N 0 3 m s 151 kg 0 3 m s 333 lb 0 3 m s SXV70SJ for U S A CAN 2 900 N 0 3 m s 296 kg 0 3 m s 653 lb 0 3 m s SXV70SJ for EUR 2 350 N 0 3 m s 240 kg 0 3 m s 528 lb 0 3 m s VT70J for U S A CAN 2 480 N 0 3 m s 253 kg 0 3 m s 557 lb 0 3 m s VT70J for EUR 970 N 0 3 m s 99 kg 0 3 m s 218 lb 0 3...

Page 80: ...rial Outside diameter High molecular weight polyethylene with rubber 178 mm 7 01 in Brake Pad thickness Pad wear limit Pad to disk clearance Disc outside diameter Disc minimum thickness 10 2 mm 0 40 in 4 7 mm 0 19 in 0 025 X 0 115 mm 0 001 X 0 005 in 220 mm 8 66 in 10 mm 0 39 in ...

Page 81: ...r U S A CAN 12 7 23 5 27 4 N mm 1 3 24 27 kg mm 72 8 134 151 lb in SXV70SJ for EUR 22 5 N mm 2 3 kg mm 128 8 lb in VT70J 7 5 mm 0 295 in SXV70SJ for U S A CAN 7 8 mm 0 307 in SXV70SJ for EUR 8 2 mm 0 323 in VT70J Shock absorber Damping force Extension Compression 671 N 0 3 m s 68 kg 0 3 m s 150 lb 0 3 m s SXV70SJ for U S A CAN 1 270 N 0 3 m s 130 kg 0 3 m s 287 lb 0 3 m s SXV70SJ for EUR 1 090 N 0...

Page 82: ...I 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 SXV70SJ F8T40171 MITSUBISHI VT70J 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 25 A 200 V Battery VT70J S...

Page 83: ...ll 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 68_...

Page 84: ... 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 85: ... Y P V S valve assembly 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 Coolant drain bolt Bleed bolt front cooling system Bleed bolt rear cooling system Magneto rotor Starter motor Starter motor assembly 13 27 15 57 40 33 33 33 57 14 5 13 13 28 33 20 23 10 10...

Page 86: ...ension wheel Rear axle Slide rail suspension mounting bolt M10 Rear pivot arm and rear pivot arm bracket Shock absorber and rear pivot arm Rear pivot arm and pull rod Rear suspension bracket and pull rod Shock absorber and rear suspension bracket Control rod and sliding frame Control rod bolt Shock absorber and front pivot arm Shock absorber and front suspension bracket Rear pivot arm bracket Rear...

Page 87: ...shaft and sliding frame Set bolt front axle Speed sensor Gear unit speed sensor Knock sensor 72 8 20 40 27 7 2 0 8 2 0 4 0 2 7 52 5 8 14 29 20 Apply LOCTITE 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 88: ... arm Front arm pivot bolt Stabilizer bar and connecting rod Connecting rod and front arm Frame cross member M10 20 Brake master cylinder assembly Brake lever adjuster locknut Rear bumper cover Seat and frame nut Shroud Fuel tank rear Passenger grip bracket Front bumper Rear bumper 15 23 23 35 35 35 42 67 25 48 21 11 11 17 48 48 35 50 50 56 78 23 23 48 10 6 3 9 3 10 9 17 26 1 5 2 3 2 3 3 5 3 5 3 5 ...

Page 89: ...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 90: ... 84 SPEC ...

Page 91: ... 85 CABLE ROUTING SPEC ...

Page 92: ...ng area of the coolant hose S Point the tip of the clamp to the downward of the vehicle S Do not clamp the coolant tem perature sensor lead 5 Ignition coil lead coupler 6 T O R S lead connector 7 CDI magneto lead coupler and cover 8 Joint connector 9 Throttle position sensor coupler 10 Pass the starter choke throttle and oil pump cables through the holder of intake silencer 11 Clamp the battery ba...

Page 93: ... 87 CABLE ROUTING SPEC ...

Page 94: ...te the main switch lead after routing it backward once 18 Pass the main harness over the oil tank breather hose 19 Brake hose 20 Wire harness 21 Starter cable 22 Oil level switch 23 Speed sensor 24 Coolant hose 25 Fold back the clamp and secure it 26 Drive V belt guard bracket 27 Secure the head light lead at the protection tube area with the clamp 28 Gear position switch lead 29 Y P V S check cou...

Page 95: ... 89 CABLE ROUTING SPEC ...

Page 96: ...tail brake light lead in front of the frame clamp 7 Frame clamp 8 Pass the tail brake light lead through the inner side of the clamp 9 Make sure to pass the tail brake light lead so that it cannot be caught between the fuel tank and panel Secure it to the groove section of the fuel tank s bottom face with an adhesive tape at 3 places 10 50 mm 1 97 in 11 To tail brake light unit 12 Adhesive tape 13...

Page 97: ... 91 CABLE ROUTING SPEC ...

Page 98: ...ch coupler 21 Fuel hose 22 Pulser hose 23 Oil delivery hose 24 Situate the CDI unit coupler in the footrest 25 CDI unit 26 Headlight dimmer relay black 27 Passenger grip warmer relay VT70J 28 Load control relay white 29 Back buzzer For model with reverse CABLE ROUTING SPEC ...

Page 99: ... 93 CABLE ROUTING SPEC ...

Page 100: ...ess 2 Align the clamp with the tape on the headlight harness 3 Clamp the headlight harness 4 Route it behind the shroud stop per 5 Fit the rubber boot into the speedometer coupler securely 6 Hook 7 Stay CABLE ROUTING SPEC ...

Page 101: ... 95 CABLE ROUTING SPEC ...

Page 102: ... hose 13 Left handlebar switch 14 Starter cable 15 Route the throttle cable and starter cable through the holder 16 Clamp the oil tank breather hose 17 Route the compression spring through the holder 18 Steering column 19 Clamp the fuel tank breather hose 20 Clamp the main harness and steering gate 21 Fuel tank breather hose 22 Fuel sender coupler 23 Oil level switch coupler 24 Y P V S lead connec...

Page 103: ... 97 CABLE ROUTING SPEC ...

Page 104: ... cooling hose and frame 43 Clamp the coolant hose and main harness Align the position ing tape of the main harness with the white mark of the coolant hose Make sure to point the tip of the clamp to the inner side of the vehicle 44 Coolant hose 45 Main harness should be posi tioned along with the coolant hose 46 Smoothing condenser 47 Fuse coupler For model with starter motor 48 Fuse box For model ...

Page 105: ... 99 CABLE ROUTING SPEC ...

Page 106: ...ap 58 Main switch 59 Clamp it at the lower part of the bending area 60 Right handlebar switch 61 Clamp the oil tank breather hose grip warmer lead engine stop switch lead and thumb warmer switch lead Do not clamp the throttle cable and thumb warmer lead 62 Throttle cable 63 Flange bolt 64 Collar 65 Oil tank 66 Grommet 67 Fuel tank 68 Screw 69 Nut 70 Flange nut 71 Hexagon bolt 72 Harness 73 Starter...

Page 107: ... 101 CABLE ROUTING SPEC ...

Page 108: ...ness Main harness from the starter relay to the starter motor 12 Starter motor For model with starter motor 13 Pass the main harness under the carburetor heater hose 14 Housing cap 15 Clamp the main harness and the metal section of the brake hose 16 Brake hose 17 Battery negative lead For model with starter motor 18 Coolant hose 19 Starter relay lead For model with starter motor 20 Battery positiv...

Page 109: ... 103 CABLE ROUTING SPEC ...

Page 110: ...of the clamp to the inner side of the vehicle 28 Follow the direction of spark plug caps as shown in the illustration 29 Position of the clamp should be at the identification tape position of the spark plug lead 30 Main wire harness This is the main wire harness to the headlight unit CABLE ROUTING SPEC ...

Page 111: ... 105 CABLE ROUTING SPEC ...

Page 112: ... starter motor 4 Pass the main harness under the coolant pipe Main harness from the starter relay to the starter motor 5 Coolant pipe 6 Coolant hose 7 Do not slack to the clutch side Slack should be to the instru ment panel side 8 Frame directly attached clamp 9 Clutch 10 Speed sensor lead coupler 11 Speed sensor lead 12 Speed sensor CABLE ROUTING SPEC ...

Page 113: ...otor 2 25 Load control relay 26 Fuse IGNITION 2 27 Fuse TAIL 2 28 Fuse HEAD 2 29 High beam switch 30 Headlight dimmer relay 31 Headlight 32 Meter assembly 33 Tachometer 34 Meter light 35 Detonation control system indicator light 36 Multi function meter 37 Coolant temperature indicator light 38 High beam indicator light 39 Oil level switch 40 Fuel sender 41 Speed sensor 42 Tail brake light 43 Brake...

Page 114: ... B R R W OFF ON START R Y R W Br W Br Br 4 Br R W R Y R W R Br W RW RW F Y Lg B Y B L Y G R L W R B W Sb G B Y G B G 32 36 36 38 34 35 34 37 B G Y B L Y W G B G R R B Y B G B G A Y B B Y B L Y B L Y W B W G B A G B G R A G R R B A R B 33 Lg B Lg B C Lg B Y G Y G C Y G Sb Sb A Sb Gy Br B R B 39 R B B G B 40 G B B G G B B G P O R B W W L Y B G 41 L Y W B G L Y B L R G Y B 42 B L R G Y B B G B B H L ...

Page 115: ... Fuse IGNITION 26 Fuse TAIL 27 Fuse HEAD 28 High beam switch 29 Headlight dimmer relay 30 Headlight 31 Meter assembly 32 Tachometer 33 Meter light 34 Detonation control system indicator light 35 Multi function meter 36 Coolant temperature indicator light 37 High beam indicator light 38 Oil level switch 39 Fuel sender 40 Speed sensor 41 Tail brake light 42 Brake light switch 43 Gear position switch...

Page 116: ... Y B L Y W G B G R R B Y B G B G A Y B B Y B L Y B L Y W B W G B A G B G R A G R R B A R B 32 Lg B Lg B C Lg B Y G Y G C Y G Sb Sb A Sb Gy Br B R B 38 R B B G B 39 G B B G G B B G P O R B W W L Y B G 40 L Y W B G L B G Y 41 B L R G Y B B G B B H L R L R H G Y G Y H L R L R G G Y G Y G OFF ON G Y L G Y L R 42 G Y 187 187 Br P L R P 44 43 B P P L R RUN STOP OFF OPEN 5 4 Br Br W B Y W B B Y Br W B Br...

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Page 118: ......

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Page 120: ...VX700F VX700DXF SX700F MM700F VT700F SERVICE MANUAL LIT 12618 02 17 8CH 28197 10 981050 ...

Page 121: ...e Replace EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct disas sembly and assembly procedures NOTICE This manual was written by the Yamaha Motor Com pany primarily for use by Yamaha dealers and their qualified mechanics It is not possible to put an entire mechanic s education into one manual so it is as sumed that persons using this b...

Page 122: ...ng fluid A Lubricant B Tightening C Wear limit clearance D Engine speed E Special tool F Ω V A Illustrated symbols G to O in the exploded diagram indicate grade of lubricant and location of lubrication point G Apply locking agent LOCTITE H Apply Yamabond No 5 I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply low temperature lithium soap base ...

Page 123: ...L INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE COOLING SYSTEM CARBURETION ELECTRICAL SPECIFICATIONS INDEX GEN INFO CHAS ENG POWR TR CARB ELEC SPEC COOL 1 INSP ADJ 2 3 4 5 6 7 8 9 ...

Page 124: ...STARTER CHOKE CABLE FREE PLAY ADJUSTMENT 2 15 EXHAUST SYSTEM INSPECTION 2 15 POWER TRAIN 2 16 SHEAVE DISTANCE AND OFFSET ADJUSTMENT 2 16 DRIVE V BELT 2 18 ENGAGEMENT SPEED CHECK 2 20 PARKING BRAKE PAD INSPECTION 2 20 PARKING BRAKE ADJUSTMENT 2 20 BRAKE LEVER ADJUSTMENT VX700DX SX700 VT700 2 21 BRAKE FLUID LEVEL INSPECTION 2 21 BRAKE PAD INSPECTION 2 22 BRAKE HOSE INSPECTION 2 22 AIR BLEEDING HYDRA...

Page 125: ...G INSTALLATION 4 28 BRAKE 4 29 BRAKE PAD REPLACEMENT 4 30 BRAKE CALIPER DISASSEMBLY 4 34 BRAKE CALIPER INSPECTION AND REPAIR 4 34 BRAKE CALIPER ASSEMBLY 4 35 BRAKE CALIPER INSTALLATION 4 35 INSPECTION 4 37 BRAKE MASTER CYLINDER ASSEMBLY 4 37 INSTALLATION 4 37 SLIDE RAIL SUSPENSION 4 38 VX700 VX700DX SX700 4 38 VT700 4 39 MM700 4 44 INSPECTION 4 49 ASSEMBLY 4 50 INSTALLATION 4 50 FRONT AXLE AND TRA...

Page 126: ...HT 8 8 CARBURETOR SWITCH 8 9 MAIN SWITCH 8 9 LOAD CONTROL RELAY 8 10 EMERGENCY ENGINE STARTING VX700 SX700 MM700 8 10 ELECTRICAL STARTING SYSTEM VX700DX VT700 8 11 CIRCUIT DIAGRAM 8 11 TROUBLESHOOTING 8 12 MAIN SWITCH 8 13 STARTER MOTOR 8 14 CHARGING SYSTEM VX700DX VT700 8 17 CIRCUIT DIAGRAM 8 17 TROUBLESHOOTING 8 18 BATTERY 8 19 STATOR COIL 8 19 LIGHTING SYSTEM 8 20 CIRCUIT DIAGRAM 8 20 TROUBLESH...

Page 127: ...43 FAULT LOCATION TABLE 8 44 CHAPTER 9 SPECIFICATIONS GENERAL SPECIFICATIONS 9 1 MAINTENANCE SPECIFICATIONS 9 4 ENGINE 9 4 POWER TRAIN 9 7 CHASSIS 9 11 ELECTRICAL 9 12 HIGH ALTITUDE SETTINGS 9 14 TIGHTENING TORQUE 9 17 GENERAL TORQUE SPECIFICATIONS 9 21 DEFINITION OF UNITS 9 21 CABLE ROUTING 9 23 ...

Page 128: ...RIAL NUMBER Theframeserialnumber1islocatedontheright handsideoftheframe just below the front of the seat ENGINE SERIAL NUMBER The engine serial number 1 is located on the right hand side of the crankcase NOTE Designs and specifications are subject to change without notice SCH1010 SCH1020 ...

Page 129: ... through normal wear Mated parts must be reused or replaced as an assembly 4 During disassembly of the machine clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help ensure that all parts are reinstalled correctly 5 Keep all parts away from any source of fire 6 Be sure to keep to the tightening torque specifications When tightening bolts nuts ...

Page 130: ...rks or numbers facing outwards In other words the stamped letters must be on the side exposed to view When installing oil seals apply a light coating of lightweightlithiumbasegreasetotheseallips Oilthebearingsliberallywhen installing CAUTION Do not use compressed air to spin the bearings dry This causes damage to the surface of the bearings CIRCLIPS All circlips should be inspected carefully befor...

Page 131: ...N YS 42421 1 15 mm offset 1 YS 42421 2 20 mm offset 2 This gauge is used to measure the sheave distance and for offset adjust ment Dial gauge P N YU 03097 for U S A Canada 90890 03097 for Europe This gauge is used for run out measurement Fuel level gauge P N YM 01312 A for U S A Canada 90890 01312 for Europe This gauge is used to measure the fuel level in the float chamber Distance gauge P N YS 91...

Page 132: ...0 01701 for Europe This tool is used to hold the primary sheave Primary sheave puller 18 mm P N YS 01881 11 YS 01882 12 This tool is used for removing the primary sheave Clutch spider separator P N YS 28890 B for U S A Canada 90890 01711 for Europe This tool is used when disassembling and assembling the primary sheave Clutch separator adapter P N YS 34480 for U S A Canada 90890 01740 for Europe Th...

Page 133: ...22 This tool is used for checking and adjusting the ski spindle camber FOR CARBURETION SERVICE Mity vac P N YB 35956 for U S A Canada 90890 06756 for Europe This tool is used to check the fuel pump FOR ELECTRICAL SERVICE Pocket tester P N YU 03112 for U S A Canada 90890 03112 for Europe This instrument is necessary for checking the electrical components Electro tester P N YU 33260 A for U S A Cana...

Page 134: ...eels Slide runners Pre operation check Daily Initial 1 month or 800 km 500 mi 40 hr Every Seasonally or 3 200 km 2 000 mi 160 hr Check condition Adjust gap and clean Replace if necessary Check oil level Air bleed the oil pump if necessary Check fuel level Check condition Replace if necessary Check fuel hose for cracks or damage Replace if necessary Check oil hose for cracks or damage Replace if ne...

Page 135: ...rake fluid level and add the fluid as required 2 On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged Item Remarks Pre operation check Daily Initial 1 month or 800 km 500 mi 40 hr Every Seasonally or 3 200 km 2 000 mi 160 hr Lubricate with specified grease Lubricate with specified gr...

Page 136: ...Regap Use a wire thickness gauge Spark plug gap a 0 7 0 8 mm 0 028 0 031 in If necessary clean the spark plugs with a spark plug cleaner Standard spark plug BR9ES NGK Before installing a spark plug clean the gasket sur face and spark plug surface 4 Install Spark plugs Spark plug 20 Nm 2 0 m kg 14 ft lb NOTE Finger tighten a the spark plug before torquing b it to specification T R SCH2010 SCH2020 S...

Page 137: ...emove Carburetors Refer to CARBURETORS in CHAPTER 7 3 Remove Rear bracket right 1 4 Place a rag under the oil pump assembly to soak up any spilled oil 5 Disconnect Oil hose 6 Drain the oil until no more air bubbles appear in the oil hose 7 Connect Oil hose 8 Disconnect Oil delivery hose 9 Feed the YAMALUBE 2 cycle oil into the oil delivery hose using an oil can for complete air bleeding 10 Connect...

Page 138: ... CHAPTER 7 Cable adjustment NOTE Before adjusting the oil pump cable the throttle cable free play should be adjusted Adjustment steps Slide back the adjuster cover Loosen the locknut 1 Turn the adjuster 2 in or out until the specified distance a is obtained Distance a 22 1 mm 0 866 0 039 in Turning in Distance a is increased Turning out Distance a is decreased Tighten the locknut and push in the a...

Page 139: ... Cracks damage Replace 3 Install Intake silencer Refer to FUEL PUMP in CHAPTER 7 COOLING SYSTEM Coolant replacement NOTE The coolant should be changed at least every sea son 1 Place the machine on a level surface 2 Remove Exhaust pipe Exhaust joint Refer to EXHAUST ASSEMBLY in CHAP TER 5 3 Make sure that the carburetor heating lever 1 is turned to ON a SCH2090 SCH2100 SCH2110 ...

Page 140: ...lant filler cap Slowly turn the cap counterclockwise until it stop This allows any residual pressure to es cape Whenthehissingsoundhasstopped press down on the cap while turning it counterclock wise to remove it 5 Place an open container under the coolant drain bolt 1 6 Remove Coolant drain bolt Gasket coolant drain bolt 7 Drain the coolant NOTE Lift up the tail of the machine to drain the coolant...

Page 141: ...tion If coolant splashes in your eyes thoroughly wash them with water and consult a doctor If coolant splashes on your skin or clothes quickly wash it away with soap and water 11 Connect Coolant hoses 12 Install Right side cover 1 MM700 Bolt side cover 3 Nm 0 3 m kg 2 2 ft lb 13 Disconnect Coolant reservoir hose 1 14 Remove Coolant reservoir cap 1 15 Drain the coolant from the coolant reservoir 16...

Page 142: ...g system Recommended coolant High quality ethylene glycol antifreeze containing corrosion inhibitors Coolant mixing ratio coolant water 3 2 60 40 Total amount VX700 VX700DX SX700 3 8 L 3 34 lmp qt 4 02 US qt MM700 3 9 L 3 43 lmp qt 4 12 US qt VT700 4 0 L 3 52 lmp qt 4 23 US qt Reservoir tank capacity 0 28 L 0 25 lmp qt 0 30 US qt From LOW to FULL level 0 13 L 0 11 lmp qt 0 14 US qt CAUTION Hard wa...

Page 143: ...he cooling system tester 1 to the coolant filler 2 Cooling system tester 90890 01325 YU 24460 01 Apply 100 kPa 1 0 kg cm2 14 psi Measure the pressure with the gauge Air bleeding 1 Remove Seat VX700 VX700DX SX700 VT700 Rear bumper cover 1 VT700 Bleed bolt cap 1 MM700 Å VT700 ı MM700 2 Bleed air from the cooling system COOLING SYSTEM SCH2220 SCH2225 SCH2230 A B ...

Page 144: ...Drain the coolant until no more air bubbles ap pear Tighten the bleed bolt 2 Bleed bolt 2 7 Nm 0 7 m kg 5 1 ft lb Install the coolant filler cap Applyandlocktheparkingbrake Starttheengine and run it at approximately 2 500 3 000 r min until the coolant circulates approximately 3 5 minutes The rear heat exchanger will be warm to the touch WARNING To avoid severe injury or death Make sure the machine...

Page 145: ...ors Refer to CARBURETORS in CHAPTER 7 2 Adjust Carburetor synchronization Adjustment steps Turn the throttle stop screw 1 of carburetor 2 until the specified throttle valve height a is ob tained Throttle valve height a 1 2 mm 0 047 in Adjust the throttle valve height a on carburetor 1 2 and 3 3 with the adjusting screws 4 Move the throttle lever 2 3 times Make sure that all of the carburetor throt...

Page 146: ...1 600 100 r min NOTE After adjusting the engine idle speed the throttle cable free play should be adjusted THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted Adjust the throttle cable free play while the cable is in the cable guide 1 Measure Throttle cable free play a Out of specification Adjust Throttle cable free play a...

Page 147: ...run the engine up to the clutch engage mentspeed Otherwise themachinecouldstart moving forward unexpectedly which could cause an accident 1 Start the engine 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 stop switch housing 2 While holding as described above press the throttle lever ...

Page 148: ...the specified free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the locknut EXHAUST SYSTEM INSPECTION 1 Open the shroud 2 Remove Springs Refer to EXHAUST ASSEMBLY in CHAP TER 5 3 Inspect Exhaust joint 1 Exhaust pipe 2 Exhaust silencer 3 Cracks damage Replace Gasket 1 4 Gasket 2 5 Gasket 3 6 Exhaust gas leaks Replace 4 Check Tightening torque 7 Bolt ...

Page 149: ...ffset a Use the sheave gauge Out of specification Adjust Sheave offset a VX700 SX700 MM700 13 5 16 5 mm 0 53 0 64 in VX700DX VT700 18 5 21 5 mm 0 73 0 85 in Sheave gauge YS 42421 1 15 mm offset YS 42421 2 20 mm offset 5 Adjust Sheave distance Adjustment steps Loosen the engine mounting bolts Adjust the position of the engine so that the sheave distance is within the specification Tighten the engin...

Page 150: ...0 04 0 08 in 7 Adjust Secondary sheave free play clearance Adjustment steps Apply the brake to lock the secondary sheave Remove the bolt 1 and washer 2 Adjust the secondary sheave free play clear ance by adding or removing a shim s 3 Shim size Part number Thickness 90201 222F0 0 5 mm 0 02 in 90201 225A4 1 0 mm 0 04 in SHEAVE DISTANCE AND OFFSET ADJUSTMENT SCH2400 SCH2410 ...

Page 151: ... adding a spacer 1 on each adjusting bolt 2 CAUTION As the V belt wears adjustment may be neces sary To ensure proper clutch performance the V beltpositionshouldbeadjustedbyaddingaspacer on each adjusting bolt when the V belt position reaches 1 5 mm 0 06 in below the edge New belt width 34 5 mm 1 36 in Belt wear limit width 32 5 mm 1 28 in 1 Measure V belt position a NOTE Install the new V belt on...

Page 152: ... ft lb 4 Inspect Drive V belt Cracks damage wear Replace Oil or grease on the V belt Check the pri mary and secondary sheaves 5 Inspect Primary sheave Secondary sheave Oil or grease on the primary and secondary sheaves Usearagsoakedinlacquerthinner or solvent to remove the oil or grease Check the primary and secondary sheaves 6 Measure Drive V belt circumference a Out of specification Replace V be...

Page 153: ...ING BRAKE PAD INSPECTION 1 Measure Parking brake pad thickness a Out of specification Replace as a set Wear limit a 6 0 mm 0 24 in PARKING BRAKE ADJUSTMENT 1 Measure Clearance a Out of specification Adjust Clearance a 1 2 1 3 mm 0 047 0 051 in 2 Adjust Clearance a Adjustment steps Loosen the locknuts 1 Turn the cable adjuster 2 in or out to until the specified clearance between the brake pad 3 and...

Page 154: ...or a correct reading of the brake fluid level make sure that the top of the handlebar brake master cylinder reservoir is horizontal CAUTION Brake fluid may corrode painted surfaces or plas tic parts Always clean up spilled fluid immedi ately WARNING Use only the designated brake fluid Other fluids may deteriorate the rubber seals caus ing leakage and poor brake performance Refill with the same typ...

Page 155: ...ry low Brake operation is faulty If the brake system is not properly bled a loss of braking performance may occur 1 Bleed Brake system Air bleeding steps Fill the brake master cylinder reservoir with the proper brake fluid Install the diaphragm Be careful not to spill any fluid or allow the brake master cylinder reservoir to overflow Connect clear plastic hoses 1 tightly to the brake caliper bleed...

Page 156: ...tem have disappeared Add brake fluid to the proper level Refer to BRAKE FLUID LEVEL INSPECTION WARNING After bleeding the brake system check the brake operation DRIVE CHAIN Oil level inspection WARNING The engine and muffler will be very hot after the engine has run Avoid touching a hot engine and muffler while they are still hot with any part of your body or clothing during inspection or repair 1...

Page 157: ...einserting the dipstick into the drive chain housing Remove the dipstick and check that the oil is between the upper a and lower b levels If not add oil to the upper level Å For models without reverse transmissions VX700 SX700 MM700 ı For models with reverse transmissions VX700DX VT700 Recommended oil Gear oil API GL 3 SAE 75 or 80 CAUTION Makesurethatnoforeignmaterialentersthegear case Reinsert t...

Page 158: ...11 ft lb Recommended oil Gear oil API GL 3 SAE 75 or 80 Oil capacity 0 25 L 8 8 Imp oz 8 5 US oz Å VX700 VX700DX SX700 VT700 ı MM700 Chain slack adjustment 1 Remove Battery VX700DX VT700 Battery bracket VX700DX VT700 WARNING Whenremovingthebattery disconnectthenega tive lead first 2 Adjust Drive chain slack Adjustment steps Loosen the locknut 1 Turn the adjusting bolt 2 in until it is finger tight...

Page 159: ...e is raised to allow the track to spin a suitable stand must be used to support the rear of the machine Never allow anyone to hold the rear of the machine off the ground to allow the track to spin Never allow anyone near a rotating track Inspect the condition of the track frequently Replace the track if it is damaged to a level where the fabric reinforcement material is visible Never install studs...

Page 160: ...unner 9 Track 0 Track metal A Gap B Forward Å VX700 VX700DX SX700 VT700 ı MM700 c Adjust the track deflection until the specified amount is obtained CAUTION The adjusters should be turned an equal amount Recheck the alignment and deflection If neces sary repeat steps a to c until the specified amount is obtained Tighten the rear axle nut Nut rear axle 75 Nm 7 5 m kg 54 ft lb Track alignment 4 Left...

Page 161: ...J SLIDE RUNNER INSPECTION SLIDE RUNNER INSPECTION 1 Inspect Slide runner 1 Cracks damage wear Replace 2 Measure Slide runner thickness a Out of specification Replace Slide runner wear limit a 10 mm 0 39 in SCH2680 ...

Page 162: ... avoid sus tained 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 failure or damage Off trail riding Avoid off trail riding until there is sufficient snow coverage It generally takes several feet of snow to provide a good overall base to properly cover debris such as rocks logs etc ...

Page 163: ...T700 13 mm 0 51 in SX700 MM700 8 mm 0 31 in CAUTION To avoid scratching wearing and damaging the plastic skis be careful when loading and unload ing the snowmobile and avoid riding in areas with little or no snow and on surfaces with sharp edges such as concrete curbs etc Å VX700 VX700DX VT700 ı SX700 MM700 SCH2690 SCH2695 SCH2700 SCH2705 SKI SKI RUNNER A A B B ...

Page 164: ...ds are in stalled securely in position If free play still exists check the steering bearing front sus pension links and ski mounting area for wear Replace if necessary Toe out adjustment 1 Place the machine on a level surface 2 Check Ski toe out Point the skis forward Out of specification Adjust Ski toe out a c 0 15 mm 0 0 59 in Ski stance b center to center VX700 VX700DX SX700 VT700 1 070 mm 42 1...

Page 165: ...ted freely through the ball joint travel If not loosenthelocknut1andre positiontheballjoint so that the tie rod 2 can be rotated freely Tighten the locknuts to specification Å Left side ı Right side Ç Inside LUBRICATION Brake lever throttle lever and throttle cable end 1 Lubricate the brake lever pivot throttle lever and the ends of the throttle cables Recommended lubricant ESSO Beacon 325 Grease ...

Page 166: ... 1 Recommended lubricant Esso Beacon 325 Grease or Aeroshell Grease 7A Å Front ı Rear VX700 VX700DX SX700 VT700 Ç Rear MM700 SCH2745 SCH2755 SCH2760 SCH2740 Relay arm steering 1 Use a grease gun to inject grease into the nipples 1 Recommended lubricant ESSO Beacon 325 Grease or Aeroshell Grease 7A SCH2750 A A ...

Page 167: ...ight s high beam and check the height of the projected beam on the wall The projection should be at the position marked in step 3 or 1 2 lower set range S D 3 0 m 10 ft 7 6 m 25 ft S 26 mm 1 0 in 66 mm 2 6 in D Distance S Set range 6 Adjust Headlight beam vertically Vertical adjustment Higher Turn the adjusting screw 1 2 clockwise Lower Turn the adjusting screw 1 2 counterclockwise 7 Adjust Headli...

Page 168: ... and get prompt medical attention Batteries produce explosive gases Keep sparks flames cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 1 Remove Battery WARNING Whenremovingthebattery disconnectthenega tive lead first 2 Inspect Fluid level should be between UPPER LEVEL a and LOWER LEVEL b marks Incor...

Page 169: ...he rest Warpage or buckling of plates or insulators is evident CAUTION Always charge a new battery before using it to ensure maximum performance 4 Inspect Battery terminal Dirty terminal Clean with a wire brush Poor connection Correct NOTE After cleaning the terminals apply grease lightly to the terminals 5 Install Battery CAUTION Connect the positive lead to the battery termi nal first Make sure ...

Page 170: ...el line and leave it for a while When the battery fluid permeates the plates and separators the fluid level begins to lower Add electrolyte and bring back to upper level line NOTE Fill the battery with diluted sulfuric acid electrolyte Connect the battery to a battery charger 1 Set the battery charger rate at 1 10 the battery capacity and charge the battery for 10 hours Charging Rate 2 0 Ah 10 hou...

Page 171: ... not obstructed FUSE INSPECTION VX700DX VT700 The following procedure applies to all of the fuses CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Check Continuity Checking steps Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 Pocket tester 90890 03112 YU 03112 If the pocket tester indic...

Page 172: ... fuse 2 HEAD fuse 3 TAIL fuse 4 IGNITION fuse 5 Reserve fuse 6 Reserve fuse Amperage 30 A 20 A 10 A 10 A 20 A 10 A 30 A Q ty 1 1 1 1 1 1 1 WARNING 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 light ing ignition grip warmer signal and meter sys tems to malfunction ...

Page 173: ...optimum fuel oil mixture depending on the throttle opening Therefore after the carbure tors have been tuned or maintained or after the float chambers are removed for cleaning or jet replacement be sure to idle the engine for about three minutes in order to avoid engine trouble CAUTION Before performing the carburetor tuning make sure that the following items are set to specification Engine idle sp...

Page 174: ...Check Spark 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 NOTE Bycheckingtheconditionofthesparkplugs itiseasy to get some idea of the condition of the engine This maydiagnosepotentialproblemsbeforeenginedam age occurs High altitude tuning U...

Page 175: ...2 42 INSP ADJ CARBURETOR TUNING Guide for carburetion SCH2815 ...

Page 176: ...er box is removed from the carbu retors the change in pressure in the intake will create a lean mixture that may cause severe engine damage The air silencer box has no effect on performance characteristics and must be se cured to the carburetors during carburetor tuning and adjustment Also it must always be in place when the engine is operated Regularly clean the silencer and keep it free from obs...

Page 177: ...s Pilot mixture screw 2 1 1 2 turns out Pilot mixture screw effects Turn in STD setting Turn out Leaner Richer Mixture Mixture 2 Set the engine idle speed by turning the throttle stopscrewin toincreaseenginespeed orout to decrease engine speed Engine idle speed 1 600 100 r min 3 If low speed performance is still poor at higher elevations under extreme conditions the stan dard pilot jets may need t...

Page 178: ...shooting Trouble Hard starting Poor idling Poor performance at low speeds Poor acceleration Slow response to throttle Engine tends to stall Diagnosis Insufficient fuel Excessive use of the starter or choke Fuel passage is clogged or frozen Overflow Improper idling speed adjustment Damaged pilot screw Clogged bypass hole Clogged or loose pilot jet Air leaking into the carbu retor joint Defective st...

Page 179: ...et clean it with compressed air and then install it Make sure that the pilot jet is fully tightened Overhaul the carburetors Remove the air vent hose and clean it Remove the main jet clean it with compressed air and then install it Make sure that the main jet is fully tightened Check and if necessary clean the float and float valve Return the starter lever to its seated position so that the starte...

Page 180: ... 50 in 84 3 mm 3 32 in 83 4 mm 3 28 in Ò Preload 343 N 35 kg 77 lb 294 N 30 kg 66 lb Spring rate 22 1 N mm 2 25 kg mm 27 0 N mm 2 75 kg mm 29 4 N mm 3 00 kg mm 126 lb in 154 lb in 168 lb in ˆ Wire diameter 5 8 mm 0 228 in 6 0 mm 0 236 in Ø Outside diameter 60 mm 2 362 in Weight ID 8CH 17605 10 8CH00 Œ Weight rivet Steel 10 3 OUT Aluminum 10 3 OUT None OUT Steel 13 9 IN Steel 13 9 IN Aluminum 13 3 ...

Page 181: ...3 4 mm 3 28 in 82 6 mm 3 25 in Ò Preload 343 N 35 kg 77 lb 294 N 30 kg 66 lb Spring rate 22 1 N mm 2 25 kg mm 27 0 N mm 2 75 kg mm 29 4 N mm 3 00 kg mm 31 9 N mm 3 25 kg mm 126 lb in 154 lb in 168 lb in 182 lb in ˆ Wire diameter 5 8 mm 0 228 in 6 0 mm 0 236 in Ø Outside diameter 60 mm 2 362 in Weight ID 8CH 17605 10 8CH00 Œ Weight rivet Steel 10 3 OUT Aluminum 10 3 OUT None OUT Steel 13 9 IN Steel...

Page 182: ... 3 46 in Ò Preload 392 N 40 kg 88 lb Spring rate 24 5 N mm 2 50 kg mm 27 0 N mm 2 75 kg mm 140 lb in 154 lb in ˆ Wire diameter 5 8 mm 0 228 in 6 0 mm 0 236 in Ø Outside diameter 60 mm 2 362 in Weight ID 8DF 17605 10 8DF00 Œ Weight rivet Steel 13 9 OUT Steel 10 3 OUT Aluminum 10 3 OUT None OUT Steel 13 9 IN Steel 13 9 IN Steel 13 9 IN Steel 13 9 IN Â Weight bushing Duralon Í Roller outer dia 16 0 m...

Page 183: ...ength 91 4 mm 3 60 in Ò Preload 441 N 45 kg 99 lb Spring rate 24 5 N mm 2 50 kg mm 140 lb in ˆ Wire diameter 6 0 mm 0 236 in Ø Outside diameter 60 mm 2 362 in Weight ID 8CR 17605 10 8CR00 Œ Weight rivet Steel 13 9 OUT Steel 10 3 OUT Aluminum 10 3 OUT Aluminum 10 3 OUT Steel 17 2 IN Steel 13 3 IN Steel 13 9 IN Aluminum 10 3 IN Â Weight bushing Duralon Í Roller outer dia 14 5 mm 0 57 in Ê Roller bus...

Page 184: ... 28 in 82 6 mm 3 25 in Ò Preload 294 N 30 kg 66 lb Spring rate 29 4 N mm 3 00 kg mm 31 9 N mm 3 25 kg mm 168 lb in 182 lb in ˆ Wire diameter 6 0 mm 0 236 in Ø Outside diameter 60 mm 2 362 in 8CH 17605 10 8CH00 Weight ID 8CR 17605 10 8CR00 8CR 17605 10 8CR00 for Europe Steel 13 9 OUT Steel 10 3 OUT Œ Weight rivet Steel 13 3 OUT Steel 17 2 IN Aluminum 10 3 OUT None OUT for Europe Steel 13 9 IN Steel...

Page 185: ...s wet snow icy snow hills or rough terrain however engine speed may decrease after the shift ing speed has been reached Å Engine speed ı Good condition Ç Bad condition Î Clutch shifting speed Clutch engagement speed Ï Starting position Ì 200 300 m 650 1 000 ft Ó Distance travelled GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions I...

Page 186: ... links 70 links 70 links 2 105 2 000 1 905 1 818 1 739 68 links 68 links 70 links 70 links 70 links ı Driven sprocket 3 Secondary sheave spring Å Part no 90508 500B1 90508 536A9 90508 556A2 90508 556A7 4 Secondary spring twist angle 90508 500B1 brown 90508 536A9 red 90508 556A2 green 90508 556A7 silver 0 3 6 9 1 10 40 70 100 2 20 50 80 110 3 30 60 90 120 ı Sheave Ç Part no Å Seat È Standard ı Spri...

Page 187: ...Part no 8BV 17604 71 8BV 17604 51 8BV 17604 31 8BV 17604 11 8BV 17604 91 GEAR SELECTION Ï Standard Î Cam angle 47 45 43 41 39 ı Effects Identification mark 8BV71 8BV51 8BV31 8BV11 8BV91 VX700 VX700DX SX700 VT700 for U S A Canada MM700 VT700 for Europe SCH2850 ...

Page 188: ...rts No Ó Wire gauge mm in È Outside diameter mm in Spring rate N mm kg mm 88 4 3 48 90 9 3 58 93 4 3 68 85 4 3 36 84 3 3 32 87 4 3 44 86 1 3 39 91 2 3 59 89 4 3 52 95 9 3 78 93 4 3 68 89 0 3 50 86 7 3 41 83 4 3 28 82 6 3 25 85 1 3 35 87 9 3 46 86 7 3 41 91 4 3 60 89 8 3 54 84 2 3 31 Free length mm in 4 91 4 91 4 91 4 92 4 66 4 92 4 66 5 25 4 92 5 65 5 25 5 25 5 25 4 82 4 60 4 82 5 08 4 82 5 39 5 0...

Page 189: ...CH 17605 10 35 32 g Å Standard 8CR 17605 10 38 09 g 8DF 17605 10 37 84 g MM700 VT700 for Europe 8DG 17605 00 39 26 g 8DJ 17605 00 37 77 g VX700 VX700DX VT700 for U S A Canada SX700 8DN 17605 20 42 09 g SCH2860 SCH2861 SCH2863 SCH2865 SCH2867 SCH2869 ...

Page 190: ...SHING TYPE P N Î IDENTIFICATION MARK Width Standard Ï EFFECTS 8CR 17624 00 00 8CR 17624 10 00 8CR 17624 20 00 8CR 17624 30 00 14 5 mm 0 57 in 15 0 mm 0 59 in 15 6 mm 0 61 in 16 0 mm 0 63 in Duralon 90380 09245 00 Duralon 90380 09245 00 Duralon 90380 09245 00 Duralon 90380 09245 00 VX700 VX700DX MM700 VT700 SX700 ...

Page 191: ...ance Adjust the primary clutch as re quired Adjust the secondary clutch as required High altitude tuning OK OK Check to see if the gearing is too high or low OK Not OK Not OK Not OK OK Not OK Not OK OK Check STD settings Carburetors Spark plugs HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions carefully tune the snowmobile as outlined below Test the main jet performan...

Page 192: ...stment steps Turn the spring 1 in or out CAUTION Be sure that the left and right spring preloads are the same WARNING This shock absorber contains highly pressurized nitrogen gas Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock absorber assembly to flames or high heat which could cause it to explode Softer Harder VX700 VX700DX VT700 1 MM700 3 SCH2880 Min M...

Page 193: ...Adjustment steps Loosen the locknut 1 Turn the adjusting nut 2 in or out to adjust the stopper band tension Adjuster VX700 MM700 thread 10 0 5 mm 0 39 0 02 in length a VX700DX 15 0 5 mm 0 59 0 02 in SX700 VT700 25 0 5 mm 0 98 0 02 in Longer Shorter Maximum Minimum Effects More weight Less weight on skis on skis Less weight More weight transfer transfer Tighten the locknut Locknut 1 16 Nm 1 6 m kg ...

Page 194: ...bsorber contains highly pressurized nitrogen gas Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock absorber assembly to flames or high heat which could cause it to explode Spring preload SX700 1 Adjust Spring preload Adjustment steps Turn the spring seat 1 in or out Standard Shorter Longer Preload Harder Softer Spring seat distance Å Front length a ı Rear l...

Page 195: ... desired position CAUTION Be sure the adjusting bolt ends are set at the same position on each side While holding the adjusting bolt securely tighten the nut 1 Nut shock absorber 1 49 Nm 4 9 m kg 35 ft lb CAUTION Never allow the adjusting bolt to move while tightening the nut This model has a Easy adjust system for the Full rateadjuster Thebolthasteethonit Sowhenthe bolt is turned it rides up and ...

Page 196: ...nsion position MM700 1 Adjust Rear suspension position NOTE Select the rear suspension position according to the snow conditions a standard b deep new snow Bolt slide rail suspension 72 Nm 7 2 m kg 52 ft lb REAR SUSPENSION T R SCH2935 ...

Page 197: ...n reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Job name Part name Handlebar removal Handlebar cover Plastic band Oil tank breather hose Thumb warmer coupler Engine stop switch coupler Brake switch coupler Headlight beam switch coupler Grip warmer lead Throttle cable holder Throttle cable Oil pump cable Brake lever holder Master cylinder assembly Handlebar holder up...

Page 198: ...al procedure Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Job name Part name Handlebar removal Handlebar cover Plastic band Oil tank breather hose Thumb warmer coupler Engine stop switch coupler Brake switch coupler Headlight beam switch coupler Grip warmer lead Throttle cable holder Throttle cable Oil pump cable Brake lever holder Master cylinder assembly Handlebar holder upper Cable holder Ha...

Page 199: ... 13 14 15 Job name Part name Steering column and tie rod removal Engine assembly Handlebar Cotter pin Clip Relay rod Lock washer Bearing holder Bearing Collar Steering column Cotter pin Tie rod Washer Washer Bushing Collar Relay arm 80 Nm 8 0 m kg 58 ft lb 23 Nm 2 3 m kg 17 ft lb 35 Nm 3 5 m kg 25 ft lb 43 Nm 4 3 m kg 31 ft lb Q ty 1 1 1 2 3 4 4 1 4 2 2 2 2 1 1 SCH3030 1 ESSO beacon 325 grease or ...

Page 200: ...ring column 1 Collars 2 Wear damage Replace Steering column 3 bearing contact sur faces Scratches wear damage Replace 3 Inspect Relay rod 1 Tie rods 2 Bends cracks damage Replace WARNING Do not attempt to straighten bent rods This may dangerously weaken the rods 4 Check Rod end movement Rod end free play exists Replace the rod end Rod end turns roughly Replace the rod end 5 Inspect Relay arm Crack...

Page 201: ... rod faces out The threads on both rod ends must be the same length CAUTION Always use new cotter pins Locknut rod end 25 Nm 2 5 m kg 18 ft lb LOCTITE Nut tie rod relay arm 35 Nm 3 5 m kg 25 ft lb Nut tie rod steering arm 43 Nm 4 3 m kg 31 ft lb T R SCH3100 SCH3110 SCH3090 Å Tie rod part number ı Set length a Ç Tie rod length b 8CR 23831 00 VX700 VX700DX SX700 VT700 517 2 mm 20 3622 in 454 2 mm 17...

Page 202: ...ction until the handlebars at right angles with respect to the direction of movement Tighten the locknuts relay rod 1 Locknut relay rod 1 25 Nm 2 5 m kg 18 ft lb LOCTITE Turning the relay rod in direction b Turningthehandlebar in direction d Turning the relay rod in direction a Turningthehandlebar in direction c T R 4 Install Relay rod 1 NOTE Make sure that the end of the relay rod with the indent...

Page 203: ...ders 2 Bolt handlebar holder 23 Nm 2 3 m kg 17 ft lb CAUTION First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side For SX700 MM700 The handlebar for the SX700 8CH5 has 8CH 10 stamped on one end for identification The handlebar for the MM700 8ED2 has 8ED 10 stamped on one end Since these handlebars are specifically designed for the SX700 8CH5 ...

Page 204: ...verse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 11 Job name Part name Ski removal Cotter pin Ski stopper Collar Washer Ski column lower bracket Ski runner Collar Collar Ski Washer Ski handle 11 Nm 1 1 m kg 8 0 ft lb Å 21 Nm 2 1 m kg 15 ft lb Ç 48 Nm 4 8 m kg 35 ft lb Î 1 ESSO beacon 325 grease or Aeroshell grease 7A SCH3190 17 Nm 1 7 m kg 12 ft lb ı ...

Page 205: ...n reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 Job name Part name Ski removal Cotter pin Ski column lower bracket Ski stopper Collar Washer Ski Ski runner Washer Ski handle 11 Nm 1 1 m kg 8 0 ft lb Å 21 Nm 2 1 m kg 15 ft lb ı 48 Nm 4 8 m kg 35 ft lb ç 1 ESSO beacon 325 grease or Aeroshell grease 7A SCH3200 ...

Page 206: ...andle 5 Wear cracks damage Replace Mounting bolt 6 Collar 7 Bolts 8 Collars 9 Wear damage Replace Å VX700 VX700DX VT700 ı SX700 MM700 SCH3210 INSTALLATION VX700 VX700DX VT700 1 Install Ski column lower bracket 1 NOTE Besuretoinstalltheskicolumnlowerbracketwiththe arrow mark a pointing forward the tip of the ski SCH3220 SCH3230 A B ...

Page 207: ... procedure Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name Part name Front suspension removal Ski Tie rod Shock absorber Cap Steering arm Ski column Bushing Washer Control rod Collar Bushing Connecting rod Collar Front arm 1 ESSO beacon 325 grease or Aeroshell grease 7A 48 Nm 4 8 m kg 35 ft lb Ç 50 Nm 5 0 m kg 36 ft lb Î 56 Nm 5 6 m kg 40 ft lb 78 Nm 7 8 m kg 56 ft lb Ï 43 Nm 4 3 m kg 31 ft lb ı SCH3...

Page 208: ...ckabsorbercontainshighlycompressed nitrogengas Beforehandlingtheshockabsorber read and make sure that you understand the following information The manufacturer cannot be held responsible for property damage or per sonal injury that may result from improper han dling Do not tamper or attempt to open the gas chamber Do not subject the shock absorber to flames or any other source of high heat This ma...

Page 209: ...3 13 CHAS 4 Inspect Connecting rod 1 Stabilizer 2 Cracks bends damage Replace Collar 3 Wear scratches damage Replace 5 Inspect Front arm 1 Cracks bends damage Replace SCH3280 SCH3290 FRONT SUSPENSION ...

Page 210: ...1 429 7 0 5 mm 16 9173 0 0197 in 428 7 0 5 mm 16 8779 0 0197 in Upper MM700 Ï Lower MM700 Ç Set angle Ì color b White 93 1 93 1 429 7 0 5 mm 16 9173 0 0197 in 428 7 0 5 mm 16 8779 0 0197 in Upper MM700 Ï Lower MM700 Green Ï Lower VX700 VX700DX SX700 VT700 87 1 87 1 475 5 0 5 mm 18 7204 0 0197 in 472 6 0 5 mm 18 6062 0 0197 in Upper VX700 VX700DX SX700 VT700 Ï Lower VX700 VX700DX SX700 VT700 Yellow...

Page 211: ...NOTE Align the punch mark a on the ski column with the punch mark b on the steering arm Install sections c without any gaps Nut steering arm 56 Nm 5 6 m kg 40 ft lb Å VX700 VX700DX VT700 ı SX700 MM700 FRONT SUSPENSION SCH3310 SCH3320 SCH3330 A B ...

Page 212: ...y pan 2 Place the angle finder up against the vertical flat surface on the trailing arm just behind the spindle weld and check the spindle camber 3 To adjust the camber loosen the lower radius rod ball joint locknut and remove the bolt securing the radius rod to the trailing arm Turn the rod in or out as necessary until the proper camber angle is obtained Ski spindle camber 0 5 to 0 5 Angle finder...

Page 213: ...the ball joint outer housing centered with the ball to prevent binding Ski alignment NOTE Be sure to verify the spring preload setting and the ski spindle camber before adjusting the ski toe out since either of those adjustments may affect the ski toe out setting Point the skis straight forward and measure the amount of ski toe out Refer to STEERING SYSTEM in CHAPTER 2 FRONT SUSPENSION Å Ski toe o...

Page 214: ... 3 3 10 10 7 10 8DM 2382E 10 L H 8DM 2382F 10 R H 8CR 2382E 20 L H 8CR 2382F 20 R H 8CS 2382E 20 L H 8CS 2382F 20 R H 8DM 2382E 20 L H 8DM 2382F 20 R H Stabilizer part number VX700 VX700DX SX700 MM700 VT700 Å Part number ı Size length a bar diameter b Ç ID color c 8CR 2386E 00 8CS 2386E 00 8CW 2386E 00 Purple White Light green 896 16 mm 35 2755 0 6299 in 832 16 mm 32 7558 0 6299 in 896 18 mm 35 27...

Page 215: ...r ı Lower Î Length a Angle b 8CR 2384E 20 8CR 2384F 20 8CS 2384E 20 8CS 2384F 20 8CR 2384E A0 8CR 2384F A0 439 5 1 mm 17 3031 0 0394 in 431 6 1 mm 16 9921 0 0394 in 393 7 1 mm 15 5000 0 0394 in 387 7 1 mm 15 2637 0 0394 in 439 5 1 mm 17 3031 0 0394 in 431 6 1 mm 16 9921 0 0394 in 10 8 0 5 10 8 0 5 8 8 0 5 8 8 0 5 10 8 0 5 10 8 0 5 SCH3410 ...

Page 216: ...E V BELT Q ty 1 1 1 Remarks Remove the parts in the order listed below For installation reverse the removal procedure Order 1 2 3 Job name Part name Primary sheave removal V belt Blind cap Primary sheave assembly Å 1st 120 Nm 12 0 m kg 85 ft lb 2nd 60 Nm 6 0 m kg 43 ft lb SCH4010 ...

Page 217: ... 6 1 1 1 1 1 1 6 Remarks Remove the parts in the order listed below VX700DX VT700 For assembly reverse the disassembly proce dure Order 1 2 3 4 5 6 7 8 9 0 A B C D E Job name Part name Primary sheave disassembly Primary sheave cap Primary sheave spring Collar Roller Washer Collar Weight Washer Fixed sheave Starter motor driven gear Stopper Sliding sheave Bushing Spider Slider ...

Page 218: ...Y SHEAVE AND DRIVE V BELT REMOVAL 1 Remove Primary sheave assembly 1 NOTE Usetheprimarysheaveholder2andprimarysheave puller 3 Primary sheave holder 90890 01701 YS 01880 Primary sheave puller YS 01881 1 YS 01882 1 SCH4030 ...

Page 219: ...80 Fit the primary sheave assembly onto the adapter and secure the supporting plates 8 NOTE Securely fit the projections on the adapter into the fixed sheave holes Set the bar wrench 9 onto the spider and turn the special tool clockwise to loosen the spider Clutch spider separator bar wrench 90890 01711 YS 28890 B CAUTION The spider has a left handed thread Since a high torque is required to loose...

Page 220: ...ave spring free length a Out of specification Replace the primary sheave spring Primary sheave spring free length a VX700 VX700DX 89 0 mm 3 50 in SX700 89 4 mm 3 52 in MM700 91 4 mm 3 60 in VT700 83 4 mm 3 28 in NOTE When changing the primary sheave springs refer to GEAR SELECTION in CHAPTER 2 4 Inspect Primary sheave cap bush 1 Sliding sheave bush 2 Cracks damage Replace Clutch bushing press YS 4...

Page 221: ...ID mark 2 side Pressorpeentherivetheadsothatthediameter a of the rivet head measures 8 2 mm 0 32 in or larger 6 Measure Bushing inside diameter Out of specification Replace as a set Bushing inside diameter Å Roller New 9 077 mm 0 357 in Wear limit 9 3 mm 0 366 in ı Weight New 8 077 mm 0 318 in Wear limit 8 3 mm 0 327 in NOTE When replacing the weight and roller bushings use the YXR clutch bushing ...

Page 222: ... to the specified area Never apply it to the bushings and other areas a 16 mm 0 63 in b 30 35 mm 1 18 1 38 in 3 Install Fixed sheave stoppers 1 NOTE Stopper tapered portion should face fixed sheave 4 Tighten Spider Tightening steps Finger tighten the spider until it is stopped by the fixed sheave stopper Hold the fixed sheave with the clutch spider separator 1 Clutch spider separator 90890 01711 Y...

Page 223: ...e sure the spider fixed sheave and special tool are well secured Tighten the spi der carefully to prevent cracks and damage to the sheaves and spider 5 Install Weight Nut 1 6 Nm 0 6 m kg 4 3 ft lb NOTE To maintain the primary sheave balance the bolts 2 mustbeinstalledwiththeirthreadedportionspointing in a counterclockwise direction as illustrated 6 Install Primary sheave spring 1 Primary sheave ca...

Page 224: ...Tighten Bolts Tightening steps Temporarity tighten the bolts 1 6 in the order shown Bolt starter motor driven gear 1 6 19 Nm 1 9 m kg 13 ft lb NOTE Clean the threads Apply LOCTITE 648 SCH4220 T R PRIMARY SHEAVE AND DRIVE V BELT ...

Page 225: ...imary sheave 3 using the primary sheave holder 2 and tighten the bolt primary sheave to specification Primary sheave holder 90890 01701 YS 01880 Bolt primary sheave 1 initial tightening 120 Nm 12 0 m kg 85 ft lb Loosen the bolt primary shave completely Retighten the bolt primary sheave to specifica tion Bolt primary sheave 1 60 Nm 6 0 m kg 43 ft lb 4 Adjust V belt position Refer to DRIVE V BELT in...

Page 226: ...rts in the order listed below Refer to SHEAVE DISTANCE AND OFFSET ADJUSTMENT in CHAPTER 2 For installation reverse the removal procedure Order 1 2 3 4 5 Job name Part name Secondary sheave removal V belt Washer Shim Collar Secondary sheave assembly 64 Nm 6 4 m kg 46 ft lb Å SCH4260 ...

Page 227: ...ure Order 1 2 3 4 5 6 7 Job name Part name Secondary sheave disassembly Spring seat Secondary sheave spring Secondary sheave plate 1 Fixed sheave Stopper Sliding sheave Secondary sheave plate 2 1 ESSO beacon 325 grease or Aeroshell grease 7A 6 5 Nm 0 65 m kg 4 6 ft lb ı 10 Nm 1 0 m kg 7 2 ft lb Ç 4 Nm 0 4 m kg 2 9 ft lb Å SCH4270 23 Nm 2 3 m kg 17 ft lb Î ...

Page 228: ...e instruc tions thoroughly 1 Remove Nuts spring seat INSPECTION 1 Inspect Sliding sheave 1 Fixed sheave 2 Spring seat 3 Cracks damage Replace Stopper 4 Wear damage Replace 2 Inspect Bushing spring seat 1 Sliding sheave V belt contact surface 2 Scratches wear damage Replace Sliding bushing 3 Unsymmetrical wear damage Replace 3 Inspect Secondary sheave spring 1 Cracks damage Replace 4 Measure Second...

Page 229: ... kg 4 6 ft lb 2 Install Fixed sheave 1 Bolts 2 along with the shims Bolt 2 10 Nm 1 0 m kg 7 2 ft lb 3 Install Secondary sheave spring 1 Spring seat 2 NOTE Hook the end of the secondary sheave spring into the spring holes in the fixed sheave Hook the other end of the spring into the holes in the spring seat Standard spring position 3 3 VX700 VX700DX SX700 1 6 MM700 VT700 T R T R SCH4320 SCH4330 SCH...

Page 230: ...ntil the bolts come through the holes While pushing down on the spring seat install the nuts and tighten them to the specified torque Nut spring seat 23 Nm 2 3 m kg 17 ft lb 4 Measure Secondary sheave clearance a Out of specification Adjust Secondary sheave clearance a 35 0 35 8 mm 1 38 1 41 in 5 Calculate Shim thickness NOTE For example if the clearance is 36 mm 1 42 in install a 0 5 mm 0 02 in s...

Page 231: ...ecommends keeping the original shims Shims Part number Thickness 90201 061H1 0 5 mm 0 02 in 90201 06037 1 0 mm 0 04 in SCH4380 INSTALLATION 1 Lubricate Splines fixed sheave Recommended grease ESSO beacon 325 grease or Aeroshell grease 7A 2 Tighten Secondary sheave bolt 64 Nm 6 4 m kg 46 ft lb 3 Adjust V belt position Refer to DRIVE V BELT in CHAPTER 2 Sheave distance Sheave offset Secondary sheave...

Page 232: ...Order 1 2 3 4 5 6 7 8 9 10 Job name Part name Drive chain housing removal Brake caliper Parking brake Chain tension adjuster Bolt Drive chain housing cover Chain tensioner Roller Drive sprocket Collar Drive chain Driven sprocket Collar Drive chain housing DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL SCH4390 16 Nm 1 6 m kg 11 ft lb Å 24 Nm 2 4 m kg 17 ft lb ı 48 Nm 4 8 m kg 35 ft lb Ç 60 Nm 6 0 m kg 4...

Page 233: ...er as a set Replacement steps Remove the circlip 5 drive chain housing Remove the bearing s 3 using a general bear ing puller Install the new bearing s NOTE Use a socket 6 that is the same size as the outside diameter of the bearing race CAUTION Do not strike the inner race 7 or ball bearings 8 Contact only the outer race 9 Install a new circlip drive chain housing CAUTION Always use new circlips ...

Page 234: ...e chain Maximum 14 link drive chain section length 133 35 mm 5 25 in Limit 137 35 mm 5 41 in NOTE Measure the length between drive chain pin 1 and E as shown Perform this measurement at two or three different places Ifreplacementisnecessary alwaysreplacethechain and the sprockets as a set 4 Inspect Drive chain 1 Stiffness Clean and lubricate or replace Drive chain plates 2 Damage wear Replace the ...

Page 235: ...ng making sure that there are no gaps C1 C2 Be sure to install the spacers in their original positions otherwise the brake disc and jackshaft will stick Î 0 1 0 5 mm 0 004 0 020 in ESSO beacon 325 grease or Aeroshell grease 7A For the jackshaft and drive chain housing installation refer to JACKSHAFT 2 Fill Drive chain housing oil Refer to DRIVE CHAIN in CHAPTER 2 3 Adjust Drive chain slack Refer t...

Page 236: ... 11 Job name Part name Drive chain housing removal Battery Battery bracket Brake caliper Parking brake Chain tension adjuster Joint Shift rod Shift lever assembly Lever Bolt Drive chain housing cover Joint Lever rod Washer Reverse drive gear Spring WITH REVERSE MODEL SCH4470 16 Nm 1 6 m kg 11 ft lb Ç 24 Nm 2 4 m kg 17 ft lb Î 48 Nm 4 8 m kg 35 ft lb 60 Nm 6 0 m kg 43 ft lb Ï 10 Nm 1 0 m kg 7 2 ft ...

Page 237: ... Spring Journal Reverse driven gear Washer Forward driven sprocket Collar Counter gear Drive sprocket Drive chain Collar Washer Plate Shaft Drive chain housing 16 Nm 1 6 m kg 11 ft lb Ç 24 Nm 2 4 m kg 17 ft lb Î 48 Nm 4 8 m kg 35 ft lb 60 Nm 6 0 m kg 43 ft lb Ï SCH4470 10 Nm 1 0 m kg 7 2 ft lb Å 13 Nm 1 3 m kg 9 4 ft lb ı Remarks For installation reverse the removal procedure ...

Page 238: ... 2 Inspect Drive sprocket 1 Forward driven sprocket 2 Reverse driven gear 3 Reverse drive gear 4 Counter gear 5 Journal 6 Chain tensioner 7 Pitting wear damage Replace Drive chain 8 Wear damage Replace Stiff Clean or replace Shift lever assembly 9 Bearing chain tensioner 0 Pitting damage Replacethebearingandthe inner race holder as a set For the bearing replacement and drive chain inspec tion refe...

Page 239: ...to install the spacers in their original positions otherwise the brake disc and jackshaft will stick Î 0 1 0 5 mm 0 004 0 020 in ESSO beacon 325 grease or Aeroshell grease 7A For the jackshaft and drive chain housing installation refer to JACKSHAFT 2 Install Lever rod 1 3 Adjust Lever rod length a Adjustment steps Loosen the locknuts 2 Turn the lever rod 1 in or out until the specified length is o...

Page 240: ...cknuts 2 Turn the shift rod 1 so that shift rod free play is 0 mm in direction where a can be shortened appropriately and then turn back the shift rod 1 4 turns Tighten the locknuts 6 Fill Drive chain housing oil Refer to DRIVE CHAIN in CHAPTER 2 7 Adjust Drive chain slack Refer to DRIVE CHAIN in CHAPTER 2 SCH4520 DRIVE CHAIN HOUSING ...

Page 241: ...to FUEL PUMP in CHAPTER 7 Refer to DRIVE CHAIN HOUSING For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 Job name Part name Jackshaft removal Secondary sheave Silencer Drive chain housing Collar Brake disc Key Washer Circlip Jackshaft Bearing holder Bearing 8 5 Nm 0 85 m kg 6 1 ft lb Å 23 Nm 2 3 m kg 17 ft lb ı SCH4530 ...

Page 242: ...earing contact surface 3 Scratches wear damage Replace the jackshaft 2 Inspect Bearing holder 1 Cracks damage Replace Bearing 2 Pitting damage Replace 3 Measure Brake disc thickness a Out of specification Replace Minimum thickness a 10 mm 0 39 in Measuring point 1 3 mm 0 04 0 12 in from the edge of the brake disc SCH4540 SCH4550 SCH4560 ...

Page 243: ...n the nuts 3 Tighten the nuts 4 Nut jackshaft 4 60 Nm 6 0 m kg 43 ft lb Retighten the nuts 3 Nut bearing holder 3 23 Nm 2 3 m kg 17 ft lb Tighten the set screws 5 Set screw bearing 5 8 5 Nm 0 85 m kg 6 1 ft lb Install the drive chain housing cover 6 Å Properly install the rubber seal onto the drive chain housing making sure that these are no gaps Tighten the bolts 7 Bolt drive chain housing cover ...

Page 244: ...parts in the order listed below For installation reverse the removal procedure Order 1 2 3 4 5 6 Job name Part name Brake pad removal Cap bolt Retaining pin Pad spring Brake pad Shim 1 Shim 2 6 Nm 0 6 m kg 4 3 ft lb Å 48 Nm 4 8 m kg 35 ft lb ı BRAKE SCH4580 ...

Page 245: ...ccur Do not disconnect any hydraulic connection otherwise the entire system must be disas sembled drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE It is not necessary to disassemble the brake caliper and brake hose in order to replace the brake pads 1 Remove Brake pads 1 NOTE Do not depress the brake lever when the caliper or disc is off the machine oth...

Page 246: ...liper bleed screw and push the pistons into the caliper with your finger Tighten the caliper bleed screw 2 Bleed screw 2 6 Nm 0 6 m kg 4 3 ft lb Install the brake pads and pad spring 3 Inspect Brake fluid level Referto BRAKEFLUIDLEVELINSPECTION in CHAPTER 2 4 Check Brake lever operation A soft or spongy feeling Bleed brake sys tem Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 2 T R SCH46...

Page 247: ...ks Remove the parts in the order listed below Drain For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 Job name Part name Brake caliper and parking brake re moval Brake fluid Brake hose Brake caliper assembly Cotter pin Parking brake cable Pin Pin Collar Spring Brake shoe SCH4620 ...

Page 248: ...emove the parts in the order listed below For assembly reverse the disassembly proce dure Order 1 2 3 4 5 6 7 8 9 Job name Part name Brake caliper disassembly Cap bolt Retaining pin Pad spring Brake pad Shim 1 Shim 2 Bleed screw Oil seal Piston SCH4630 ...

Page 249: ...the piston seals and reinstall the piston Repeat the previous steps to force out the right piston from the caliper body WARNING Never try to pry out the pistons Do not loosen the retaining pin 3 BRAKE CALIPER INSPECTION AND REPAIR Recommended brake component replacement schedule WARNING All internal brake components should be cleaned only with new brake fluid Do not use solvents as they will cause...

Page 250: ...hen ever a caliper is disassembled BRAKE CALIPER ASSEMBLY WARNING All internal parts should be cleaned only with new brake fluid Internal parts should be lubricated with brake fluid when installed Recommended brake fluid DOT 4 Replace the piston seals and dust seals when ever a caliper is disassembled BRAKE CALIPER INSTALLATION 1 Install Brake hose 1 CAUTION When installing the brake hose 1 onto t...

Page 251: ...ter cylinder disassembly Boot Circlip Master cylinder kit Master cylinder body Q ty 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed below Drain For installation reverse the removal procedure Order 1 2 3 4 5 6 7 Job name Part name Brake master cylinder removal Brake fluid Parking brake cable Brake switch Brake lever Parking brake lever Brake hose joint Holder Master cylinder assembly ...

Page 252: ...TER CYLINDER ASSEMBLY WARNING All internal parts should be cleaned only with new brake fluid Internal parts should be lubricated with brake fluid when installed Recommended brake fluid DOT 4 Replace the piston seals and dust seals when ever a caliper is disassembled INSTALLATION 1 Connect Brake hose NOTE Install the brake hose with the mark a facing up wards as shown in the diagram Brake hose join...

Page 253: ...rks Remove the parts in the order listed below Loosen Loosen For installation reverse the removal procedure Order 1 2 3 4 Job name Part name Slide rail suspension removal Rear axle nut Tension adjuster Blind cap Suspension rear plate Slide rail suspension Collar 72 Nm 7 2 m kg 52 ft lb Å SCH4730 ...

Page 254: ...order listed below Loosen Loosen For installation reverse the removal procedure Order 1 2 3 Job name Part name Slide rail suspension removal Rear axle nut Tension adjuster Blind cap Suspension rear plate Slide rail suspension 24 Nm 2 4 m kg 17 ft lb Å ı 72 Nm 7 2 m kg 52 ft lb SCH4740 ...

Page 255: ...Ç 49 Nm 4 9 m kg 35 ft lb 72 Nm 7 2 m kg 52 ft lb Ï Job name Part name Slide rail suspension disassembly Stopper band Hook Bushing Collar Front shock absorber Suspension wheel Collar Wheel bracket Shaft Rubber damper Front pivot arm Bushing Collar Bushing Collar Front pivot arm bracket Bracket Front suspension bracket SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Î 30 Nm 3 0 m kg 22 ft lb SCH4750 ...

Page 256: ...N O P Q R S T Job name Part name Suspension wheel Collar Wheel bracket Circlip Suspension wheel Spacer Bushing Collar Rear suspension bracket Spacer Bushing Collar 24 Nm 2 4 m kg 17 ft lb Å 49 Nm 4 9 m kg 35 ft lb ı 72 Nm 7 2 m kg 52 ft lb Ç å For SX700 SCH4760 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 257: ... VX700DX VT700 VT700 VT700 Order U V W X Y Z a b Job name Part name Rear shock absorber Bushing Collar Pull rod Collar Bushing Rear bracket Collar Suspension wheel Control rod Bushing Bushing 49 Nm 4 9 m kg 35 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı SCH4770 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 258: ...name Rear pivot arm Bushing Collar Collar Rear pivot arm bracket Collar Circlip Suspension wheel Wheel bracket shaft Rear axle Guide wheel Collar Tension adjuster Collar Collar Sliding frame SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı 75 Nm 7 5 m kg 54 ft lb Ç For SX700 VT700 å SCH4780 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 259: ...s Remove the parts in the order listed below Loosen Loosen For installation reverse the removal procedure Order 1 2 Job name Part name Slide rail suspension removal Rear axle nut Tension adjuster Slide rail suspension Collar 72 Nm 7 2 m kg 52 ft lb Å SCH4790 ...

Page 260: ... 35 ft lb 72 Nm 7 2 m kg 52 ft lb Ï Job name Part name Slide rail suspension disassembly Stopper band Hook Rubber collar Rubber collar Shaft Bushing Collar Front shock absorber Front pivot arm Bushing Collar Bushing Collar Front suspension bracket Suspension wheel Collar Wheel bracket SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Î 30 Nm 3 0 m kg 22 ft lb SCH4800 1 ESSO beacon 325 grease or Aerosh...

Page 261: ...Job name Part name Suspension wheel Collar Wheel bracket Front pivot arm bracket Circlip Suspension wheel Collar Bushing Collar Rear suspension bracket Spacer Bushing Collar 24 Nm 2 4 m kg 17 ft lb Å 49 Nm 4 9 m kg 35 ft lb ı 72 Nm 7 2 m kg 52 ft lb Ç SCH4810 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 262: ...Remarks Order U V W X Y Z a Job name Part name Rear shock absorber Bushing Collar Pull rod Collar Bushing Suspension wheel Control rod Bushing Bushing Shaft 49 Nm 4 9 m kg 35 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı SCH4820 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 263: ...e Part name Rear pivot arm Bushing Collar Collar Rear pivot arm bracket Collar Circlip Suspension wheel Wheel bracket shaft Rear axle Guide wheel Collar Tension adjuster Collar Collar Sliding frame SLIDE RAIL SUSPENSION 24 Nm 2 4 m kg 17 ft lb Å 72 Nm 7 2 m kg 52 ft lb ı 75 Nm 7 5 m kg 54 ft lb Ç SCH4830 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 264: ...er band 1 Frayed damage Replace Pull rod 2 Bends damage Replace Shock absorber 3 Oil leaks damage Replace Bushings Wear cracks damage Replace Front pivot arm 4 Rear pivot arm 5 Rear pivot arm bracket 6 Suspension wheel bracket 7 Sliding frame 8 Cracks damage Replace Slide runner 9 Wear damage Replace Å VX700 VX700DX SX700 VT700 ı MM700 SCH4840 SCH4850 SCH4860 B A ...

Page 265: ...g 52 ft lb 2 Install Stopper band 1 NOTE For VX700 VX700DX SX700 VT700 Install the stopper band with a toward the hook and b toward the front suspension bracket For MM700 Install the stopper band with a toward the hook and b toward the shaft Nut stopper band 4 Nm 0 4 m kg 2 9 ft lb INSTALLATION 1 Adjust Slide rail suspension position MM700 Referto REARSUSPENSION inCHAPTER2 SCH4870 SCH4880 T R T R ...

Page 266: ...her plate parts number Ó Washer plate thickness È Upper Ô Lower VX700 90202 16229 8CR 4745A 01 90202 16232 2 5 mm 0 0984 in VX700DX SX700 10 0 mm 0 3937 in 90202 16232 8CR 4745B 00 10 0 mm 0 3937 in MM700 8ED 4745A 00 90202 16229 90202 16231 2 5 mm 0 0984 in 7 5 mm 0 2953 in VT700 8CR 4745A 01 90202 16230 90202 16229 5 0 mm 0 1969 in 2 5 mm 0 0984 in Ï Control rod 2 parts number Control rod 1 part...

Page 267: ...ARY SHEAVE For installation reverse the removal procedure Order 1 2 3 4 5 6 Job name Part name Front axle and track removal Drive chain housing Slide rail suspension Secondary sheave Speedometer gear assembly Cable joint Set bolt Front axle assembly Bearing Track FRONT AXLE AND TRACK 8 Nm 0 8 m kg 5 8 ft lb Å 20 Nm 2 0 m kg 14 ft lb ı Q ty 1 1 2 1 1 1 SCH4900 ...

Page 268: ...123 mm 4 84 in 102 mm 4 02 in 27 mm 1 06 in 39 mm 1 54 in 39 mm 1 54 in 43 1 mm 1 70 in 60 mm 2 36 in 111 9 mm 4 41 in 201 4 mm 7 93 in FRONT AXLE AND TRACK INSPECTION 1 Inspect Track 1 Slide metal 2 Wear cracks damage Replace 2 Inspect Sprocket wheel 1 Wear break damage Replace Front axle 2 Bends scratches excessive damage Replace INSTALLATION 1 Install Sprocket wheels Guide wheels NOTE When pres...

Page 269: ...k with a direction of rotation mark a Install the track with the mark pointing in the direc tion of track rotation For VT700 Be sure it is positioned as shown in the illustration Å VX700 VX700DX SX700 ı MM700 Ç VT700 Î Turning direction Forward SCH4960 SCH4970 SCH4980 FRONT AXLE AND TRACK A B C ...

Page 270: ...pen For installation reverse the removal procedure Q ty 2 2 1 1 1 1 1 1 2 1 1 Job name Part name Exhaust assembly removal Shroud Shroud s stopper wire Spring 1 Spring 2 Spring 3 Exhaust pipe Gasket 1 Gasket 2 Exhaust joint Gasket 3 Spring 4 Spring 5 Exhaust silencer 1st 18 Nm 1 8 m kg 13 ft lb Å SCH5010 2nd 27 Nm 2 7 m kg 19 ft lb ...

Page 271: ... the gasket 3 with its projection a facing the primary sheave side Tighten the bolts 1 6 in a crisscross pattern Bolt exhaust joint 1 6 1st 18 Nm 1 8 m kg 13 ft lb 2nd 27 Nm 2 7 m kg 19 ft lb 2 Install Spring 5 1 Springs 4 2 Spring 3 3 Springs 2 4 Springs 1 5 NOTE Install the springs as shown T R SCH5020 SCH5030 ...

Page 272: ...DX VT700 VX700DX VT700 For installation reverse the removal procedure Q ty 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 Job name Part name Engine removal Exhaust assembly Carburetors Recoil starter AC magneto rotor Primary sheave Coolant Coolant hose 1 Coolant hose 2 Carburetor heating hose 1 Plastic band Carburetor heating hose 3 Battery negative lead Water temperature sensor coupler Ignition coil coupler Rear ...

Page 273: ...d hose routings 1 Fasten Plastic band 1 NOTE Fasten the carburetor heating hose 3 2 without squashing it Clamp the starter motor lead 3 and carburetor heating hose 3 2together so that the white tape on the starter motor lead 3 is positioned behind the front bracket 2 Install Starter motor lead 1 VX700DX VT700 NOTE Route the starter motor lead as shown in the illustra tion SCH5050 SCH5060 SCH5070 ...

Page 274: ...Oil system Refer to OIL PUMP in CHAPTER 2 Cooling system Refer to COOLING SYSTEM in CHAPTER 2 4 Adjust Oil pump cable distance a Refer to OIL PUMP in CHAPTER 2 Distance a 22 1 mm 0 866 0 039 in ENGINE ASSEMBLY SCH5075 ...

Page 275: ... 6 7 8 9 10 Job name Part name Cylinder head and cylinder removal Spark plug cap Clamp Sub wire harness 2 Bracket Plastic band Ignition coil 3 Spacer 1 Ignition coil 2 Spacer 2 Ignition coil 1 Remarks Remove the parts in the order listed below Å 10 Nm 1 0 m kg 7 2 ft lb SCH5080 ı 14 Nm 1 4 m kg 10 ft lb ...

Page 276: ...sor Cylinder head Gasket Cylinder Gasket Clamp Intake manifold Spacer Reed valve seat Reed valve stopper Reed valve Gasket Piston ring Piston pin Piston Bearing Remarks For installation reverse the removal procedure 14 Nm 1 4 m kg 10 ft lb Å 20 Nm 2 0 m kg 14 ft lb Ç 1st 11 Nm 1 1 m kg 8 0 ft lb 2nd 23 Nm 2 3 m kg 17 ft lb ı 23 Nm 2 3 m kg 17 ft lb Î SCH5090 28 Nm 2 8 m kg 20 ft lb ...

Page 277: ... the crankcase Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and the piston pin is still difficult to remove use the piston pin puller Put identification marks on each piston head for reference during reinstallation Piston pin puller 90890 01304 YU 01304 CAUTION Do not use a hammer to drive out the piston pin out 1 Piston pin 2 Piston ...

Page 278: ...of minerals rust Clean 3 Measure Cylinder head warpage Out of specification Resurface Warpage limit 0 03 mm 0 0012 in Straight edge 1 Thickness gauge 2 4 Eliminate Carbon deposits from the cylinders Use the rounded scraper 1 CAUTION Do not use a sharp instrument Avoid damaging or scratching the surface 5 Eliminate Carbon deposits from the piston crown and ring grooves 6 Inspect Piston crown Burrs ...

Page 279: ...erbore C withacylinderbore gauge 1 NOTE Measure the cylinder bore C parallel to and at right angles to the crankshaft Then find the average of the measurements C Maximum D T Maximum of D1 or D2 Maximum of D5 or D6 R Maximum of D1 D3 or D5 Minimum of D2 D4 or D6 If out of specification replace cylinder and re place piston and piston rings as a set Standard Wear limit Cylinder bore C Taper T Out of ...

Page 280: ... Piston skirt diameter P If out of specification rebore or replace cylinder and replace piston and piston rings as a set Piston to cylinder clearance 0 070 0 075 mm 0 0028 0 0030 in Limit 0 15 mm 0 006 in 9 Measure Side clearance piston rings Use the thickness gauge 1 Out of specification Replace the piston and or rings NOTE Eliminate the carbon deposits from the piston ring grooves and rings befo...

Page 281: ...uge 1 Out of specification Replace the rings as a set End gap top 0 35 0 55 mm 0 014 0 022 in End gap 2nd 0 35 0 55 mm 0 014 0 022 in a 20 mm 0 8 in 12 Measure Outside diameter piston pin a Out of specification Replace the piston pin Outside diameter piston pin a 19 995 20 000 mm 0 7872 0 7874 in 13 Measure Piston pin to piston clearance Out of specification Replace the piston Piston pin to piston...

Page 282: ... 15 Measure Valve stopper height a Out of specification Replace the valve stop per Valve stopper height a 10 3 10 7 mm 0 41 0 42 in 16 Measure Reed valve bending limit a Out of specification Replace the reed valve Reed valve bending limit a less than 1 5 mm 0 059 in SCH5250 SCH5260 SCH5270 ...

Page 283: ...ten each screw gradually to avoid warping 3 Install Small end bearing Piston Piston pin Piston pin clip Piston rings NOTE The arrow a on the piston must point toward to the front of the engine Before installing the piston pin clip cover the crankcase with a clean rag so that you do not accidentallydropthepinclipandothermaterialinto the crankcase Position each piston very carefully in its original ...

Page 284: ...5 Install Gasket cylinder NOTE Install the gasket cylinder with its projection a facing the AC magneto side CAUTION Always use new gasket 6 Install Cylinder NOTE Install the cylinder with one hand while compressing the piston rings with the other hand 7 Tighten Nuts cylinder Nut cylinder 28 Nm 2 8 m kg 20 ft lb 8 Install Gaskets cylinder head NOTE Install with the mark a facing upwards and the pro...

Page 285: ...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 NOTE Connect the black leads of the sub wire harness to the ignition coils as follows the longest lead to ignition coil 1 the medium size lead to ignition coil 2 and the sh...

Page 286: ... bracket Damper Clamp Front upper bracket Clamp Water pump cover Gasket Oil hose 2 Lower crankcase Crankshaft assembly Oil seal Upper crankcase 8 Nm 0 8 m kg 5 8 ft lb Å 13 Nm 1 3 m kg 9 4 ft lb ı 15 Nm 1 5 m kg 11 ft lb Ç 40 Nm 4 0 m kg 29 ft lb Remarks Remove the parts in the order listed below VX700DX VT700 VX700DX VT700 For installation reverse the removal procedure 2nd 27 Nm 2 7 m kg 19 ft lb...

Page 287: ...Use the dial gauge Out of specification Replace the defective parts Small end free play a 0 8 1 0 mm 0 03 0 04 in Big end side clearance b Use the thickness gauge Out of specification Replace the defective parts Big end side clearance b 0 25 0 75 mm 0 01 0 03 in 3 Inspect Crankshaft bearing 1 Pitting damage Replace Stopper ring 2 Bends damage Replace Crankshaft oil seals 3 Impeller drive gear teet...

Page 288: ...rackets 3 Front upper brackets 4 Rear bracket 5 Dampers 6 Cracks damage Replace 5 Inspect Impeller driven gear teeth 1 Wear damage Replace the impeller shaft Impeller shaft 2 Bearing 3 Pitting damage Replace 6 Inspect Oil pump Cracks damage Replace Oil hoses Clogs damage Replace SCH5430 SCH5440 SCH5450 ...

Page 289: ... upper crankcase Å NOTE Turn the bearings and labyrinth seal to set the knock pins 1 on the bearings and labyrinth seal into the pin holes 2 in the upper crankcase Å 3 Bearing AC magneto side NOTE Turn bearing 3 to set the knock pin 4 on the upper crankcase Å into the pin hole 5 in the bearing CAUTION The oil seal lip must fit into the crankcase groove SCH5460 SCH5470 SCH5485 SCH5480 ...

Page 290: ...s be sure to check that the crankshaft turns smoothly 4 Tighten Crankcase bolts 1 F M8 80 NOTE Tighten the bolts in order starting with the lowest number and torque the bolts in two stages Bolt crankcase 1 F 1st 13 Nm 1 3 m kg 9 4 ft lb 2nd 27 Nm 2 7 m kg 19 ft lb 5 Tighten Crankcase bolts 1 6 M8 35 NOTE Tighten the bolts in order starting with the lowest number Bolt crankcase 1 6 15 Nm 1 5 m kg 1...

Page 291: ...5 22 ENG a OIL PUMP CRANKCASE AND CRANKSHAFT 6 Install Oil hose 1 NOTE Install so that the mark a on the check valve faces the crankcase SCH5530 ...

Page 292: ...or installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 Job name Part name AC magneto removal Recoil starter Frame cross member AC magneto coupler Plastic band Starter pulley Spacer Magneto rotor Woodruff key Clamp Plate Stator coil assembly 23 Nm 2 3 m kg 17 ft lb Å 48 Nm 4 8 m kg 35 ft lb ı 110 Nm 11 m kg 80 ft lb Ç SCH5540 ...

Page 293: ...sheave holder 90890 01701 YS 01880 2 Remove Magneto rotor 1 NOTE Remove the magneto rotor using the rotor puller 2 Fully tighten the tool holding bolts making sure the tool body is parallel with the magneto rotor If necessary one screw may be backed out slightly to level the tool body Rotor holding puller 90890 01362 YU 33270 SCH5550 SCH5560 ...

Page 294: ...e to remove any oil or grease from the tapered portion of the crankshaft using a cloth dampened with thinner NOTE Pass the magneto leads through the hole and install the grommet in the crankcase 3 Install Magneto rotor Washer Nut CAUTION Be sure to remove any oil or grease from the tapered portion of the magneto rotor using a cloth dampened with thinner NOTE When installing the magneto rotor make ...

Page 295: ...ten Bolts 1 Nut 2 Bolt starter pulley 1 23 Nm 2 3 m kg 17 ft lb Nut magneto rotor 2 110 Nm 11 m kg 80 ft lb NOTE Attach the primary sheave holder to hold the primary sheave Primary sheave holder 90890 01701 YS 01880 T R SCH5590 ...

Page 296: ...For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 11 12 Nm 1 2 m kg 8 7 ft lb Å 18 Nm 1 8 m kg 13 ft lb ı Job name Part name Recoil starter removal Exhaust silencer Starter handle Recoil starter case Drive plate Cam guide Drive plate spring Washer Drive pawl Return spring Sheave drum Starter rope Starter spring SCH5600 ...

Page 297: ...o that it is not pulled into the recoil starter case 4 INSPECTION 1 Inspect Drive plate 1 Cracks bends damage Replace Drive pawl 2 Return spring 3 Cam guide 4 Wear cracks damage Replace Drive plate spring 5 Wear damage Replace Sheave drum 6 Cracks damage Replace Starter spring 7 Cracks bends damage Replace Starter rope 8 Wear breaks damage Replace SCH5610 SCH5620 SCH5630 ...

Page 298: ...eter Mesh the sheave drum hook 4 with the spring hook 5 3 Install Drive pawl 1 Cam guide 2 Drive plate 3 NOTE The cam guide 2 should not be on top of the drive pawl 1 4 Pull about 102 mm 4 in of starter rope out of the cutout portion in the sheave drum and rotate the sheave drum 4 1 2 times counterclockwise to preload the starter spring NOTE Pass the rope through the case hole and make a knot 1 in...

Page 299: ...2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Job name Part name Heat exchanger removal Coolant Coolant filler cap Coolant hose 1 Spring 1 Filler cap body Carburetor heating hose 1 Carburetor heating lever assembly Carburetor heating hose 2 Plastic band Carburetor heating hose 3 Clamp Coolant hose 2 Spring 2 Coolant hose 3 Heat exchanger right Coolant hose 4 Coolant hose 5 Heat exchanger left H...

Page 300: ...13 14 15 16 17 18 19 20 Job name Part name Heat exchanger removal Coolant Coolant filler cap Coolant hose 1 Spring 1 Filler cap body Carburetor heating hose 1 Carburetor heating lever assembly Carburetor heating hose 2 Plastic band Carburetor heating hose 3 Clamp Coolant hose 2 Spring 2 Coolant hose 3 Heat exchanger right Coolant hose 4 Coolant hose 5 Heat exchanger left Heat exchanger rear Coolan...

Page 301: ...ANGER INSPECTION 1 Inspect Coolant hoses 1 Heat exchangers 2 Filler cap body 3 Carburetor heating lever assembly 4 Carburetor heating hoses 5 Cracks damage Replace Å VX700 VX700DX SX700 VT700 ı MM700 SCH6030 SCH6040 A B ...

Page 302: ...e 95 125 kPa 0 95 1 25 kg cm2 14 18 psi Measurement steps Attach the cooling system tester 1 to the coolant filler cap 2 Cooling system tester 90890 01325 YU 24460 01 Apply the specified pressure for 10 seconds and make sure there is no pressure drop INSTALLATION 1 Install Heat exchangers Use the rivet gun SCH6050 HEAT EXCHANGER ...

Page 303: ...tallation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 11 Job name Part name Water pump and thermostatic valve removal Exhaust joint Coolant Thermostatic cover Plain washer Gasket Plastic band Clamp Engine bracket Carburetor heating hose 3 Coolant hose Water pump cover Gasket Impeller 10 Nm 1 0 m kg 7 2 ft lb Å 13 Nm 1 3 m kg 9 4 ft lb ı 33 Nm 3 3 m kg 24 ft lb Ç 90 Nm 9 0 m kg 65 ft l...

Page 304: ...ATION 1 Install Impeller 1 NOTE Attach the primary sheave holder to hold the primary sheave Primary sheave holder 90890 01701 YS 01880 Bolt impeller 10 Nm 1 0 m kg 7 2 ft lb 2 Fasten Plastic band 1 NOTE Fasten the carburetor heating hose 3 2 without squashing it Clamp the starter motor lead 3 and carburetor heating hose 3 2together so that the white tape on the starter motor lead 3 is positioned b...

Page 305: ...heating lever is turned to OFF Unfasten Loosen Disconnect For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 Job name Part name Carburetors removal Intake silencer Carburetor heating lever Carburetor switch T O R S lead Throttle cable Starter cable Clamp Carburetor heating hose Clamp screw Fuel delivery hose Carburetor CARBURETION CARBURETORS SCH7010 ...

Page 306: ...oce dure Order 1 2 3 4 5 6 7 8 9 0 A B C D E Job name Part name Carburetor separation Carburetor heating hose Starter cable holder Collar Spring Screw Starter rod Spring Starter lever Breather hose Top cover Gasket Throttle shaft connecting screw Clamp Connecting plate upper Connecting plate lower SCH7020 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 307: ...sembly Throttle stop screw Carburetor switch T O R S Throttle cable holder Throttle valve assembly Inner throttle lever assembly Boot Starter plunger assembly Pilot mixture screw Spring Washer O ring Float chamber 0 7 Nm 0 07 m kg 0 51 ft lb Å 1 Nm 0 1 m kg 0 7 ft lb ı 1 8 Nm 0 18 m kg 1 3 ft lb Ç 2 5 Nm 0 25 m kg 1 8 ft lb Î SCH7030 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Page 308: ... Part name Gasket Main jet Main jet ring Main nozzle Pilot jet Pilot jet sleeve Float pin Float Needle valve Screw valve seat Valve seat assembly O ring CARBURETORS 0 7 Nm 0 07 m kg 0 51 ft lb Å 1 Nm 0 1 m kg 0 7 ft lb ı 1 8 Nm 0 18 m kg 1 3 ft lb Ç 2 5 Nm 0 25 m kg 1 8 ft lb Î 1 ESSO beacon 325 grease or Aeroshell grease 7A SCH7030 ...

Page 309: ...pressed air 2 Inspect Rubber seals 1 Bearing 2 Wear damage Replace 3 Inspect Float 1 Damage Replace 4 Inspect Valve seat assembly 1 Main nozzle 2 Main jet 3 Main jet ring 4 Pilot jet 5 Pilot jet sleeve 6 Pilot mixture screw assembly 7 Starter plunger assembly 8 Jet needle 9 Bends wear damage Replace Blockage Blow out the jets with compressed air SCH7040 SCH7050 SCH7060 SCH7070 ...

Page 310: ...lean gaso line Always use new gaskets and O rings 1 Tighten Inner parts Pilot air jet 0 7 Nm 0 07 m kg 0 51 ft lb Screw valve seat 1 Nm 0 1 m kg 0 7 ft lb Pilot jet 0 7 Nm 0 07 m kg 0 51 ft lb Main jet 1 8 Nm 0 18 m kg 1 3 ft lb Starter plunger assembly 2 5 Nm 0 25 m kg 1 8 ft lb 2 Measure Float height a Out of specification Adjust Float height a 11 3 15 3 mm 0 44 0 60 in T R SCH7080 SCH7090 ...

Page 311: ...t height is not within specification in spect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by bending the float arm tang 1 on the float Recheck the float height 3 Install Return springs 1 Carburetors No 1 No 3 NOTE Hook the spring hooks 2 to the projections on the connecting lever 3 and carburetor body 4 while twisting the spring cloc...

Page 312: ... 01312 A NOTE Use the adapter outside diameter ø6 hose 2 when attaching the fuel level gauge Loosen the drain screw 3 and start the engine Place the tube along the seam line 4 of the carburetor body Measure the fuel level a with the gauge If the fuel level is incorrect adjust the fuel level Remove the carburetor Inspect the valve seat and needle valve If either is worn replace them both If both ar...

Page 313: ...check the cable lead and hose routings 1 Fasten Carburetor heating hose 1 NOTE Fasten the carburetor heating hose with a clamp 2 at the white mark a 2 Adjust Starter cable free play Refer to STARTER CHOKE CABLE FREE PLAY ADJUSTMENT in CHAPTER 2 3 Bleed Cooling system Refer to COOLING SYSTEM in CHAPTER 2 SCH7150 ...

Page 314: ...r lift up the throttle and oil pump cables Disconnect Disconnect Disconnect Disconnect For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name Part name Fuel pump removal Carburetor heating lever assembly Air filter element Screw Plastic band Wire harness Throttle cable Oil pump cable Intake silencer Fuel hose Fuel delivery hose Vacuum hose Oil hose Fuel pump as...

Page 315: ...sconnect For installation reverse the removal procedure Order 1 2 3 4 5 6 7 8 9 10 11 Job name Part name Fuel pump removal Carburetor heating lever assembly Air filter element Screw Plastic band Wire harness Intake silencer Fuel hose Fuel delivery hose Vacuum hose Oil hose Fuel pump assembly 5 Nm 0 5 m kg 3 6 ft lb Å 10 Nm 1 0 m kg 7 2 ft lb ı SCH7170 ...

Page 316: ...2 Mity vac 90890 06756 YB 35956 Place a container 3 under the end of the fuel delivery hoses 4 Operate the Mity vac 1 while checking that fuel flows from the fuel delivery hoses 4 If fuel does not flow out replace the fuel pump INSTALLATION NOTE After installing all parts refer to CABLE ROUTING in CHAPTER 9 to check the cable lead and hose routings 1 Bleed Oil system Refer to OIL PUMP in CHAPTER 2...

Page 317: ...e switch 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 column and the switch lead colors in the top row For each switch position indicates the terminals with continuity The ex...

Page 318: ... Ch Ch RUN IDLE B Y L R Br W Y R B B Y B W Br O Gy W Y G W R W G W B L W Y W B W Lg C B Y B G R E B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C O B O B O B D LO HI OFF L M G R Y L O B Y R O ...

Page 319: ... K Frame ground S Brake light switch T Tail brake light U Fuel sender V Oil level switch W Speedometer X Oil level indicator light Y Water temperature indicator light Z High beam indicator light Speedometer light Tachometer light Tachometer _ Fuel meter a Headlight b Headlight beam switch c Headlight relay blue d Load control relay black e IGNITION fuse 2 1 VX700 SX700 MM700 2 VX700DX VT700 ı VX70...

Page 320: ...IFICATION Replace the condenser Check the stator coil and pickup coil OK OUT OF SPECIFICATION Replace the stator coil assembly Check the spark plug gap OK OUT OF SPECIFICATION Repair or replace the spark plug Check the spark plug cap resistance OK OUT OF SPECIFICATION Replace the spark plug cap Check the ignition coil resistance OK OUT OF SPECIFICATION Replace the ignition coil Check the engine st...

Page 321: ... and or signal system and or meter system Correct the connection and or replace the rectifier regulator and or CDI unit NOTE For VX700 SX700 MM700 If a short circuit occurred in the lighting system the signal system or the meter system the engine can be started and the vehicle ridden in an emergency by cutting off the load control relay IGNITION SYSTEM ...

Page 322: ...n Replace Condenser capacity 6 800 µF at 20 C 68 F SCH8190 SCH8200 SCH8210 AC MAGNETO 1 Disconnect AC magneto couplers 1 2 Connect Pocket tester to the AC magneto coupler 3 Measure Stator coil pickup coil resistances Out of specification Replace Pickup coil resistance a White Red White Green 189 231 Ω at 20 C 68 F Stator coil resistance b White White 0 36 0 44 Ω at 20 C 68 F ...

Page 323: ...ark plug cap resistance Out of specification Replace Spark plug cap resistance 5 kΩ at 20 C 68 F IGNITION COIL 1 Disconnect Ignition coil lead Spark plug lead 2 Connect Pocket tester to the ignition coil and spark plug lead 3 Measure Primary coil resistance a Secondary coil resistance b Out of specification Replace Primary coil resistance a 0 36 0 48 Ω at 20 C 68 F Secondary coil resistance b 5 4 ...

Page 324: ...out a problem before restarting the engine Be sure to use the standard resistance type spark plug and spark plug cap Otherwise T O R S will not work properly Throttle switch OFF OFF T O R S operating ON OFF Running Idling or starting OFF ON Running Carburetor switch Status Switch Engine Trouble Running B 1 Carburetor switch 2 Throttle switch 3 Throttle cable 4 Throttle stop screw a ON b OFF SCH826...

Page 325: ...Carburetor switch lead 1 2 Connect Pocket tester 3 Check Carburetor switch continuity Faulty Replace Carburetor switch position Continuity Throttle lever is operated No Throttle lever is not operated Yes SCH8330 SCH8060 IGNITION SYSTEM MAIN SWITCH 1 Disconnect Main switch coupler 1 2 Connect Pocket tester 3 Check Main switch continuity Faulty Replace Switch position Continuity OFF Yes ON No Switch...

Page 326: ...ttery terminal Brown 1 Negative battery terminal Brown White 2 Positive tester probe Red 3 Negative tester probe Blue 4 If load control relay does not have continuity between the red and blue terminals replace it EMERGENCY ENGINE STARTING VX700 SX700 MM700 If a short circuit occurred in the lighting system the signal system or the meter system the engine can be started in an emergency by cutting o...

Page 327: ... B Y L R Br W Y R B B Y B W Br O Gy W Y G W R W G W B L W Y W Lg C B Y B G R E B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK Y W BLACK P L R L R L R B O B Y R L Br Br W D B L R Y R B A A B Lg B Lg B W B B B Br B B L d ı Ç Br R e f g Br W L W 30A 10A 10A 20A L ELECTRICAL STARTING SYSTEM VX700DX VT700 CIRCUIT DIAGRAM ELECTRICAL STARTING SYSTEM VX700DX VT700 4 Main f...

Page 328: ...ly to produce sparks so be sure that no flammable gas or fluid is in the vicinity 3 Disconnect Starter relay coupler 4 Connect Starter relay coupler terminals 1 Jumper lead 2 Check Starter motor operation OK 1 Jumper lead 5 Check Starter motor operation NO Replace the starter relay OK Repair or replace the starter motor Charge and or replace the battery Refer to BATTERY CHARGING in CHAPTER 2 NO Ch...

Page 329: ... or IGNITION fuse ELECTRICAL STARTING SYSTEM VX700DX VT700 Check the main switch FAULTY Replace the main switch MAIN SWITCH 1 Disconnect Main switch coupler 1 2 Connect Pocket tester 3 Check Main switch continuity Faulty Replace Switch position Continuity OFF Yes ON No Switch Color code position Br R R W B B W OFF ON START Continuity SCH8060 OK ...

Page 330: ...PTER 5 For assembly reverse the disassembly proce dure Order 1 2 3 4 5 6 7 8 9 0 A B C D E F Job name Part name Starter motor disassembly Starter motor removal Rear bracket O ring Brush plate Brush 1 Brush 2 Brush spring Washer Yoke Clip Pinion stopper Return spring Washer Pinion gear Armature coil Washer Front bracket ELECTRICAL STARTING SYSTEM VX700DX VT700 SCH8070 ...

Page 331: ... 1 between commutator segments Out of specification Scrape mica to proper limits Use a hacksaw blade 2 that is ground to fit Mica undercut a 0 6 mm 0 024 in 4 Measure Armature coil resistance insulation continuity Defect s Replace the starter motor Inspecting steps Connect the pocket tester for the continuity check 1 and the insulation check 2 Measure the armature coil resistances Armature coil re...

Page 332: ...re Note the following points 1 Beforeinstallingthefrontbracketandrearbracket apply bearing grease to the bearings of the front bracket and rear bracket 2 Make sure the front bracket and rear bracket cover are fitted with O rings 3 When installing the rear bracket assembly take care not to scratch the brushes 4 Install Securing bolts starter motor NOTE Align the match marks 1 on the bracket with th...

Page 333: ...W B Y Ch Ch RUN IDLE B Y L R Br W Y R B B Y B W Br O Gy W Y G W R W G W B L W Y W Lg C B Y B G R E B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK Y W BLACK P L R L R L R B O B Y R L Br Br W D B L R Y R B A A B Lg B Lg B W B B B L R G B G B G B A L L Br B G B B Y B L G B d ı Ç Br R e f g Br W HI L W b 30A 10A 10A 20A L CHARGING SYSTEM VX700DX VT700 CIRCUIT DIAGRAM C...

Page 334: ...tartor coil assembly FAULTY Replace the rectifier regulator OK 3 Start the engine and accelerate to 5 000 r min 4 Measure Charging voltage Charging voltage 14 V 5 000 r min Correct connector OK WARNING Be sure the V belt is removed CAUTION Never disconnect battery cables while generator isoperating otherwise therectifier regulatorwill be damaged OUT OF SPECIFICATIONS Check the battery Refer to BAT...

Page 335: ...s Recharge the battery periodically Store the battery in a cool dry place Recharge the battery before reinstalling Specific gravity 1 280 at 20 C 68 F 2 0 Amp for 10 hours new battery 10 hours or until specific gravity reaches 1 280 Distilled water to maximum level line Check once per month or more often as required Battery Electrolyte Initial charg ing rate Recharging rate Refill fluid Refill per...

Page 336: ...Y Ch Ch RUN IDLE B Y L R Br W Y R B B Y B W Br O Gy W Y G W R W G W B L W Y W B W Lg C B Y B G R E B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C O B O B O B D LO HI OFF L M G R Y L O B Y R O...

Page 337: ...ch E CDI unit K Frame ground T Tail brake light Z High beam indicator light Speedometer light Tachometer light a Headlight b Headlight beam switch c Headlight relay blue d Load control relay black e IGNITION fuse 2 f TAIL fuse 2 g HEAD fuse 2 1 VX700 SX700 MM700 2 VX700DX VT700 ı VX700 SX700 MM700 Ç VX700DX VT700 ...

Page 338: ...TTERY CHARGING in CHAPTER 2 For VX700 SX700 MM700 Check the condenser Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the condenser Check the stator coil and pickup coil Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM OK FAULTY Replace the main switch Check the headlight beam switch OK FAULTY Replace the head...

Page 339: ...CATION Replace and or charge the battery Refer to BATTERY CHARGING in CHAPTER 2 For VX700 SX700 MM700 Check the condenser Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the condenser Check the stator coil and pickup coil Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM OK FAULTY Replace the main switch Check ...

Page 340: ...rom the bulb while it is on it will be hot Do not touch the bulb until it cools down 3 Check Bulb s Terminal Continuity 1 2 Yes 1 3 Yes HEADLIGHT BEAM SWITCH 1 Disconnect Headlight beam switch coupler 2 Connect Pocket tester to the headlight beam switch coupler 3 Check Headlight beam switch continuity Faulty Replace Switch position a Continuity b Continuity HI No Yes LO Yes No SCH8380 SCH8390 SCH8...

Page 341: ...e coupler Connect the pocket tester Ω 1 and battery 12 V to the headlight relay terminals as shown Positive battery terminal Green 1 Negative battery terminal Black 2 Positive tester probe Blue White 3 Negative tester probe Yellow 4 If headlight relay does not have continuity be tween the blue white and yellow terminals re place it SCH8420 SCH8410 ...

Page 342: ...B Y Ch Ch RUN IDLE B Y L R Br W Y R B B Y B W Br O Gy W Y G W R W G W B L W Y W B W Lg C B Y B G R E B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C O B O B O B D LO HI OFF L M G R Y L O B Y R...

Page 343: ... K Frame ground Q DC back buzzer 2 R Gear position switch 2 S Brake light switch T Tail brake light U Fuel sender V Oil level switch X Oil level indicator light Y Water temperature indicator light Fuel meter d Load control relay black e IGNITION fuse 2 f TAIL fuse 2 g HEAD fuse 2 1 VX700 SX700 MM700 2 VX700DX VT700 ı VX700 SX700 MM700 Ç VX700DX VT700 ...

Page 344: ...place and or charge the battery Refer to BATTERY CHARGING in CHAPTER 2 For VX700 SX700 MM700 Check the condenser Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the condenser Check the stator coil and pickup coil Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM OK FAULTY Replace the main switch Check the brake...

Page 345: ...700 SX700 MM700 Check the condenser Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the condenser Check the stator coil and pickup coil Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM OK FAULTY Replace the main switch Check the water temperature sensor or oil level switch OK FAULTY Replace the water temperatu...

Page 346: ...VX700 SX700 MM700 Check the condenser Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the condenser Check the stator coil and pickup coil Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM OK FAULTY Replace the main switch Check the fuel sender OK FAULTY Replace the fuel sender Check the load control relay Refer...

Page 347: ...RY CHARGING in CHAPTER 2 Check the stator coil and pickup coil Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM OK FAULTY Replace the main switch Check the gear position switch OK FAULTY Replace the gear position switch Check the load control relay Refer to IGNITION SYSTEM OK FAULTY Replace the load control relay Check...

Page 348: ...erates Yes Brake lever does not operate No SIGNAL SYSTEM SCH8440 GEAR POSITION SWITCH VX700DX VT700 1 Check Gear position switch 1 continuity Faulty Replace Shift lever position Continuity FORWARD No REVERSE Yes DC BACK BUZZER VX700DX VT700 1 Disconnect DC back buzzer coupler 1 2 Connect Battery 3 Check DC back buzzer Does not sound Replace SCH8510 SCH8520 SCH8530 ...

Page 349: ...ition 3 Immerse the water temperature sensor 2 in coolant 3 and check the water temperature sensor operation Water temperature sensor resistance 5 2 6 4 kΩ at 0 C 34 F 0 300 0 364 kΩ at 80 C 176 F 0 170 0 208 kΩ at 100 C 212 F 4 Temperature gauge CAUTION Never heat the coolant to a temperature of 120 C 248 5 F or more 4 If the water temperature sensor operation is defective replace it 5 Install th...

Page 350: ...continuity Faulty Replace Continuity No continuity FUEL SENDER 1 Remove Intake silencer Refer to FUEL PUMP in CHAPTER 7 Fuel sender 1 from the fuel tank 2 Connect Pocket tester to the fuel sender coupler 3 Measure Fuel sender resistance Out of specification Replace Fuel sender resistance full a 4 10 Ω at 20 C 68 F Fuel sender resistance empty b 90 100 Ω at 20 C 68 F Switch position Good condition ...

Page 351: ...8 35 ELEC ...

Page 352: ...h Ch RUN IDLE B Y L R Br W Y R B B Y B W Br O Gy W Y G W R W G W B L W Y W B W Lg C B Y B G R E B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C O B O B O B D LO HI OFF L M G R Y L O B Y R O B ...

Page 353: ...F Variable resistor thumb warmer G Variable resistor grip warmer K Frame ground L Passenger grip warmer switch 3 M Passenger grip warmer right 3 N Passenger grip warmer left 3 O Resistor 3 P Passenger grip warmer relay 3 d Load control relay black e IGNITION fuse 2 f TAIL fuse 2 1 VX700 SX700 MM700 2 VX700DX VT700 3 VT700 ı VX700 SX700 MM700 Ç VX700DX VT700 ...

Page 354: ...heck the condenser Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the condenser Check the stator coil and pickup coil Refer to IGNITION SYSTEM OK OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM OK NO CONTINUITY Replace the main switch Check the grip and thumb warmer OK NO CONTINUITY Replace the grip and or thumb warmer Check the variab...

Page 355: ...OK OUT OF SPECIFICATION Replace the stator coil assembly Check the main switch Refer to IGNITION SYSTEM OK NO CONTINUITY Replace the main switch Check the passenger grip warmer OK NO CONTINUITY Replace the passenger grip warmer Check the passenger grip warmer switch OK NO CONTINUITY Replace the passenger grip warmer switch Check the resistor CORRECT INCORRECT Replace the resistor Check the passeng...

Page 356: ... Check Grip warmer 1 continuity Thumb warmer 2 continuity No continuity Replace both grips together or separately and or the handlebar switch VARIABLE RESISTOR THUMB WARMER 1 Disconnect Variable resistor coupler 1 2 Connect Pocket tester to the variable resistor coupler 3 Check Variable resistor resistance When pulley is turned once Out of specification Replace the variable resistor Variable resis...

Page 357: ...ulley is turned once Out of specification Replace the variable resistor Variable resistor resistance Yellow White Black Red 400 600 Ω at 20 C 68 F GRIP WARMER SYSTEM PASSENGER GRIP WARMER VT700 1 Disconnect Passenger grip warmer coupler 1 2 Connect Pocket tester to the passenger grip warmer coupler 3 Check Passenger grip warmer continuity Nocontinuity Replacebothpassengergrips together or separate...

Page 358: ...warmer switch coupler 3 Check Passenger grip warmer switch continuity Faulty Replace Y L O B LO OFF HI Continuity Y R RESISTOR VT700 1 Disconnect Resistor coupler 1 2 Connect Pocket tester to the resistor coupler 3 Measure Resistor resistance Out of specification Replace Resistor resistance Black Black 1 4 1 7 Ω at 20 C 68 F GRIP WARMER SYSTEM SCH8630 SCH8640 SCH8650 SCH8660 SCH8670 ...

Page 359: ...m the coupler Connect the pocket tester Ω 1 and battery 12 V to the passenger grip warmer relay termi nals as shown Positive battery terminal Blue Red 1 Negative battery terminal Yellow 2 Positive tester probe Blue Red 3 Negative tester probe Orange Black 4 If load control relay does not have continuity between the blue red and orange black termi nals replace it GRIP WARMER SYSTEM ...

Page 360: ...Condition Reference Refer to SIGNAL SYSTEM Refer to WATER TEMPERATURE SENSOR Refer to VARI ABLE RESISTOR GRIP WARMER Water temperature indicator light is good If the water tempera ture indicator light does not come on replace it Overheat Shorting of the water temperature sensor is detected Discontinuity of the variable resistor grip warmer is detected If the CDI unit is working properly the water ...

Page 361: ... GRIP WARMER SYSTEM Refer to VARI ABLE RESIS TOR THUMB WARMER Refer to GRIP WARMER SYSTEM Refer to GRIP WARMER SYSTEM Shorting of grip warmer is detected Discontinuity of the variable resistor thumb warmer is detected Shorting of thumb warmer is detected Abnormal electric source voltage 4 5 6 7 SCH8740 SCH8750 SCH8760 SCH8770 ON Warning light is on OFF Warning light is off s Second ...

Page 362: ... 990 mm 117 7 in MM700 VT700 1 200 mm 47 2 in VX700 VX700DX SX700 VT700 1 115 mm 43 9 in MM700 1 230 mm 48 4 in VX700 SX700 1 330 mm 52 4 in VX700DX VT700 1 215 mm 47 8 in MM700 215 kg 474 lb VX700 229 kg 505 lb VX700DX 222 kg 489 lb SX700 234 kg 516 lb MM700 257 kg 567 lb VT700 4 0 m 13 1 ft 4 0 m 13 1 ft Liquid cooled 2 stroke piston port Crankcase reed valve Forward inclined parallel 3 cylinder...

Page 363: ...0 MM700 VT700 Regular unleaded gasoline Pump Octane R M 88 2 Research Octane 93 for Europe 44 3 L 9 7 Imp gal 11 7 US gal TM33 3 MIKUNI BR9ES NGK 0 7 0 8 mm 0 028 0 031 in V Belt 3 8 1 0 1 Automatic centrifugal engagement Chain 1 739 40 23 VX700 1 773 39 22 VX700DX SX700 VT700 for U S A Canada 1 905 40 21 MM700 1 950 39 20 VT700 for Europe No VX700 SX700 MM700 Yes VX700DX VT700 Monocoque 25 5 1 07...

Page 364: ...ometer light Speedometer light High beam indicator light Water temperature indicator light Oil level indicator light VX700 VX700DX SX700 MM700 VT700 12 V 60 W 55 W 2 12 V 8 W 23 W 1 12 V 1 7 W 1 12 V 1 7 W 1 12 V 1 7 W 1 12 V 1 7 W 1 12 V 1 7 W 1 GENERAL SPECIFICATIONS ...

Page 365: ...in Keystone B 1 20 mm 0 047 in T 2 55 mm 0 100 in Keystone B 1 20 mm 0 047 in T 2 55 mm 0 100 in 0 35 0 55 mm 0 014 0 022 in 0 35 0 55 mm 0 014 0 022 in 0 02 0 06 mm 0 0008 0 0024 in 0 02 0 06 mm 0 0008 0 0024 in Chrome plated Parkerrizing Chrome plated Parkerrizing Model Cylinder head Volume with spark plug Warp limit Cylinder Material Bore size Wear limit Taper limit Out of round limit Piston Pi...

Page 366: ...meter Big end diameter Read valve Material Thickness Bending limit Stopper height VX700 VX700DX SX700 MM700 VT700 55 95 56 00 mm 2 203 2 205 in 291 75 292 30 mm 11 486 11 508 in 0 03 mm 0 0012 in 0 04 mm 0 0016 in 0 03 mm 0 0012 in 90 mm 3 54 in 85 mm 3 35 in 0 25 0 75 mm 0 01 0 03 in 0 026 0 040 mm 0 0010 0 0016 in 0 8 1 0 mm 0 03 0 04 in Needle bearing Needle bearing 26 991 27 000 mm 1 0626 1 06...

Page 367: ...r pump type Coolant type Coolant mixing ratio coolant water Coolant total amount Reservoir tank capacity VX700 VX700DX SX700 MM700 VT700 TM33 3 MIKUNI 8CH10 1 145 2 3 143 8 45 6DGM05 3 1 Q 8 2 3 Q 4 1 0 ø0 8 ø0 8 1 1 2 turns out C A 3 5 ø1 2 ø1 1 11 3 15 3 mm 0 44 0 60 in 36 38 mm 1 42 1 50 in 1 600 100 r min Diaphragm TAIYO GIKEN 22 1 mm 0 866 0 039 in 95 125 kPa 0 95 1 25 kg cm2 14 18 psi Impell...

Page 368: ...5 mm 0 53 0 64 in VX700 SX700 MM700 18 5 21 5 mm 0 73 0 85 in VX700DX VT700 8DN 17641 00 MITSUBOSHI 1 129 1 137 mm 44 4 44 7 in 34 5 mm 1 36 in 32 5 mm 1 28 in 90501 583L4 VX700 VX700DX 90501 582L7 SX700 90501 603L2 MM700 90501 601L7 VT700 White Silver White VX700 VX700DX Yellow Green Yellow SX700 Yellow White Yellow MM700 Pink Pink Pink VT700 60 mm 2 362 in 5 8 mm 0 228 in VX700 VX700DX SX700 6 0...

Page 369: ...334 oz SX700 38 09 g 1 345 oz MM700 VT700 for Europe 90261 06015 VX700 VX700DX 90261 06034 SX700 VT700 for U S A Canada 90261 06028 MM700 90261 06019 VT700 for Europe Steel VX700 VX700DX SX700 VT700 Aluminum MM700 10 3 mm 0 41 in VX700 VX700DX MM700 13 9 mm 0 55 in SX700 VT700 for U S A Canada 13 3 mm 0 52 in VT700 for Europe 3 3 90261 06034 VX700 VX700DX SX700 90261 06028 MM700 90261 06033 VT700 ...

Page 370: ...X SX700 56 MM700 54 VT700 5 5 mm 0 22 in VX700 VX700DX SX700 7 25 mm 0 29 in MM700 6 0 mm 0 24 in VT700 23 mm 0 91 in VX700 VX700DX SX700 50 8 mm 2 00 in MM700 19 mm 0 75 in VT700 25 30 mm 0 98 1 18 in VX700 VX700DX SX700 VT700 20 25 mm 0 79 0 98 in MM700 292 mm 11 5 in 19 6 N mm 2 0 kg mm 112 lb in VX700 VX700DX 14 8 24 5 N mm 1 5 2 5 kg mm 84 140 lb in SX700 29 4 N mm 3 0 kg mm 168 lb in MM700 1...

Page 371: ...lb 0 3 m s MM700 510 N 0 3 m s 52 kg 0 3 m s 115 lb 0 3 m s VT700 1 304 N 0 3 m s 133 kg 0 3 m s 293 lb 0 3 m s VX700 1 020 N 0 3 m s 104 kg 0 3 m s 229 lb 0 3 m s VX700DX 1 950 N 0 3 m s 199 kg 0 3 m s 439 lb 0 3 m s SX700 860 N 0 3 m s 88 kg 0 3 m s 194 lb 0 3 m s MM700 1 775 N 0 3 m s 181 kg 0 3 m s 399 lb 0 3 m s VT700 2 206 N 0 3 m s 225 kg 0 3 m s 496 lb 0 3 m s VX700 VX700DX 2 900 N 0 3 m s...

Page 372: ...00 VX700DX VT700 1 025 mm 40 4 in SX700 1 010 mm 39 8 in MM700 132 0 mm 5 20 in VX700 VX700DX VT700 130 0 mm 5 12 in SX700 139 7 mm 5 50 in MM700 Proaction system 221 mm 8 70 in VX700 VX700DX SX700 VT700 170 mm 6 69 in MM700 Coil spring 22 54 N mm 2 3 kg mm 128 8 lb in VX700 VX700DX VT700 12 74 20 58 24 50 N mm 1 3 2 1 2 5 kg mm 72 8 117 6 140 lb in SX700 20 58 N mm 2 1 kg mm 117 6 lb in MM700 8 2...

Page 373: ...rer No load regulated voltage DC Capacity DC Withstand voltage Battery VX700DX VT700 Specific gravity Manufacturer Type Ten hour rate amperage Electric starter system VX700DX VT700 Type VX700 VX700DX SX700 MM700 VT700 12 V 18 at 1 500 r min Digital type F6T535 MITSUBISHI 6 mm 0 236 in or more 0 36 0 48 Ω at 20 C 68 F 5 4 7 4 kΩ at 20 C 68 F Rubber type 8DF TOKAI DENSO 5 kΩ at 20 C 68 F AC magneto ...

Page 374: ... individual circuit Main fuse Head fuse Tail fuse Ignition fuse Reserve fuse Reserve fuse Reserve fuse Water temperature sensor Model Manufacturer Resistance DB4XF DENSO 12 V 0 6 kW 0 014 0 018 Ω at 20 C 68 F More than 100 kΩ at 20 C 68 F 12 mm 0 47 in 8 5 mm 0 33 in 6 38 9 32 N 650 950 g 22 9 33 5 oz 28 mm 1 10 in 27 mm 1 06 in 0 6 mm 0 024 in MS5F 441 JIDECO 180 A 4 2 4 6 Ω at 20 C 68 F 8CR ASTI...

Page 375: ... 3 MJ 1 145 MJ 2 3 143 8 PJ 45 PS 1 1 2 JN 3 MJ 1 142 5 MJ 2 3 141 3 PJ 50 PS 1 1 2 JN 2 5 MJ 1 140 MJ 2 3 138 8 PJ 52 5 PS 1 5 8 JN 2 MJ 1 137 5 MJ 2 3 136 3 PJ 55 PS 1 7 8 JN 2 MJ 1 135 MJ 2 3 133 8 PJ 57 5 PS 2 JN 2 MJ 1 132 5 MJ 2 3 131 3 PJ 60 PS 2 1 8 JN 2 40 C 29 C 18 C 7 C 4 C 16 C 40 F 20 F 0 F 20 F 40 F 60 F MJ 1 148 8 MJ 2 3 147 5 PJ 45 PS 1 1 2 JN 3 MJ 1 147 5 MJ 2 3 146 3 PJ 45 PS 1 1...

Page 376: ...5 PS 1 1 2 JN 3 MJ 1 145 MJ 2 3 143 8 PJ 45 PS 1 1 2 JN 3 MJ 1 142 5 MJ 2 3 141 3 PJ 50 PS 1 1 2 JN 2 5 MJ 1 140 MJ 2 3 138 8 PJ 52 5 PS 1 5 8 JN 2 MJ 1 137 5 MJ 2 3 136 3 PJ 55 PS 1 7 8 JN 2 MJ 1 135 MJ 2 3 133 8 PJ 57 5 PS 2 JN 2 MJ 1 132 5 MJ 2 3 131 3 PJ 60 PS 2 1 8 JN 2 40 C 29 C 18 C 7 C 4 C 16 C 40 F 20 F 0 F 20 F 40 F 60 F MJ 1 148 8 MJ 2 3 147 5 PJ 45 PS 1 1 2 JN 3 MJ 1 147 5 MJ 2 3 146 3...

Page 377: ... 1 1 2 JN 3 MJ 1 145 MJ 2 3 143 8 PJ 45 PS 1 1 2 JN 3 MJ 1 142 5 MJ 2 3 141 3 PJ 50 PS 1 1 2 JN 2 5 MJ 1 140 MJ 2 3 138 8 PJ 55 PS 1 5 8 JN 2 MJ 1 137 5 MJ 2 3 136 3 PJ 57 5 PS 1 7 8 JN 2 MJ 1 135 MJ 2 3 133 8 PJ 60 PS 2 JN 2 MJ 1 132 5 MJ 2 3 131 3 PJ 62 5 PS 2 1 8 JN 2 40 C 29 C 18 C 7 C 4 C 16 C 40 F 20 F 0 F 20 F 40 F 60 F MJ 1 148 8 MJ 2 3 147 5 PJ 45 PS 1 1 2 JN 3 MJ 1 147 5 MJ 2 3 146 3 PJ ...

Page 378: ...ine Engine bracket right rear and engine Engine bracket left rear and engine Engine bracket rear and frame Exhaust joint 1st 2nd Water pump cover Cylinder head Nut 1st 2nd Cylinder Nut Spark plug Water temperature sensor Ignition coil and bracket Thermostatic cover Oil pump Oil pump cable adjuster locknut Fuel pump Starter pulley Drive plate Recoil starter case Clamp and intake manifold Bracket an...

Page 379: ... cover Shaft reverse drive gear Chain housing and brake caliper Bleed screw brake caliper Brake hose Brake hose joint Brake master cylinder side Brake hose side Bearing set screw jackshaft Bearing holder jackshaft Stopper band Hook and front pivot arm Wheel bracket and sliding frame Bracket bolt rear Bracket bolt front Front suspension bracket bolt rear Front suspension bracket bolt front Shaft an...

Page 380: ...liding frame Set bolt front axle Speedometer gear assembly 72 8 20 7 2 0 8 2 0 52 5 8 14 NOTE Tightening steps 1 Tighten the bolt to a torque of 120 Nm 12 m kg 85 ft lb 2 Loosen the bolt completely 3 Retighten the bolt to a torque of 60 Nm 6 0 m kg 43 ft lb MAINTENANCE SPECIFICATIONS Apply LOCTITE ...

Page 381: ...lay rod Relay rod and relay arm Relay arm and tie rod Tie rod and steering arm Relay arm Locknut relay rod tie rod Ski Ski runner Ski column lower bracket Ski and ski handle M7 55 Ski and ski handle M7 100 Ski and ski handle Shock absorber upper Shock absorber lower Steering arm and ski column Lower control rod and frame Upper control rod and frame Control rod and front arm Front arm pivot bolt St...

Page 382: ...e General torque specifications Nm m kg ft lb A nut B bolt 4 3 11 22 40 61 94 6 15 30 55 85 130 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 0 6 1 5 3 0 5 5 8 5 13 0 A Distance across flats B Outside thread diameter DEFINITION OF UNITS Unit Read Definition Measurement mm cm kg N Nm m kg Pa N mm L cm3 r min Millimeter Centimeter Kilogram Newton Newton meter Meter kilogram P...

Page 383: ...9 22 SPEC ...

Page 384: ...SPEC 9 23 CABLE ROUTING SCH9010 ...

Page 385: ...gative leads and starter relay leads to the coolant hose with a plastic band VX700DX VT700 6 Fasten the coolant reservoir hose and coolant hose with a plastic clamp 7 Ensure this is not kink 8 Fasten the starter motor and battery negative leads to the coolant hose with a plastic band above the brake caliper VX700DX VT700 9 Route the starter motor and battery negative leads behind the coolant hose ...

Page 386: ...SPEC 9 25 CABLE ROUTING SCH9010 ...

Page 387: ...passes over the oil pump and throttle cables and through the right side of the hose guide J Oil pump cable VX700 VX700DX VT700 K Throttle cable VX700 VX700DX VT700 L Oil level switch M Variable resistor couplers N Fuse box VX700DX VT700 O Route the oil pump and throttle cables in the groove of the intake silencer and route the throttle cable above the oil pump cable VX700 VX700DX VT700 P Carbureto...

Page 388: ...SPEC 9 27 CABLE ROUTING SCH9020 ...

Page 389: ...9 28 SPEC CABLE ROUTING 1 Brake hose 2 Oil pump cable 3 Throttle cable 4 Wire harness 5 Starter cable ...

Page 390: ...SPEC 9 29 CABLE ROUTING SCH9030 ...

Page 391: ...l tank breather hose fuel tank breather hose and wire harness at the inside of the instrument panel screw with a plastic band Route the tail brake light lead between the fuel tank and the snowmobile body Make sure that the fuel tank does not crush the tail brake light lead Then fasten the three pieces of adhesive tape below the fuel tank as shown A Adhesive tapes B To the tail brake light C Pass t...

Page 392: ...SPEC 9 31 CABLE ROUTING SCH9030 ...

Page 393: ...erminal N Route the fuel tank breather hose behind the condenser VX700 SX700 MM700 O Condenser VX700 SX700 MM700 P Fasten the condenser leads and CDI unit leads with a plastic band Q CDI unit R Pass the CDI unit lead behind the footrest S Condenser coupler VX700 SX700 MM700 T Load control relay black U Headlight relay blue V Rectifier regulator ...

Page 394: ...SPEC 9 33 CABLE ROUTING SCH9040 ...

Page 395: ...achometer coupler 3 Plastic band 4 Clamp 5 Headlight leads 6 Speedometer cable 7 Fasten the headlight leads and speedometer cable at the white tape mark with a plastic band 8 Route the wire harness and speedometer cable under the shroud s stopper wire ...

Page 396: ...SPEC 9 35 CABLE ROUTING SCH9050 ...

Page 397: ... oil tank breather hose with a plastic band D Fasten the wire harness and the oil tank breather hose behind the steering column with a plastic band Do not fasten the parking brake cable and brake hose E Fasten the wire harness and fuel tank breather hose with a plastic band Be sure to position the fastener facing downward F Fuse box VX700DX VT700 G Condenser coupler H Ground lead I Fuel sender cou...

Page 398: ...SPEC 9 37 CABLE ROUTING SCH9050 ...

Page 399: ... Z Passenger grip warmer relay VT700 DC back buzzer VX700DX VT700 DC back buzzer coupler VX700DX VT700 DC back buzzer coupler VX700 SX700 MM700 _ Connectors of the gear position switch VX700 SX700 MM700 a Pass the brake hose through the hose guide b Connectors of the gear position switch VX700DX VT700 c To the gear position switch d Ensure this is not kink e Fasten the wire harness fuel tank breat...

Page 400: ...SPEC 9 39 CABLE ROUTING SCH9060 ...

Page 401: ...around the wire harness 4 Connectors of the carburetor switch 5 Water temperature sensor coupler 6 Starter relay lead VX700DX VT700 7 Ignition coil coupler 8 Make sure a plastic band is fastened around the wire harness to prevent the coolant reservoir hose from kinking 9 AC magneto couplers 0 Starter relay coupler VX700 SX700 MM700 A To the coolant reservoir tank B Coolant reservoir hose C Wire ha...

Page 402: ...retor switch D Water temperature sensor E CDI unit F Variable resistor thumb warmer G Variable resistor grip warmer H Ignition coil I Spark plug J Engine ground K Frame ground L Passenger grip warmer switch 3 M Passenger grip warmer right 3 N Passenger grip warmer left 3 O Resistor 3 P Passenger grip warmer relay 3 Q DC back buzzer 2 R Gear position switch 2 S Brake light switch T Tail brake light...

Page 403: ...W B Y Ch B Y B W B RUN OFF OFF OPEN 0 9 B W B Y Ch Ch RUN IDLE B Y L R Br W Y R B B Y B W Br O Gy W Y G W R W G W B L W Y W B W Lg C B Y B G R E B W Y Br W Lg G R O W Br Gy B Y R WHITE G W G B Y Y B L W L R W B W R Y W BLACK I H O B B W I H B B W I H J B B K B Y W W B Y W B R Y W G W B Y W B R L W W B L W F W B BLACK BLACK BLACK BLACK BLACK P L R L R L R B O B Y L R O B L R Y R L Br Br W O B O B C...

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