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Yamaha VX500SXBC, Service Manual

The Yamaha VX500SXBC Service Manual is an essential companion for maintaining and repairing your Yamaha VX500SXBC. With easy-to-follow instructions and comprehensive diagrams, this manual ensures you have all the information needed to keep your vehicle in top shape. Download this manual for free at manualshive.com.

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–26–

BRAKE

POWR

TR

NOTE:

2. Install:

S

Brake pads

S

Pad spring

Installation steps:

S

Connect a suitable hose 

1

 tightly to the

caliper bleed screw 

2

. Put the other

end of this hose into an open container.

S

Loosen the caliper bleed screw and
push the pistons into the caliper with
the finger.

S

Tighten the caliper bleed screw 

2

.

Bleed screw:

6 Nm (0.6 m

S

kg, 4.3 ft

S

lb)

S

Install the brake pads and pad spring.

The tangs 

a

 of the pad spring must point in

the direction of the disc rotation.

3. Inspect:

S

Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION”.

4. Check:

S

Brake lever operation
A soft or spongy feeling 

!

 Bleed brake

system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)”.

Summary of Contents for VX500SXBC

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

Page 2: ...UPPLEMENTARY SERVICE MANUAL 1998 by Yamaha Motor Corporation U S A 1st Edition March 1998 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A OE011 HOW TO USE THIS MANUAL Particularly important information is distin guished in this manual by the following notations The Safety Alert Symbol m...

Page 3: ...cations Illustrated symbols 11 to 17 are used to iden tify the specifications which appear 11 Filling fluid 12 Lubricant 13 Tightening 14 Wear limit clearance 15 Engine speed 16 Special tool 17 Ω V A Illustrated symbols 18 to 26 in the exploded diagram indicate grade of lubricant and location of lubrication point 18 Apply locking agent LOCTITE 19 Apply Yamabond No 5 20 Apply engine oil 21 Apply ge...

Page 4: ... HOUSING 18 WITHOUT REVERSE MODEL 500 18 INSTALLATION 19 DRIVE CHAIN HOUSING AND JACKSHAFT INSTALLATION 20 WITH REVERSE MODEL 700 21 INSTALLATION 23 JACKSHAFT 23 INSPECTION 23 BRAKE 24 BRAKE PAD REPLACEMENT 25 SLIDE RAIL SUSPENSION 27 FRONT AXLE AND TRACK 32 INSTALLATION 32 ENGINE 33 ENGINE ASSEMBLY 33 500 33 700 34 CYLINDER HEAD AND CYLINDER 35 INSPECTION 35 COOLING SYSTEM 37 HEAT EXCHANGER 37 CA...

Page 5: ... hand side of the frame just below the front of the seat ENGINE SERIAL NUMBER The engine serial number 1 is located on the right hand side of the crankcase Designs and specifications are subject to change without notice IMPORTANT INFORMATION LOCTITE After installing fasteners that have LOC TITE applied wait 24 hours before using the machine This will give the LOCTITE time to properly dry ...

Page 6: ...necessary To ensure proper clutch perfor mance the V belt position should be ad justed by adding a spacer on each adjusting bolt when the V belt position reaches below the edge For this adjustment consult a Yamaha deal er or another qualified mechanic New belt width 35 0 mm 1 38 in 500 34 5 mm 1 36 in 700 Belt wear limit width 33 0 mm 1 30 in 500 32 5 mm 1 28 in 700 1 Measure SV belt position a or...

Page 7: ...ect SDrive V belt Cracks damage wear Replace Oil or grease on the V belt Check the primary and secondary sheaves 5 Inspect SPrimary sheave SSecondary sheave Oil or grease on the primary and sec ondary sheaves Use a rag soaked in lacquer thinner or solvent to remove the oil or grease Check the primary and secondary sheaves 6 Measure SDrive V belt length a Out of specification Replace Drive V belt l...

Page 8: ...nspect SBrake pad Wear indicator 1 nearly contacts the brake disc Replace the brake pads as a set Wear limit a 4 7 mm 0 185 in SLIDE RUNNER INSPECTION 1 Inspect SSlide runner 1 Cracks damage wear Replace 2 Measure SSlide runner thickness 2 Out of specification Replace Slide runner wear limit 10 mm 0 39 in ...

Page 9: ...crew 1 3 4 STD Gearing 22 39 70L 21 39 68L 20 39 68L 19 39 68L Primary spring Color Length Preload rate Wire diameter Outside diameter W P W 78 7 mm 30 kg 2 25 kg mm ø5 5 mm ø60 mm z z z z z Y P Y 77 4 mm 30 kg 2 5 kg mm ø5 8 mm z O P O 74 6 mm 30 kg 3 25 kg mm ø6 0 mm z Weight 1D Weight rivet Weight bushing 8CR Steel 13 9 OUT Aluminum 10 3 IN Duralon z Aluminum 10 3 OUT None IN z z None OUT None ...

Page 10: ... 70L Primary spring Color Length Preload rate Wire diameter Outside diameter W S W 81 0 mm 35 kg 2 25 kg mm ø5 5 mm ø48 0 mm G P G 76 3 mm 30 kg 2 75 kg mm ø5 8 mm ø48 0 mm P 75 4 mm 30 kg 3 0 kg mm ø6 0 mm ø60 0 mm z z z z z Weight 1D Weight rivet Weight bushing 8CH 00 Steel 10 3 OUT Steel 13 9 IN Duralon z Steel 10 3 OUT Steel 13 9 IN z z Aluminum 10 3 OUT Steel 13 9 IN z z None OUT Steel 13 3 I...

Page 11: ...machine has been started at full throttle from a dead stop and has travelled 200 X 300 m 650 X 1 000 ft Normally when a machine reaches shifting speed the vehicle speed increases but the engine speed remains nearly constant Un der unfavorable conditions wet snow icy snow hills or rough terrain however en gine speed may decrease after the shifting speed has been reached A Engine speed B Good condit...

Page 12: ...n gear ratios while the number on the follow ing line followed by an L designates the number of chain links Do not set the gearing to any of the indicated x settings 1 Chain and sprocket parts number Parts name Teeth Links Parts No Standard 18T 89J 17682 80 19T 89J 17682 91 Drive sprocket 20T 89J 17682 00 Drive sprocket 21T 89J 17682 10 22T 89J 17682 20 VX500 VX700 23T 89J 17682 30 39T 89J 47587 9...

Page 13: ... 5 2 BROWN 5 0 75 90508 536A9 7147 729 5 5 RED 5 3 75 VX500 90508 556A2 8314 848 5 5 GREEN 5 5 75 VX700 90508 556A7 9460 965 4 8 SILVER 5 5 75 4 Secondary spring twist angle 0 3 6 9 1 10_ 40_ 70_ 100_ 2 20_ 50_ 80_ 110_ 3 30_ 60_ 90_ 120_ 5 Torque cam secondary spring seat Parts No Cam angle Standard 8BV 17604 10 41_ 8BV 17604 30 43_ VX500 8BV 17604 50 45_ VX700 8BV 17604 70 47_ 8BV 17604 90 39_ ...

Page 14: ...01 550J8 22 2 25 294 30 W P W 5 5 60 4 62 78 7 VX500 90501 553G6 22 2 25 245 25 W Y W 5 5 60 4 61 76 5 90501 555J9 22 2 25 343 35 W S W 5 5 48 4 66 81 0 VX700 90501 556G5 22 2 25 196 1 20 W B W 5 5 60 4 62 74 3 90501 557G6 22 2 25 147 15 W G W 5 5 60 4 62 72 1 90501 556G7 24 5 2 5 196 1 20 Y G Y 5 5 60 4 36 73 4 90501 581J7 24 5 2 5 245 25 Y 5 8 60 4 96 75 4 90501 582J1 24 5 2 5 294 30 Y P Y 5 8 6...

Page 15: ...load 500 1 Adjust STurn the spring seat 1 in or out Spring seat distance Standard Shorter z Longer Preload Harder z Softer Length Max Min 213 mm 223 mm 233 mm 8 39 in 8 78 in 9 17 in This shock absorber contains highly pressu rized nitrogen gas Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock absorber assembly to an open flame or high temperature as this c...

Page 16: ... nut 2 in or out to adjust the stopper band tension Adjuster Thread length Longer z Shorter maximum minimum STD 500 15 mm 0 59 in 700 10 mm 0 39 in Effects More weight Less on skis Less weight on weight skis More transfer weight transfer S Tighten the locknut Spring preload 700 1 Adjust STurn the adjusting ring 1 to the proper position Spring adjuster position 1 2 3 4 5 Preload Softer z Harder Sta...

Page 17: ...fter Length front Max Min 172 mm 182 mm 192 mm 6 77 in 7 17 in 7 56 in Length rear Max Min 302 mm 312 mm 322 mm 11 89 in 12 28 in 12 68 in This shock absorber contains highly pressu rized nitrogen gas Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock absorber assembly to an open flame or high heat which could cause it to explode ...

Page 18: ...bracket Ski stopper Collar Washers Ski Ski runner Washers Ski handle 1 1 1 1 6 1 1 6 1 Remove the parts in the order below For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb A 21 Nm 2 1 mSkg 15 ftSlb B 48 Nm 4 8 mSkg 35 ftSlb C ESSO beacon 325 grease or Aeroshell grease 7A CHASSIS SKI 500 ...

Page 19: ...bsorber read and make sure that you understand the following information The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling D Do not tamper or attempt to open the gas chamber D Do not subject the shock absorber to an open flame or any other source of high heat This may cause the unit to explode due to excessive gas pressure D D...

Page 20: ...mm 18 012 0 0197 in 93 1 Lower 472 6 0 5 mm 18 606 0 0197 in 93 1 Right hand Model Set length mm Set angle _ VX500 Upper 460 2 0 5 mm 18 11 0 0197 in 86 1 Lower 458 7 0 5 mm 18 059 0 0197 in 86 1 VX700 Upper 475 5 0 5 mm 18 012 0 0197 in 87 1 Lower 472 6 0 5 mm 18 606 0 0197 in 87 1 A 14 mm 62 X 84 Nm 6 2 X 8 4 mSkg 14 mm 45 X 60 ftSlb 2 Install SSteering arm 1 Align the punch mark a on the ski co...

Page 21: ...nd of the spring into the holes in the spring seat Standard spring position 500 3 6 700 3 3 Installation steps D Hold the spring seat 1 and turn the slid ing sheave 2 counterclockwise to the specified angle a The holes in the spring seat should align with the bolts on the fixed sheave a sheave side hole number spring seat hole number 10 Standard angle 500 90_ 700 60_ D Push down on the spring seat...

Page 22: ...Collar Drive chain Driven sprocket Collar Drive chain housing 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order below Refer to BRAKE Loosen Refer to SLIDE RAIL SUSPENSION Oil drain For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb A 24 Nm 2 4 mSkg 17 ftSlb B 48 Nm 4 8 mSkg 35 ftSlb C 60 Nm 6 0 mSkg 43 ftSlb D DRIVE CHAIN HOUSING POWR TR DRIVE CHAIN HOUSING WITHOUT REVERSE MOD...

Page 23: ...ing seals face towards the drive chain as shown B Properly install the rubber seal onto the drive chain housing making sure that these are no gaps C Be sure to install the spacers in their original positions of the brake disc and jackshaft will stick D 0 1 X 0 5 mm 0 004 X 0 020 in ESSO beacon 325 grease or Aero shell grease 7A ...

Page 24: ... Bolt drive chain housing 48 Nm 4 8 mSkg 35 ftSlb D Temporarily tighten the nuts 3 D Tighten the nuts 3 Nut jackshaft 60 Nm 6 0 mSkg 43 ftSlb D Retighten the nuts 3 Nut bearing holder 23 Nm 2 3 mSkg 17 ftSlb D Tighten the set screws 5 Set screw bearing 8 5 Nm 0 85 mSkg 6 1 ftSlb D Install the drive chain housing cover 6 D Tighten the bolts 7 Bolt drive chain housing cover 24 Nm 2 4 mSkg 17 ftSlb ...

Page 25: ... Shift rod Shift lever assembly Lever Joints Lever rod Bolt Drive chain housing cover Washer 2 1 1 1 2 1 1 1 1 Remove the parts in the order below Refer to BRAKE Loosen Refer to SLIDE RAIL SUSPENSION Oil drain 10 Nm 1 0 mSkg 7 2 ftSlb A 24 Nm 2 4 mSkg 17 ftSlb B 48 Nm 4 8 mSkg 35 ftSlb C 60 Nm 6 0 mSkg 43 ftSlb D DRIVE CHAIN HOUSING POWR TR WITH REVERSE MODEL 700 ...

Page 26: ... gear Spring Chain tensioner Roller Collar Spring Journal Reverse driven gear Washer Forward driven sprocket Collar Counter gear Drive sprocket Drive chain Collar Washer Plate Shaft Drive chain housing 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure DRIVE CHAIN HOUSING POWR TR ...

Page 27: ...face towards the drive chain as shown C Be sure to install the spacers in their original positions of the brake disc and jackshaft will stick D 0 1 X 0 5 mm 0 004 X 0 020 in ESSO beacon 325 grease or Aero shell grease 7A Drive chain housing and jackshaft installa tion steps refer to the WITH OUT REVERSE MODEL JACKSHAFT INSPECTION 1 Measure SBrake disc thickness a Out of specification Replace Minim...

Page 28: ...taining pin Pad spring Brake pads Shim 1 Shim 2 Bleed screws Oil seals Pistons 1 1 1 2 2 2 2 4 2 Disassembly the parts in the order below For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 1 5 Nm 0 15 mSkg 1 1 ftSlb A 6 Nm 0 6 mSkg 4 3 ftSlb B A B BRAKE POWR TR BRAKE ...

Page 29: ...e damage may occur D Disconnect any hydraulic connection of herwise the entie system must be disas sembled drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Remove SBrake pads 1 D Do not depress the brake lever when the caliper or disc is off the machine other wise...

Page 30: ...nd push the pistons into the caliper with the finger STighten the caliper bleed screw 2 Bleed screw 6 Nm 0 6 mSkg 4 3 ftSlb SInstall the brake pads and pad spring The tangs a of the pad spring must point in the direction of the disc rotation 3 Inspect SBrake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION 4 Check SBrake lever operation A soft or spongy feeling Bleed brake system Refer to AIR BL...

Page 31: ...il suspension removal Tension adjuster Blind caps Bolts Washer Slide rail suspension 2 6 2 1 Remove the parts in the order below Loosen For installation reverse the removal procedure 71 Nm 7 1 mSkg 51 ftSlb A SLIDE RAIL SUSPENSION POWR TR SLIDE RAIL SUSPENSION ...

Page 32: ...ings Shaft Bushings Collars Suspension wheels Collar Wheel brackets Front pivot arm brackets 2 2 4 2 1 2 1 1 2 2 1 4 2 2 2 2 2 Disassemble the parts in the order below 700 700 4 Nm 0 4 mSkg 2 9 ftSlb A 15 Nm 1 5 mSkg 11 ftSlb B 30 Nm 3 0 mSkg 22 ftSlb C 49 Nm 4 9 mSkg 35 ftSlb D 71 Nm 7 1 mSkg 50 ftSlb E 24 Nm 2 4 mSkg 17 ftSlb F 1 10 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 SLIDE RAIL SUSPENSION POWR...

Page 33: ...lips Suspension wheels Bushings Shaft Rear suspension bracket Spacers Bushings Collar 2 2 2 2 2 2 1 1 2 2 1 24 Nm 2 4 mSkg 17 ftSlb A 49 Nm 4 9 mSkg 35 ftSlb B 71 Nm 7 1 mSkg 50 ftSlb C 18 19 20 21 22 23 24 25 26 27 28 26 27 25 28 27 26 24 23 22 21 20 19 18 SLIDE RAIL SUSPENSION POWR TR ...

Page 34: ...sorber Bushings Collar Pull rod Collars Bushings Collars Suspension wheels Control rods Bushings Screw Bushings 1 2 1 2 4 4 2 2 2 2 2 2 700 49 Nm 4 9 mSkg 35 ftSlb A 71 Nm 7 1 mSkg 50 ftSlb B 29 30 31 32 33 34 35 36 37 38 39 40 SLIDE RAIL SUSPENSION POWR TR ...

Page 35: ...e wheels Collars Tension adjusters Collar Collar Sliding frames 1 2 1 1 1 1 2 2 1 1 3 2 2 1 1 2 For assembly reverse the disassembly procedure 24 Nm 2 4 mSkg 17 ftSlb A 71 Nm 7 1 mSkg 50 ftSlb B 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 75 Nm 7 5 mSkg 54 ftSlb C 42 41 47 48 49 48 47 51 52 53 56 55 51 54 56 46 45 52 51 50 43 44 42 SLIDE RAIL SUSPENSION POWR TR ...

Page 36: ... in FRONT AXLE AND TRACK POWR TR NOTE NOTE FRONT AXLE AND TRACK INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Install SSprocket wheels SGuide wheels D When pressing the sprocket wheels onto the front axle align the lugs on each sprocket wheel D Locate each sprocket wheel and guide wheel on the axle where shown in the il lustration A 500 B 700 2 Place the track in the chass...

Page 37: ...eto couplers Thermo sensor coupler Spark plug caps Engine assembly 1 2 1 1 2 1 2 1 Remove the parts in the order below Refer to CARBURETOR Refer to RECOIL STARTER Refer to WATER PUMP AND THERMOSTATIC VALVE Refer to PRIMARY SHEAVE AND DRIVE V BELT For installation reverse the removal procedure 90 Nm 9 0 mSkg 65 ftSlb A 60 Nm 6 0 mSkg 43 ftSlb B 8 A B ENGINE ASSEMBLY ENG ENGINE ENGINE ASSEMBLY 500 ...

Page 38: ...r bracket right Oil pump cable Oil hoses Vacuum hose Starter motor Engine assembly 1 1 1 2 1 1 2 1 1 1 Remove the parts in the order below Refer to CARBURETOR Refer to RECOIL STARTER Refer to CDI MAGNETO Refer to PRIMARY SHEAVE AND DRIVE V BELT Drain Refer to COOLANT REPLACEMENT For installation reverse the removal pro cedure 23 Nm 2 3 mSkg 17 ftSlb A 60 Nm 6 0 mSkg 43 ftSlb B 90 Nm 9 0 mSkg 65 ft...

Page 39: ...right angles to the crankshaft Then find the average of the measurements Standard Wear limit Cylinder bore C 500 68 00 X 68 02 mm 2 677 X 2 678 in 700 70 50 X 70 52 mm 2 775 X 2 776 in 68 1 mm 2 681 in 70 6 mm 2 780 in Taper T 0 05 mm 0 0019 in Out of round R 0 01 mm 0 0004 in C Maximum D T Maximum D1 or D2 Maximum D5 or D6 R Maximum D1 D3 or D5 Minimum D2 D4 or D6 SIf out of specification replace...

Page 40: ...X 2 7728 in SIf out of specification replace piston and piston rings as a set 3rd step SCalculate the piston to cylinder clear ance with the following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P SIf out of specification rebore or replace cylinder and replace piston and piston rings as a set Piston to cylinder clearance 500 0 095 X 0 100 mm 0 0037 X 0 0039 in Limit ...

Page 41: ...at pressure below the speci fied pressure Replace Cap opening pressure 95 X 125 kPa 0 95 X 1 25 kg cm2 13 58 X 17 87 psi Measurement steps D Attach the cooling system tester 90890 01325 YU 24460 01 to the coolant filler cap D Apply the specified pressure for 10 seconds and make sure there is no pressure drop ...

Page 42: ...rts in the order below Loosen For installation reverse the removal procedure Intake silencer D First remove the throttle cable from the cable guide on the steering column D Adjust the throttle cable free play while the cable is in the cable guide D After adjusting the throttle cable free play properly install the upper and lower intake silencer plates and seal 1 2 6 7 3 4 5 2 CARBURETORS CARB CARB...

Page 43: ...3 6 2 1 3 1 1 3 1 Remove the parts in the order below Loosen For installation reverse the removal procedure Intake silencer D First remove the throttle cable from the cable guide on the steering column D Adjust the throttle cable free play while the cable is in the cable guide D After adjusting the throttle cable free play properly install the upper and lower intake silencer plates and seal CARBUR...

Page 44: ...w Starter rod Spring Starter levers Breather hoses Top covers Gaskets Throttle shaft connecting screws Connecting plate upper Connecting plate lower 4 1 1 1 3 1 1 3 3 3 3 3 1 1 Separation the parts in the order below Loosen For assembly reverse the separation procedure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CARBURETORS CARB ...

Page 45: ...n upside down position SMeasure the distance between the car buretor body and top of the floats The float arm should be resting on the valve but not compressing the needle valve spring SIf the float height is not within specifica tion inspect the valve seat and needle valve SIf either is worn replace them both SIf both are fine adjust the float height by bending the float arm tang 1 on the float S...

Page 46: ... PIston reed valve Forward inclined parallel 2 cylinder 494 cm3 30 1 cu in 68 68 mm 2 68 2 68 in 6 5 1 7 750 250 r min 7 750 250 r min Recoil hand starter z Crankcase reed valve Forward indined parallel 3 cylinder 698 cm3 42 6 cu in 70 5 59 6 mm 2 78 2 35 in 6 7 1 8 500 250 r min 8 250 250 r min Electric and recoil hand starter Lubrication system Separate lubrication YAMAHA AUTOLUBE z Engine oil T...

Page 47: ...0 mm 42 1 in Suspension Front suspension type Rear suspension type Leading arm Slide rail suspension z z Track Track type Track width Length on ground Track deflection mm 10 kg 22 lb Internal drive type 381 mm 15 0 in 752 mm 29 6 in 25 X 30 mm 0 98 X 1 18 in z z z z Brake Brake type Operation method Caliper type disc brake Handle lever left hand operated z z Electrical Ignition system manufacturer...

Page 48: ...9 in 0 11 mm 0 0043 in 20 004 X 20 015 mm 0 7876 X 0 7880 in 70 425 X 70 430 mm 2 7727 X 2 7728 in 15 mm 0 59 in 0 070 X 0 075 mm 0 0028 X 0 0030 in 0 1 mm 0 0039 in z 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 z z Piston ring Sectional sketch Top Ring 2nd Ring End gap installed Top Ring 2nd Ring Side clearance Top...

Page 49: ... mm 0 0020 in 80 mm 3 15 in 99 mm 3 90 in 0 25 X 0 75 mm 0 01 X 0 03 in 0 8 X 1 0 mm 0 03 X 0 04 in 55 95 X 56 00 mm 2 203 X 2 205 in 291 75 X 292 30 mm 11 486 X 11 508 in z z z Below 0 04 mm 0 0016 in Below 0 03 mm 0 0012 in 90 mm 3 54 in 85 mm 3 35 in z z Big end bearing Type Needle bearing z Small end bearing Type Needle bearing z Crank pin Crank pin outside diameter Connecting rod Small end di...

Page 50: ... 8 z 6DGM5 3 1 Q 8 2 3 Q 4 1 0 ø0 8 0 8 1 1 2 3 5 ø1 2 ø1 1 13 3 2 0 mm 0 524 0 080 in 37 1 mm 1 457 0 039 in z Fuel pump Type Manufacturer DIAPHRAM TAIYO GIKEN z z Oil pump Pump cable adjusting length Align the marks 21 X 23 mm 0 83 X 0 90 in Cooling system Water pump drive belt tension New belt Filler cap opening pressure Water pump type Coolant type Coolant mixing ratio coolant water Coolant ca...

Page 51: ... 47 MAINTENANCE SPECIFICATIONS SPEC Model VX500SXB VX700ER Thermostat Opening temperature Valve lift 50 X 55_C 122_F X 132_F 8 mm 70_C 159_F z z ...

Page 52: ...7641 00 DAYCO 1 119 mm X 1 129 mm 44 063 X 44 437 in 35 0 mm 1 38 in 33 0 mm 1 30 in 8DN 17641 00 MITSUBOSHI 1 129 mm X 1 137 mm 44 4 X 44 7 in 34 5 mm 1 36 in 32 5 mm 1 28 in Primary sheave spring Part number Color code Diameter Wire diameter Preload Spring rate Number of coils Free length 90501 550J8 White Pink White 60 mm 2 36 in 5 5 mm 0 21 in 294 N 30 kg 66 lb 22 N mm 2 25 kg mm 123 lb in 4 6...

Page 53: ... mm 0 40 in z z 90261 06034 Steel 13 9 mm 0 55 in z z Secondary sheave spring Part number Color code Outside diameter Wire diameter Hole position Sheave side spring side twist angle Spring rate Number of coils Free length Torque cam angle 90508 536A9 Red 69 5 mm 2 736 in 5 3 mm 0 208 in 3 6 90_ 7 23 N mm 0 74 kg mm 40 49 lb in 5 53 75 mm 2 95 in 43_ 90508 556A2 Green z 5 5 mm 0 216 in 3 3 60_ 8 49...

Page 54: ...ont travel Rear travel Suspension spring rate Front Rear 178 mm 7 in 203 mm 8 in 47 N mm 4 8 kg mm 274 lb in 27 44 X 47 04 N mm 2 8 X 4 8 kg mm 160 X 273 lb in 228 mm 9 in 279 mm 11 in 19 6 N mm 2 kg mm 112 lb in 29 4 X 44 1 N mm 3 0 X 4 5 kg mm 174 X 251 lb in Spring wire diameter Front Rear 9 0 mm 0 35 in 10 8 mm 0 425 in 7 8 mm 0 30in 11 5 mm 0 45 in Suspension setting position Stopper band hol...

Page 55: ...10N 0 3m s 2 206 N 657N 0 3m s 726 N 216N 0 3m s Slide runner Thickness Wear limit 17 8 mm 0 70 in 10 mm 0 39 in z z Track sprocket wheel Material Number of teeth Polyethylene 9T z z Rear guide wheel Material Outside diameter Aluminum with rubber 178 mm 7 in High molecular weight polyethylene with rubber z Brake Pad thickness Pad wear limit Disc outside diameter Disc thickness 10 2 mm 0 40 in 4 7 ...

Page 56: ...4_ R ski 34 7_ L ski 34 7_ R ski 29 4_ L ski z z z Ski Ski material Length Width Thickness Ski ground length Plastic 1 000 mm 39 4 in 130 mm 5 12 in 2 mm 0 08 in 178 mm 7 in Steel Skin 1 032 mm 40 6 in 110 mm 4 33 in 1 6 mm 0 06 in z Ski suspension Type Travel Spring type Spring rate Wire diameter Proaction system 178 mm 7 in Coil spring 22 5 N mm 2 3 kg mm 7 8 mm 0 307 in z 228 mm 9 in z 21 N mm ...

Page 57: ... magneto z CDI Magneto model Manufacturer Pickup coil resistance color code Source coil resistance color code Charging current Minimum Charging current Maximum Charging coil resistance color code Lighting voltage Minimum Lighting voltage Maximum Lighting coil resistance color code Grip warmer coil resistance color code CDI unit manufacturer F4T 318 MITSUBISHI 189 X 231 Ω at 20_C 68_F White Red Whi...

Page 58: ...80 GM18Z 3A Electric starter system for electric model Type Bendix Starter motor for electric model Model manufacturer Output Armature coil resistance Brush Overall length Wear limit Spring pressure Commutator diameter Wear limit Mica undercut DB4XF DENSO 0 6 kW 0 014 X 0 018 Ω at 20_C 68_F 12 mm 0 47 in 8 5 mm 0 33 in 6 5 X 9 5 N 650 X 950 g 22 9 X 33 5 oz 28 mm 1 10 in 27 mm 1 06 in 0 4 X 0 8 mm...

Page 59: ... 1 5 MJ 146 3 JN 1 5 MJ 145 JN 1 5 MJ 143 8 JN 1 5 1 500 X 2 000 m 4 900 X 6 600 ft MJ 146 3 JN 1 5 MJ 145 JN 1 5 MJ 143 8 JN 1 5 MJ 142 5 JN 1 5 MJ 141 3 JN 1 0 2 000 X 2 500 m 6 600 X 8 200 ft MJ 143 8 JN 1 0 MJ 142 5 JN 1 0 MJ 141 3 JN 1 0 MJ 140 JN 1 0 PJ 50 PS 2 1 2 MJ 138 8 JN 1 0 PJ 50 PS 2 1 2 2 500 X 3 000 m 8 200 X 9 800 ft MJ 142 5 JN 1 0 MJ 141 3 JN 1 0 MJ 140 JN 1 0 MJ 138 8 JN 0 5 PA...

Page 60: ...PJ 52 5 JN 2 5 PS 1 5 8 MJ 1 140 0 MJ 2 3 138 8 PJ 52 5 JN 2 0 PS 1 5 8 MJ 1 138 8 MJ 2 3 137 5 PJ 52 5 JN 2 0 PS 1 5 8 MJ 1 137 5 MJ 2 3 136 3 PJ 52 5 JN 2 0 PS 1 1 2 1 500 X 2 000 m 4 900 X 6 600 ft MJ 1 140 0 MJ 2 3 138 8 PJ 55 0 JN 2 0 PS 2 0 MJ 1 138 8 MJ 2 3 137 5 PJ 55 0 JN 2 0 PS 1 7 8 MJ 1 137 5 MJ 2 3 136 3 PJ 55 0 JN 2 0 PS 1 7 8 MJ 1 136 3 MJ 2 3 135 0 PJ 55 0 JN 2 0 PS 1 7 8 MJ 1 135 ...

Page 61: ...er and sliding sheave Primary sheave cap and sliding sheave Roller and weight primary sheave Bolt Screw Ring gear Secondary sheave Drive sprocket Lock nut chain tensioner Chain housing and frame Driven sprocket Drain bolt Chain housing cover Chain housing and brake caliper Bearing holder jackshaft Suspension wheel Guide wheel 13 27 40 90 90 27 60 40 27 13 23 13 25 33 28 20 7 23 14 10 8 10 12 0 7 1...

Page 62: ... column and relay rod Relay rod and relay arm Relay arm and tie rod Tie rod and steering arm Locknut relay rod Ski runner Ski Shock absorber upper Shock absorber lower Steering arm and ski column Lower control arm and frame Upper control arm and frame Control arm and front arm Front arm pivot bolt Stabilizer bar and connecting rod Connecting rod and front arm Hood Seat and frame nut Front cowling ...

Page 63: ... 59 MAINTENANCE SPECIFICATIONS SPEC ...

Page 64: ... 60 CABLE ROUTING SPEC CABLE ROUTING 500 ...

Page 65: ...g brake cable 12 Oil breather hose 13 Fasten the oil breather hose with a plastic clamp 14 Fasten the wire harness and oil breather hose behind the steering colum with a plastic band Do not fasten the parking brake cable and brake hose 15 Grip warmer control knob 16 Fasten the wire harness and fuel breather hose with a plastic clamp 17 Ground lead 18 Fuel sender coupler 19 Oil level switch coupler...

Page 66: ... 62 CABLE ROUTING SPEC ...

Page 67: ...e harness with a plastic clamp 42 To reverse gear 43 Fasten the wire harness fuel breather hose and oil breather hose with a plastic clamp 44 Main switch assembly 45 Starter choke lever assembly 46 Speedometer coupler 47 Tachometer coupler 48 Install the smoothing condenser so it is flush with the inner edge of the tab 49 Smoothing condenser coupler 50 Speedometer cable 51 Clamp 52 Headlight lead ...

Page 68: ... 64 CABLE ROUTING SPEC 30_ ...

Page 69: ... Battery negative lead 11 To battery negative terminal 12 To starter relay 13 To reverse gear 14 Gear position switch lead reverse model 15 Route the main switch harness along the under of the oil and fuel breather hose 16 Brake hose 17 Oil tank 18 Route the parking brake cable along the under of the oil breather hose 19 Main switch assembly 20 Starter cable assembly 21 Oil pump cable 22 Throttle ...

Page 70: ... 66 30_ CABLE ROUTING SPEC ...

Page 71: ... lever 35 Coolant hose 36 Speedometer cable 37 Fasten the throttle cable water temperature sensor lead carburetor switch lead and solenoid lead with a plastic clamp 38 Water temperature sensor coupler 39 Under 50 mm 1 97 in 40 Fasten the speedometer cable and wire harness with a plastic clamp ...

Page 72: ... 68 CABLE ROUTING SPEC ...

Page 73: ... sender coupler 13 Oil level switch 14 Oil hose 15 Pulser hose 16 Fuel hose 17 To carburetor left side 18 To carburetor right side 19 Fasten the wire harness with a plastic clamp Route the wire harness through the slot on the intake silencer 20 Air vent hose ECC model 21 CDI unit and ECU 22 Fasten the wire harness with a plastic clamp Route the wire harness through the slot on the intake silencer ...

Page 74: ... 70 CABLE ROUTING SPEC CABLE ROUTING 700 ...

Page 75: ...14 Fasten the wire harness and oil breather hose behind the steering column with a plastic band Do not fasten the parking brake cable and brake hose 15 Variable resistor 16 Fasten the wire harness and fuel breather hose with a plastic clamp 17 Fuel breather hose 18 Ground read 19 Fuel sender coupler electrical fuel gauge model 20 Oil level switch coupler 21 Bolt 22 Clamp 23 Compression spring 24 C...

Page 76: ... 72 CABLE ROUTING SPEC ...

Page 77: ...ire harness with a plastic clamp 44 To reverse gear 45 Fasten the wire harness fuel breather hose and oil breather hose with a plastic clamp 46 Main switch assembly 47 Starter choke cable assembly 48 Speedometer coupler 49 Tachometer coupler 50 Install the smoothing condenser so it is flush with the inner edge of the tab 51 Smoothing condenser coupler 52 Speedometer cable 53 Clamp 54 Head light le...

Page 78: ... 74 CABLE ROUTING SPEC ...

Page 79: ...p 9 Starter relay sub lead 10 Wire lead 11 Wire negative lead 12 To starter relay 13 To battery negative lead 14 To reverse gear 15 Gear position switch coupler 16 Route the main switch harness along the under of the oil and fuel breather hose 17 Starter relay lead 18 Brake hose 19 Oil tank 20 Route the parking brake cable along the under of the oil breather hose 21 Main switch assembly 22 Starter...

Page 80: ... 76 CABLE ROUTING SPEC ...

Page 81: ...ail brake light 10 50 mm 1 97 in 11 Fuel tank 12 Compression spring 13 Clip 14 Fuel sender coupler 15 Oil level switch coupler 16 Fuel hose 17 Pulser hose 18 Oil hose 19 Wire harness 20 To the conduction 21 Fasten the wire harness and starter cable with a plastic clamp Route the wire harness and starter cable through the slot on the intake silencer 22 Starter cable 23 CDI unit 24 Carburetor switch...

Page 82: ...er temp indicator light 26 High beam indicator light 27 Speedometer light 28 Tachometer assembly 29 Tachometer light 30 Tachometer 31 Fuelmeter 32 DC back buzzer 33 Gear position switch 34 Passenger grip warmer switch 35 Passenger grip warmer 36 Passenger grip warmer switch 37 Passenger grip warmer resistor 38 Fuel sender 39 Condenser COLOR CODE B Black G Green L Blue O Orange P Pink R Red W White...

Page 83: ...p indicator light 26 High beam indicator light 27 Speedometer light 28 Tachometer assembly 29 Fuel meter 30 Tachometer 31 Tachometer light 32 DC back buzzer 33 Gear position switch 34 Passenger grip warmer switch 35 Passenger grip warmer 36 Passenger grip warmer switch 37 Resistor 38 Fuel sender COLOR CODE B Black G Green L Blue O Orange P Pink R Red W White Y Yellow Br Brown Ch Chocolate B R Blac...

Page 84: ...PRINTED IN USA ੑ PRINTED ON RECYCLED PAPER ...

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