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Yamaha SXV70ERG Supplementary Service Manual

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SUPPLEMENTARY SERVICE MANUAL

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  • Page 1 SUPPLEMENTARY SERVICE MANUAL...
  • Page 2 (LIT-12618-02-17) bile operator, a bystander, or a person inspect- NOTICE ing or repairing the snowmobile. This manual was written by the Yamaha Motor CAUTION: Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible A CAUTION indicates special precautions that to put an entire mechanic’s education into one...
  • Page 3 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. POWR 1 General information CHAS 2 Periodic inspections and adjustments 3 Chassis 4 Power train 5 Engine COOL 6 Cooling system...
  • Page 4 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTIONS AND INSP ADJUSTMENTS CHASSIS CHAS POWER TRAIN POWR ENGINE COLLING SYSTEM COOL CARBURETION CARB ELECTRICAL ELEC SPECIFICATIONS SPEC...

  • Page 5: Table Of Contents

    ....PRIMARY SHEAVE AND DRIVE YAMAHA POWER VALVE SYSTEM V-BELT ......
  • Page 6 RECOIL STARTER ....YAMAHA POWER VALVE SYSTEM INSPECTION ..... .

  • Page 7: General Information

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number 1 is located on the right-hand side of the crankcase.

  • Page 8: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent dam- age that can be caused by the use of improper tools or improvised techniques. NOTE: Be sure to use the correct part number when ordering the tool, since the part number may differ according to country.
  • Page 9 SPECIAL TOOLS INFO FOR ENGINE SERVICE S Piston pin puller P/N: YU-01304 (for U.S.A./Canada) 90890-01304 (for Europe) This tool is used to remove the piston pin. S Rotor holding puller P/N: YU-33270 (for U.S.A./Canada) 90890-01362 (for Europe) This tool is used to remove the magneto rotor. S Cooling system tester P/N: YU-24460-01 (for U.S.A./Canada) 90890-01325 (for Europe)
  • Page 10 S Electro tester P/N: YU-33260-A (for U.S.A./Canada) 90890-03021 (for Europe) This instrument is invaluable for checking the electrical system. S Yamaha power valve system (Y.P.V.S.) adjustment coupler. P/N: YS-43092-1 This tool is used for adjusting the Y.P.V.S. S Speedometer unit test coupler.

  • Page 11: Periodic Inspections And Adjustments

    INSP INTRODUCTION/PERIODIC MAINTENANCE TABLE PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine op- eration and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being pre- pared for sale.
  • Page 12 INSP PERIODIC MAINTENANCE TABLE Every Initial Preoperation 1 month Seasonally or check or 800 km Item Remarks 3,200 km (Daily) (500 mi) (2,000 mi) (40 hr) (160 hr) Check operation and fluid leakage. Brake and parking brake Adjust free play and/or replace pads if necessary. Replace brake fluid.

  • Page 13: Engine

    INSP OIL PUMP ENGINE OIL PUMP Air bleeding CAUTION: The oil pump and oil delivery line must be bled in the following cases: S Any portion of the oil system has been dis- connected. S The machine has been turned on its side. S The oil tank has been run empty.
  • Page 14 INSP OIL PUMP 14. Install: S Gasket (bleed bolt) S Bleed bolt 15. Install: S Rear bracket (right) M8 mounting bolt (rear): 33 Nm (3.3 mSkg, 24 ftSlb) M10 mounting bolt (rear): 57 Nm (5.7 mSkg, 41 ftSlb) 16. Install: S Carburetors Refer to “CARBURETORS”...

  • Page 15: Cooling System

    INSP COOLING SYSTEM COOLING SYSTEM Coolant replacement NOTE: The coolant should be changed at least every season. 1. Place the machine on a level surface. 2. Remove: S Exhaust pipe S Exhaust joint Refer to “EXHAUST ASSEMBLY” in CHAP- TER 5. 3.
  • Page 16 INSP COOLING SYSTEM 5. Place an open container under the coolant drain bolt 1 . 6. Remove: S Coolant drain bolt S Gasket (coolant drain bolt) 7. Drain the coolant. NOTE: Lift up the tail of the machine to drain the cool- ant.
  • Page 17 INSP COOLING SYSTEM 13. Inspect: S Gasket (coolant drain bolt) Damage ! Replace. 14. Install: S Gasket S Coolant drain bolt 1 Coolant drain bolt: 13 Nm (1.3 mSkg, 9.4 ftSlb) 15. Install: S Exhaust joint S Exhaust pipe S Exhaust joint nut 1 Refer to “EXHAUST ASSEMBLY”...
  • Page 18 INSP COOLING SYSTEM Inspection steps: S Attach the cooling system tester 1 to the cool- ant filler 2 . Cooling system tester: 90890-01325, YU-24460-01 S Apply 100 kPa (1.0 kg/cm , 14 psi). S Measure the pressure with the gauge. Air bleeding 1.

  • Page 19: Heat Sheld Clamp Replacement

    COOLING SYSTEM/ INSP HEAT SHIELD CLAMP REPLACEMENT WARNING To avoid severe injury or death: S Make sure the machine is securely sup- ported with a suitable stand. S Do 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.

  • Page 20: Yamaha Power Valve System (Y.p.v.s.) Adjustment

    S When battery power is applied, the Y.P.V.S. valve should fully open. S If the valve does not fully open, check the Ser- vo motor. Refer to “YAMAHA POWER VALVE SYSTEM (Y.P.V.S.)”. WARNING Failure to use the proper Y.P.V.S. adjustment coupler may result in internal damage to the CDI unit.

  • Page 21: Yamaha Power Valve System (Y.p.v.s.) Pre-Season Checks

    INSP YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) ADJUSTMENT/ YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) PRE-SEASON CHECKS S Loosen the bolts Y.P.V.S. valve clearance: 2.0 X 3.5 mm (0.08 X 0.14 in) Turning in ! Clearance a is increased. Turning out ! Clearance a is decreased.
  • Page 22 S If the valve is stuck, inspect it and then either remove any carbon or reassemble the valve, refer to the “YAMAHA POWER VALVE SYSTEM (Y.P.V.S.)” in CHAPTER 5. S If the valve is not stuck, but the warning light and self-diagnosis warning indicator remains lit, refer to the “SELF-DIAGNOSIS”...

  • Page 23: Power Train

    INSP SHEAVE DISTANCE AND OFFSET ADJUSTMENT POWER TRAIN SHEAVE DISTANCE AND OFFSET ADJUST- MENT 1. Open the shroud. 2. Remove: S Drive V-belt guard S Drive V-velt 3. Measure: S Sheave distance a Use the distance gauge. Out of specification ! Adjust. Sheave distance: 268 X 271 mm (10.55 X 10.67 in) Distance gauge:...
  • Page 24 INSP SHEAVE DISTANCE AND OFFSET ADJUSTMENT S Sheave clearance c Use the sheave gauge. Out of specification ! Adjust. Sheave clearance: 0 X 1 mm (0 X 0.04 in) A SXV70 B SXV70ER –18–...

  • Page 25: Engagement Speed Check

    ENGAGEMENT SPEED CHECK/ INSP TRACK TENSION ADJUSTMENT ENGAGEMENT SPEED CHECK 1. Place the machine on a level surface of hard- packed snow. 2. Check: S Clutch engagement speed Checking steps: S Start the engine, and open the throttle lever gradually. S Check the engine speed when the machine starts moving forward.

  • Page 26: Chassis

    INSP SKI/SKI RUNNER/STEERING SYSTEM CHASSIS SKI/SKI RUNNER 1. Inspect: S Ski S Ski runner Damage/wear ! Replace. S Ski runner thickness a S Plastic ski thickness b Out of specification ! Replace. Ski runner wear limit: 8 mm (0.31 in) Plastic ski wear limit: 13 mm (0.51 in) CAUTION:...

  • Page 27: Electrical

    HEADLIGHT BEAM ADJUSTMENT/ INSP FUSE INSPECTION (SXV70ER) ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Adjust: S Headlight beam (vertically) Vertical adjustment Higher Turn the adjusting screw 1 clockwise. Lower Turn the adjusting screw 1 counter clockwise. FUSE INSPECTION (SXV70ER) The following procedure applies to all of the fuses.
  • Page 28 INSP FUSE INSPECTION (SXV70ER) 2. Replace: S Blown fuse Replacing steps: S Set the main switch to “OFF”. S Install a new fuse of the correct amperage. S Set the main switch to “ON” and verify if the electrical circuit is operational. S If the fuse immediately blows again, check the electrical circuit.

  • Page 29: Speedometer Unit Inspection

    INSP SPEEDOMETER UNIT INSPECTION SPEEDOMETER UNIT INSPECTION 1. Inspect: S Speedometer unit Inspection steps: S Remove the speedometer coupler 1 and headlight coupler 2 . S Connect the speedometer unit test coupler 3 to the speedometer coupler and headlight coupler. S Connect the speedometer unit test coupler leads as follows.

  • Page 30: Tuning

    INSP CARBURETOR TUNING TUNING CARBURETOR TUNING The carburetors are set at the factory to run at temperatures of 0_C X–20_C (32_F X–4_F) at sea level. If the machine is to be operated un- der conditions other than those specified above, the carburetors must be properly ad- justed.
  • Page 31 NOTE: These jetting specifications are subject to change. Consult the latest technical information from Yamaha to be sure you have the most up-to- date jetting specifications. 1 Clip 2 Jet needle 3 Pilot mixture screw 4 Main jet...
  • Page 32 INSP CARBURETOR TUNING Guide for carburetion Throttle valve opening Mid-range speed tuning High speed tuning Fully opened Closed Low speed tuning Closed Fully opened Throttle valve opening –26–...
  • Page 33 INSP CARBURETOR TUNING A Standard main jet B Main jet whose diameter is 10% smaller than standard C Main jet whose diameter is 10% larger than stan- dard Fully opened Throttle opening A No. 2 position B No. 1 position C No.
  • Page 34 INSP CARBURETOR TUNING Low-speed tuning The carburetors are built so that low speed tun- ing can be done by adjusting the pilot mixture screw 1 and throttle stop screw 2 . CAUTION: Never run the engine without the air intake silencer installed.
  • Page 35 INSP CARBURETOR TUNING Main jet selection chart Spark plug color Diagnosis Remedy Light tan or gray Carburetors are tuned properly. Dry black or fluffy Mixture is too rich. Replace the main jet with the next smaller deposits size. White or light gray Mixture is too lean.
  • Page 36 INSP CARBURETOR TUNING Trouble Diagnosis Adjustment S Remove the pilot jet, clean it with Poor performance at Clogged or loose pilot jet mid-range speeds: compressed air, and then install it. S Momentary slow S Make sure that the pilot jet is fully tightened. response to the throttle Lean mixture...

  • Page 37: Clutch

    INSP CLUTCH CLUTCH R Red High altitude W White Y Yellow Specifications Model: SXV70/SXV70ER X 800 m 600 X 1,400 m 1,200 X 2,000 m 1,800 X 2,600 m 2,400 X 3,000 m Elevation (2,000 X 4,500 ft) (4,000 X 6,500 ft) (6,000 X 8,500 ft) (8,000 X 10,000 ft) (X 2,500 ft)

  • Page 38: Gear Selection

    INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the de- sired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the en- gine speed at which the machine first begins to move from a complete stop.
  • Page 39 INSP GEAR SELECTION 1 Chain and sprocket part number Parts name Teeth & links Parts no. Standard 20 teeth 8DW-17682-00 21 teeth 8DW-17682-10 Drive sprocket Drive s rocket 22 teeth 8DW-17682-20 SXV70/SXV70ER 23 teeth 8DW-17682-30 37 teeth 8DW-47587-70 Driven sprocket 38 teeth 8DW-47587-80 SXV70...
  • Page 40 INSP GEAR SELECTION 5 Torque cam (secondary spring seat) Identification mark Effects Part no. Cam angle Identification mark Standard Quicker upshifting 8BV-17604-71 8BV71 SXV70/SXV70ER during acceleration 8BV-17604-51 8BV51 8BV-17604-31 8BV31 8BV-17604-11 8BV11 Quicker backshifting 8BV-17604-91 8BV91 under load –34–...
  • Page 41 INSP GEAR SELECTION 6 Primary spring Spring identification color code Spring rate color Preload color Color Standard Parts No. Spring rate Preload Wire Outside No. of Free N / mm N (kg) gauge diameter coils length (kg / mm) mm (in) mm (in) mm (in) 90501-551L3...
  • Page 42 INSP GEAR SELECTION 7 Clutch weight Parts no. Weight g (oz) Shape & ID mark Standard without bush and rivets 35.32 8CH-17605-10 (1.247) 38.09 8CR-17605-10 (1.345) 34.26 8DG-17605-00 (1.209) 37.77 8DJ-17605-00 (1.333) 42.09 8DN-17605-20 (1.486) 39.00 8EK-17605-00 SXV70/SXV70ER (1.376) –36–...
  • Page 43 INSP GEAR SELECTION 8 Weight rivets Parts No. Material Length Weight Standard Effects mm (in) g (oz) 90261-06033 Steel 17.2 (0.678) 4.5 (0.159) SXV70 (out) / SXV70ER (out) Increased 90261-06034 Steel 13.9 (0.548) 3.6 (0.127) SXV70 (in) / SXV70ER (in) Force 90261-06019 Steel...

  • Page 44: High Altitude Tuning

    INSP HIGH ALTITUDE TUNING HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below. Check STD settings S Carburetors S Spark plugs Adjust the main jet size according to the chart Test the main jet Not OK Adjust the size of the main jet...

  • Page 45: Front Suspension

    INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: S Spring preload Adjustment steps: S Turn the spring 1 in or out. Spring seat Standard Shorter z ! Longer distance Harder z ! Softer Preload Min. Max. Length 250 mm 260 mm 263.5 mm (9.84 in) (10.24 in) (10.37 in) CAUTION:...

  • Page 46: Rear Suspension

    INSP REAR SUSPENSION REAR SUSPENSION Stopper band 1. Adjust: S Stopper band tension CAUTION: Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. NOTE: This adjustment affects the handling character- istics of the machine. Adjustment steps: S Loosen the locknut 1 .
  • Page 47 INSP REAR SUSPENSION Spring preload 1. Adjust: S Spring preload Adjustment steps: S Turn the spring seat 1 in or out. Spring seat Standard Shorter z ! Longer distance Harder z ! Softer Preload Min. Max. Front: 203 mm 213 mm 215 mm length (7.99 in)
  • Page 48 INSP REAR SUSPENSION Rear suspension full rate 1. Adjust: S Full rate adjuster Adjustment steps: Installation position Spring rate Soft Medium Hard and damping Standard NOTE: Be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile. S Loosen the nut 1 1/2 or 3/4 turns, while holding the adjusting bolt 2 securely with a wrench so it does not move.
  • Page 49 INSP REAR SUSPENSION Control rod 1. Adjust: S Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: S Loosen the lock nut 1 . S Turn the adjusting nut 2 in or out to adjust the control rod stroke.

  • Page 50: Chassis

    CHAS STEERING CHASSIS STEERING 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Oil tank breather hose Disconnect.
  • Page 51 CHAS STEERING 23 Nm (2.3 mSkg, 17 ftSlb) 25 Nm (2.5 mSkg, 18 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 42 Nm (4.2 mSkg, 30 ftSlb) 67 Nm (6.7 mSkg, 48 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty...

  • Page 52: Installation

    CHAS STEERING INSTALLATION 1. Install: S Bushings 1 NOTE: Mount the bushing with clearance a to the end of the relay arm 2 . a Approx. 1 mm (0.04 in) 2. Install: S Tie rod 1 S Locknut 2 S Joints 3 Tie rod Tie rod part number...
  • Page 53 CHAS STEERING 4. Install: S Relay rod 1 NOTE: Make sure that the end of the relay rod with the indentation a is connected to the relay arm. CAUTION: Always use new cotter pins. Nut (relay rod): 35 Nm (3.5 mSkg, 25 ftSlb) 5.
  • Page 54 CHAS STEERING 6. Install: S Handlebar CAUTION: S Be sure the projection on the handlebar is not installed into the area a shown. S Be sure the side of the holder with the small gap b faces forward. S Center the match mark c on the handlebar 1 between the lower handlebar holders 2 .

  • Page 55: Front Suspension

    CHAS FRONT SUSPENSION FRONT SUSPENSION 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) 56 Nm (5.6 mSkg, 40 ftSlb) 78 Nm (7.8 mSkg, 56 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A...

  • Page 56: Handling Notes

    CHAS FRONT SUSPENSION HANDLING NOTES WARNING This shock absorber contains highly com- pressed nitrogen gas. Before handling the shock absorber 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.

  • Page 57: Installation

    CHAS FRONT SUSPENSION 4. Inspect: S Connecting rod 1 S Stabilizer 2 Cracks/bends/damage ! Replace. S Collar 3 Wear/scratches/damage ! Replace. 5. Inspect: S Front arm 1 Cracks/bends/damage ! Replace. INSTALLATION 1. Install: S Control rod 1 S Locknut 2 S Joint 3 a Set length Left hand...
  • Page 58 CHAS FRONT SUSPENSION 2. Install: S Steering arm 1 NOTE: S Align the punch mark a on the ski column with the punch mark b on the steering arm. S Install sections c without any gaps. Nut (steering arm): 35 Nm (3.5 mSkg, 25 ftSlb) –52–...
  • Page 59 CHAS FRONT SUSPENSION Front arm part number Caster Control rod Shock absorber Part number bracket angle bracket angle mark 8DM-2382E-10 (L / H) 25.5_ 8DM-2382F-10 (R / H) Stabilizer part number Size length Part number ID color bar diameter 16 mm 8CR-2386E-00 Purple (35.2755...

  • Page 60: Power Train

    POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT 120 Nm (12.0 mSkg, 85 ftSlb) 60 Nm (6.0 mSkg, 43 ftSlb) Order Job name/Part name Q’ty Remarks Primary sheave removal Remove the parts in the order listed below. V-belt Blind cap Primary sheave assembly...
  • Page 61 POWR PRIMARY SHEAVE AND DRIVE V-BELT 6 Nm (0.6 mSkg, 4.3 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) 19 Nm (1.9 mSkg, 13 ftSlb) 200 Nm (20.0 mSkg, 145 ftSlb) Clean the threads. Apply LOCTITE #648 as illustrated in And then tighten the spider. (The spider must be a 16 mm (0.63 in) turned counterclockwise to be tightened.) b 30 mm (1.18 in)

  • Page 62: Inspection

    POWR PRIMARY SHEAVE AND DRIVE V-BELT INSPECTION 1. Inspect: S Spider 1 S Sliding sheave 2 S Fixed sheave 3 S Primary sheave cap 4 Cracks/damage ! Replace. 2. Inspect: S Primary sheave spring 1 Cracks/damage ! Replace. 3. Measure: S Primary sheave spring free length a Out of specification ! Replace the primary sheave spring.

  • Page 63: Secondary Sheave

    POWR SECONDARY SHEAVE SECONDARY SHEAVE 64 Nm (6.4 mSkg, 46 ftSlb) Order Job name/Part name Q’ty Remarks Secondary sheave removal Remove the parts in the order listed below. V-belt Washer Shim – Refer to “SHEAVE DISTANCE AND OFFSET ADJUSTMENT” in CHAPTER 2. Collar Secondary sheave assembly For installation, reverse the removal...
  • Page 64 POWR SECONDARY SHEAVE 4 Nm (0.4 mSkg, 2.9 ftSlb) 6.5 Nm (0.65 mSkg, 4.6 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Secondary sheave disassembly Remove the parts in the order listed below.

  • Page 65: Inspection

    POWR SECONDARY SHEAVE INSPECTION 1. Inspect: S Sliding sheave 1 S Fixed sheave 2 S Spring seat 3 Cracks/damage ! Replace. S Stopper 4 Wear/damage ! Replace. 2. Inspect: S Bushing (spring seat) 1 S Sliding sheave (V-belt contact surface) 2 Scratches/wear/damage ! Replace.
  • Page 66 POWR SECONDARY SHEAVE 2. Install: S Fixed sheave 1 S Bolts 2 (along with the shims) Bolt: 10 Nm (1.0 mSkg, 7.2 ftSlb) 3. Install: S Secondary sheave spring 1 S Spring seat 2 NOTE: Hook the end of the secondary sheave spring into the spring holes in the fixed sheave.
  • Page 67 S Install new shims of the proper thickness and reassemble the secondary sheave. S Measure the secondary sheave clearance again. Repeat these steps until the clearance is with- in specification. NOTE: Yamaha recommends keeping the original shims. Shims: Part number Thickness 90201-061H1 0.5 mm (0.02 in) 90201-06037 1.0 mm (0.04 in)

  • Page 68: Drive Chain Housing

    POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING SXV70 16 Nm (1.6 mSkg, 11 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 60 Nm (6.0 mSkg, 43 ftSlb) Order Job name/Part name Q’ty Remarks Drive chain housing removal Remove the parts in the order listed below.

  • Page 69: Inspection

    POWR DRIVE CHAIN HOUSING INSPECTION 1. Inspect: S Drive chain housing 1 S Drive chain housing cover 2 Cracks/damage ! Replace. S Oil seals (drive chain housing) Wear/damage ! Replace. S Bearings (drive chain housing and cover) 3 Pitting/damage ! Replace. S Bearing (chain tensioner) 4 Pitting/damage ! Replace the bearing and the inner race holder as a set.
  • Page 70 POWR DRIVE CHAIN HOUSING 3. Measure: S 14 link section a of the drive chain Using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b . Out of specification ! Replace the drive chain.

  • Page 71: Installation

    POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the fol- lowing. A Make sure that the bearing seals face towards the drive chain as shown. B Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps.

  • Page 72: Sxv70Er

    POWR DRIVE CHAIN HOUSING SXV70ER 10 Nm (1.0 mSkg, 7.2 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 16 Nm (1.6 mSkg, 11 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 60 Nm (6.0 mSkg, 43 ftSlb) Order Job name/Part name Q’ty...
  • Page 73 POWR DRIVE CHAIN HOUSING 10 Nm (1.0 mSkg, 7.2 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 16 Nm (1.6 mSkg, 11 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 60 Nm (6.0 mSkg, 43 ftSlb) Order Job name/Part name Q’ty...

  • Page 74: Slide Rail Suspension

    POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Blind cap Suspension rear plate Slide rail suspension Collar...
  • Page 75 POWR SLIDE RAIL SUSPENSION 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) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order...
  • Page 76 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Suspension wheel Collar Wheel bracket Circlip Suspension wheel Collar...
  • Page 77 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear shock absorber Collar Pull rod Collar Suspension wheel Control rod Bushing Bushing –71–...
  • Page 78 POWR SLIDE RAIL SUSPENSION 24 Nm (2.4 mSkg, 17 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Rear pivot arm Bushing Shaft Shaft Rear pivot arm bracket...

  • Page 79: Inspection

    POWR SLIDE RAIL SUSPENSION INSPECTION 1. Inspect: S Suspension wheel S Guide wheel Cracks/damage ! Replace. S Wheel bearing Wheel turns roughly ! Replace. 2. Inspect: S Stopper band 1 Frayed/damage ! Replace. S Pull rod 2 Bends/damage ! Replace. S Shock absorber 3 Oil leaks/damage ! Replace.
  • Page 80 POWR SLIDE RAIL SUSPENSION Control rod parts number Length mm (in) Length mm (in) Length mm (in) 2.5P 3 = 7.5 Control rod 1 303.5 (11.95) 150.0 (5.91) (0.098P 3 = 0.295) Washer plate parts number Control rod 1 Control rod 2 Washer plate thickness mm (in) parts number parts number...

  • Page 81: Front Axle And Track

    POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK 8 Nm (0.8 mSkg, 5.8 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job name/Part name Q’ty Remarks Front axle and track removal Remove the parts in the order listed below. Drive chain housing Refer to “DRIVE CHAIN HOUSING”.

  • Page 82: Inspection

    POWR FRONT AXLE AND TRACK INSPECTION 1. Inspect: S Track 1 S Slide metal 2 Wear/cracks/damage ! Replace. 2. Inspect: S Sprocket wheel 1 Wear/break/damage ! Replace. S Front axle 2 Bends/scratches (excessive)/damage ! Replace. INSTALLATION 1. Install: S Sprocket wheels S Guide wheels NOTE: S When pressing the sprocket wheels onto the...

  • Page 83: Engine

    EXHAUST ASSEMBLY ENGINE EXHAUST ASSEMBLY 14.5 Nm (1.5 mSkg, 10 ftSlb) Order Job name/Part name Q’ty Remarks Exhaust assembly removal Remove the parts in the order listed below. Shroud Open. Shroud’s stopper wire Spring 1 Spring 2 Spring 3 Exhaust pipe Gasket 1 Gasket 2 Exhaust joint...

  • Page 84: Exhaust Assembly Installation

    EXHAUST ASSEMBLY INSTALLATION 1. Install: S Gasket S Exhaust joint NOTE: S Install the gasket with its projection a facing the primary sheave side. S Tighten the nuts 1 X in a crisscross pat- tern Nut (exhaust joint): 14.5 Nm (1.5 mSkg, 10 ftSlb) 2.

  • Page 85: Engine Assembly

    Remove the parts in the order listed below. Exhaust assembly Refer to “EXHAUST ASSEMBLY”. Carburetors Refer to “CARBURETORS” in CHAPTER 7. Y.P.V.S. Refer to “YAMAHA POWER VALVE SYSTEM (Y.P.V.S.)”. Recoil starter Refer to “RECOIL STARTER”. AC magneto Refer to “AC MAGNETO”.

  • Page 86: Inspection

    ENGINE ASSEMBLY INSPECTION 1. Inspect: S Rear bracket (right) 1 Cracks/damage ! Replace. INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Be sure to fasten the oil pump cable 1 with the cable holder 2 on the ignition coil brack- 2.

  • Page 87: Cylinder Head And Cylinder

    CYLINDER HEAD AND CYLINDER CYLINDER HEAD AND CYLINDER 10 Nm (1.0 mSkg, 7.2 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) Order Job name/Part name Q’ty Remarks Cylinder head and cylinder removal Remove the parts in the order listed below. Spark plug cap Clamp Sub-wire harness 2 Bracket...
  • Page 88 CYLINDER HEAD AND CYLINDER 14 Nm (1.4 mSkg, 10 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 33 Nm (3.3 mSkg, 24 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) Order Job name/Part name Q’ty Remarks Spark plug Cylinder head Gasket...

  • Page 89: Inspection

    CYLINDER HEAD AND CYLINDER INSPECTION 1. Measure: S Piston-to-cylinder clearance Measurement steps: 1st step: S Measure the cylinder bore (C) with a cylinder bore gauge 1 . NOTE: Measure the cylinder bore (C) parallel to and at right angles to the crankshaft. Then find the av- erage of the measurements.
  • Page 90 CYLINDER HEAD AND CYLINDER 3rd step: S Calculate the piston-to-cylinder clearance with the following formula: Piston-to-cylinder clearance = Cylinder bore (C) – Piston skirt diameter (P) S If out of specification, rebore or replace cylin- der, and replace piston and piston rings as a set.

  • Page 91: Installation

    CYLINDER HEAD AND CYLINDER INSTALLATION 1. Install: S Reed valves S Reed valve stoppers NOTE: Place the reed valve 1 with its concave surface facing toward the reed valve seat 2 . 2. Tighten: S Screws (reed valve) 1 Screws (reed valve): 1 Nm (0.1 mSkg, 0.7 ftSlb) ...
  • Page 92 CYLINDER HEAD AND CYLINDER 5. Install: S Gasket (cylinder) NOTE: S Install the gasket so that the side with eleva- tions faces upward. S The edge with the notch a should be between cylinders #1 and #2. CAUTION: Always use new gasket. 6.
  • Page 93 CYLINDER HEAD AND CYLINDER 9. Tighten: S Nuts (cylinder head) Tightening steps: S Temporarily tighten the cylinder head nuts 1 as follows. 1st step: S Tighten the nuts 1 X Nut (cylinder head): 13 Nm (1.3 mSkg, 9.4 ftSlb) 2nd step: S Retighten the nuts 1 X Nut (cylinder head): 28 Nm (2.8 mSkg, 20 ftSlb)
  • Page 94 OIL PUMP, CRANKCASE AND CRANKSHAFT OIL PUMP, CRANKCASE AND CRANKSHAFT 8 Nm (0.8 mSkg, 5.8 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 33 Nm (3.3 mSkg, 24 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 27 Nm (2.7 mSkg, 19 ftSlb) Order...

  • Page 95: Inspection

    OIL PUMP, CRANKCASE AND CRANKSHAFT INSPECTION 1. Measure: S Runout Use the V-blocks and a dial gauge. Out of specification ! Replace or repair the crankshaft. Dial gauge: 90890-03097, YU-03097 Maximum runout: : 0.03 mm (0.0012 in) : 0.04 mm (0.0016 in) : 0.03 mm (0.0012 in) a 89.5 mm (3.52 in) b 84.5 mm (3.33 in)
  • Page 96 OIL PUMP, CRANKCASE AND CRANKSHAFT 4. Inspect: S Lower crankcase 1 S Upper crankcase 2 S Front lower brackets 3 S Front upper brackets 4 S Rear bracket 5 S Dampers 6 Cracks/damage ! Replace. 5. Inspect: S Impeller driven gear teeth 1 Wear/damage ! Replace the impeller shaft.

  • Page 97: Oil Pump, Crankcase And Crankshaft

    OIL PUMP, CRANKCASE AND CRANKSHAFT INSTALLATION 1. Install: S Stopper rings 1 (onto the lower crankcase bearing 2 as shown) 3 Knock pin 2. Install: S Crankshaft assembly (onto the upper crankcase A ) 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 A .
  • Page 98 OIL PUMP, CRANKCASE AND CRANKSHAFT 3. Fill: S Gear room 1 Recommended oil: YAMALUBE 2-cycle Gear room capacity: 25 cm (0.88 Imp oz, 0.85 US oz) CAUTION: Before installing and torquing the crank- case bolts, be sure to check that the crank- shaft turns smoothly.

  • Page 99: Ac Magneto

    AC MAGNETO AC MAGNETO 23 Nm (2.3 mSkg, 17 ftSlb) 110 Nm (11.0 mSkg, 80 ftSlb) Order Job name/Part name Q’ty Remarks AC magneto removal Remove the parts in the order listed below. Recoil starter Refer to “RECOIL STARTER”. AC magneto coupler Disconnect.

  • Page 100: Installation

    AC MAGNETO INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Install: S Stator coil S Pickup coil NOTE: S Pass the pickup coil lead 1 under the pickup coil 2 as shown.
  • Page 101 AC MAGNETO 4. Tighten: S Starter pulley bolt 1 S Magneto rotor nut 2 Starter pulley bolt: 23 Nm (2.3 mSkg, 17 ftSlb) Magneto rotor nut: 110 Nm (11 mSkg, 80 ftSlb) NOTE: Attach the primary sheave holder to hold the pri- mary sheave.

  • Page 102: Recoil Starter

    RECOIL STARTER RECOIL STARTER 18 Nm (1.8 mSkg, 13 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) Order Job name/Part name Q’ty Remarks Recoil starter removal Remove the parts in the order listed below. Exhaust silencer Refer to “EXHAUST ASSEMBLY”.

  • Page 103: Inspection

    RECOIL STARTER INSPECTION 1. Inspect: S Drive plate 1 Cracks/bends/damage ! Replace. S Drive pawl 2 S Return spring 3 S Cam guide 4 Wear/cracks/damage ! Replace. S Drive plate spring 5 Wear/damage ! Replace. S Sheave drum 6 Cracks/damage ! Replace. S Starter spring 7 Cracks/bends/damage ! Replace.

  • Page 104: Installation

    RECOIL STARTER INSTALLATION 1. Wind: S Starter rope (2 1/2 times counterclockwise) (in the sheave drum) 2. Install: S Starter spring 1 S Sheave drum assembly 2 NOTE: S Mesh the spring hook 3 with the case slit, then wind the spring counterclockwise into the case from a larger to a smaller diameter.

  • Page 105: Yamaha Power Valve System

    YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) 6.5 Nm (0.65 mSkg, 4.7 ftSlb) 7.5 Nm (0.75 mSkg, 5.4 ftSlb) Order Job name/Part name Q’ty Remarks YAMAHA POWER VALVE SYSTEM Remove the parts in the order listed below.
  • Page 106 YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) 7 Nm (0.7 mSkg, 5.1 ftSlb) 7.5 Nm (0.75 mSkg, 5.4 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Y.P.V.S. disassembly Remove the parts in the order listed below.

  • Page 107: Removal

    YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) REMOVAL 1. Remove: S Y.P.V.S. valve assembly NOTE: Put identification marks on each valve for refer- ence during reinstallation. INSPECTION 1. Eliminate: S Carbon deposit (from the valve) Use the rounded scraper 1 . CAUTION: Do not use a sharp instrument.
  • Page 108 YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) 3. Install: S Valve housing 1 NOTE: Align the projection a on valve housing 1 with the projection b on valve housing 2. 4. Install: S Y.P.V.S. cables Refer to the illustrations. Cable Installation Position...

  • Page 109: Installation

    YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING”, to check the cable, lead and hose rout- ings. 1. Install: S Y.P.V.S. valve assembly NOTE: S Position each valve very carefully in its original place.

  • Page 110: Cooling System

    COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAPTER 2. Coolant filler cap Coolant reservoir tank Thermostat housing Coolant hose 1 Coolant hose 2 Joint pipe...

  • Page 111: Heat Exchanger Inspection

    COOL HEAT EXCHANGER INSPECTION 1. Inspect: S Coolant hoses 1 S Heat exchangers 2 S Joint pipe 3 S Coolant reservoir tank 4 S Carburetor heating hoses 5 Cracks/damage ! Replace. –105–...

  • Page 112: Thermostat

    COOL THERMOSTAT THERMOSTAT 10 Nm (1.0 mSkg, 7.2 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job name/Part name Q’ty Remarks Thermostat disassembly Remove the parts in the order listed below. Washer Carburetor heating knob O-ring Thermostat cover Thermostatic valve Thermostat housing Water temperature sensor For assembly, reverse the disassembly...

  • Page 113: Inspection

    COOL THERMOSTAT INSPECTION 1. Inspect: S Thermostat cover 1 S Thermostat housing 2 S Thermostat 3 S Carburetor heating knob 4 Cracks/damage ! Replace. 2. Inspect: S Thermostatic valve 1 Valve does not open at 48 X 52_C (119 X 126_F) ! Replace.

  • Page 114: Installation

    COOL THERMOSTAT INSTALLATION 1. Install: S Thermostat 1 NOTE: Align the hole a in the thermostat with to mark b in the thermostat housing. 2. Install: S Thermo sensor 1 Water temperature sensor: 23 Nm (2.3 mSkg, 17 ftSlb) CAUTION: Be very careful when handling the water temperature sensor and thermo unit.

  • Page 115: Carburetion

    CARB CARBURETORS CARBURETION CARBURETORS Order Job name/Part name Q’ty Remarks Carburetors removal Remove the parts in the order listed below. Intake silencer Refer to “FUEL PUMP”. Carburetor heating knob Before removing the carburetors, make sure that the carburetor heating knob is turned to “OFF”.

  • Page 116: Throttle Position Sensor

    CARB CARBURETORS 3.5 Nm (0.35 mSkg, 2.5 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Carburetor separation Remove the parts in the order listed below. Carburetor heating hose Starter cable holder Collar Spring Screw Loosen.
  • Page 117 CARB CARBURETORS 0.7 Nm (0.07 mSkg, 0.51 ftSlb) 1 Nm (0.1 mSkg, 0.7 ftSlb) 1.8 Nm (0.18 mSkg, 1.3 ftSlb) 2.5 Nm (0.25 mSkg, 1.8 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Carburetor disassembly Remove the parts in the order listed below.
  • Page 118 CARB CARBURETORS 0.7 Nm (0.07 mSkg, 0.51 ftSlb) 1 Nm (0.1 mSkg, 0.7 ftSlb) 1.8 Nm (0.18 mSkg, 1.3 ftSlb) 2.5 Nm (0.25 mSkg, 1.8 ftSlb) ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Gasket Main jet Main jet ring...

  • Page 119: Adjustment

    CARB CARBURETORS THROTTLE POSITION SENSOR (T.P.S.) IN- SPECTION AND ADJUSTMENT NOTE: Before adjusting the T.P.S., properly adjust the idle speed. 1. Inspect: S T.P.S. Inspection steps: S Disconnect T.P.S. coupler. S Connect the pocket taster (Ω 1k) to the T.P.S. coupler. Tester (–) lead ! Gray/Black terminal 1 Tester (+) lead ! Red/Yellow terminal 2 S Check the T.P.S.
  • Page 120 CARB CARBURETORS 2. Adjust: S T.P.S. position Adjustment steps: S Disconnect the T.P.S. coupler. S Connect the test coupler to the T.P.S. S Connect three dry cells (1.5 V 3 pcs.) in se- ries to the test coupler. Dry cells (–) ! 1 Dry cells (+) ! 2 S Connect the digital multimeter to the test cou- pler.

  • Page 121: Installation

    CARB CARBURETORS INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in chapter 9, to check the cable, lead and hose routings. 1. Adjust: S Starter cable freeplay Refer to “STARTER (CHOKE) CABLE AD- JUSTMENT” in CHAPTER 2. 2.

  • Page 122: Electrical

    ELEC SWITCH INSPECTION ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: 90890-03112, YU-03112 NOTE: S Set the pocket tester to “0” before starting a test.

  • Page 123: Combination Meter Function

    ELEC COMBINATION METER FUNCTION COMBINATION METER FUNCTION Change the “kilometers” to “miles” To switch the speedometer, odometer, and trip- meter displays between kilometers and miles, select the odometer mode “ODO”, and then push the select/reset button 1 for at least 10 seconds.

  • Page 124: Lighting System

    ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM –118–...

  • Page 125: Troubleshooting

    ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT AND/OR METER LIGHT DO NOT COME ON. Check the bulb(s). NO CONTINUITY Replace the bulb(s). For SXV70ER: Check the main fuse, “IGNITION” fuse and “HEAD” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or “IGNITION” fuse and/or “HEAD”...

  • Page 126: Bulb(S)

    ELEC LIGHTING SYSTEM BULB(S) 1. Remove: S Headlight bulb a S Tail/brake light bulb b S Meter light bulb c 2. Connect: S Pocket tester (to the bulb terminals) WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot.

  • Page 127: Headlight Relay

    ELEC LIGHTING SYSTEM HEADLIGHT RELAY 1. Inspect: S Headlight relay (black) 1 Inspection steps: S Disconnect the headlight relay from the cou- pler. S Connect the pocket tester (Ω 1) and battery (12 V) to the headlight relay terminals as shown.

  • Page 128: Yamaha Power Valve System

    ELEC YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) CIRCUIT DIAGRAM –122–...

  • Page 129: Troubleshooting

    ELEC YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) TROUBLESHOOTING SERVOMOTOR DOES NOT MOVE. Check the main switch. NO CONTINUITY Replace the main switch. Check the servomotor operation. DOES NOT MOVE Replace the servomotor. Check for voltage on the condenser coupler. OUT OF SPECIFICATION Correct connection and/or replace the DC regulator.

  • Page 130: Servomotor

    ELEC YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) SERVOMOTOR SXV70 1. Remove: S Front panel (right). 2. Disconnect the Y.P.V.S. check coupler cap 1 from the Y.P.V.S. check coupler 2 . 3. Inspect: S Servomotor Inspection steps: S Connect the Y.P.V.S. adjustment coupler 1 to the Y.P.V.S.

  • Page 131: Self-Diagnosis

    ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS This model features a self-diagnosing system for following displays. 1. Fuel meter, fuel level warning indicator 1 and the warning light 4 2. Coolant temperature warning light 2 and the warning light 4 3. Self-diagnosis warning indicator 3 and the warning light 4 1.

  • Page 132: Self-Diagnosis Warning Indicator And The Warning Light

    3. SELF-DIAGNOSIS WARNING INDICATOR AND THE WARNING LIGHT The self-diagnosis warning indicator and the warning light faults are displayed as follows S Throttle position sensor (T.P.S.) S Yamaha Power Valve System (Y.P.V.S.) S Variable resistor (grip and thumb warmer) S Grip and thumb warmer...
  • Page 133 ELEC SELF-DIAGNOSIS Item Variable resistor (thumb warmer) Condition Disconnected Item Thumb warmer Condition Short-circuit Item Voltage Condition Wrong Warning light ON Warning light OFF s Time (second) –127–...

  • Page 134: Specifications

    Maximum torque r/min 8,000 r/min Starting system Recoil hand starter (SXV70) Electric and recoil hand starter (SXV70ER) Lubrication system Separate lubrication (YAMAHA AUTOLUBE) Engine oil: Type YAMALUBE 2-cycle oil Tank capacity 3.0 L (2.6 Imp qt, 3.2 US qt) Drive chain housing oil: Type Gear oil API “GL-3”...
  • Page 135 SPEC GENERAL SPECIFICATIONS Model SXV70/SXV70ER Spark plug: Type BR9ES Manufacturer 0.7 X 0.8 mm (0.028 X 0.031 in) Transmission: Primary reduction system V-Belt 3.8 X 1.0 : 1 Primary reduction ratio Clutch type Automatic centrifugal engagement Secondary reduction system Chain Secondary reduction ratio 1.727 (38/22) Reverse system...

  • Page 136: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model SXV70/SXV70ER Cylinder head: #1: 24.55 X 24.85 cm (1.50 X 1.52 cu.in) Volume (with spark plug) #2, #3: 21.35 X 21.65 cm (1.30 X 1.32 cu.in) <Warp limit> <0.03 mm (0.0012 in)> *Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating...
  • Page 137 SPEC MAINTENANCE SPECIFICATIONS Model SXV70/SXV70ER Crankshaft: 56.95 X 57.00 mm (2.242 X 2.244 in) Crank width “A” 292.75 X 293.30 mm (11.526 X 11.547 in) Crank width “B” Maximum runout “C”: C 0.03 mm (0.0012 in) 0.04 mm (0.0016 in) 0.03 mm (0.0012 in) Measuring points: 1 89.5 mm (3.52 in)
  • Page 138 SPEC MAINTENANCE SPECIFICATIONS Model SXV70/SXV70ER Carburetor: Type/Quantity TM33/3 Manufacturer MIKUNI I.D. mark 8EK1 00 Main jet (M.J) #156.3 Pilot jet (P.J) Jet needle (J.N) 6HEY2-59-3 Needle jet (N.J) Pilot air jet (P.A.J) Pilot outlet (P.O) ø0.9 Bypass (B.P.1) ø0.8 Pilot screw (P.S) 1-7/8 turns out Throttle valve...
  • Page 139 SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model SXV70/SXV70ER Transmission: Type V-belt automatic 3.8 X 1.0 : 1 Range of ratio 3,900 ± 200 r/min (3,700 X 4,100 r/min) Engagement speed r/min 8,400 ± 250 r/min (8,150 X 8,650 r/min) Shift r/min 268 X 271 mm (10.55 X 10.67 in) Sheave distance V-Belt:...
  • Page 140 SPEC MAINTENANCE SPECIFICATIONS Model SXV70/SXV70ER Secondary sheave spring: Part number 90508-536A9 Color code Outside diameter 69.5 mm (2.736 in) Wire diameter 5.3 mm (0.209 in) Hole position Sheave side-spring side (twist angle) 1-6 (70_) Spring rate 7.3 N/mm (0.744 kg/mm, 41.66 lb/in) Number of coils 5.53 Free length...
  • Page 141 SPEC MAINTENANCE SPECIFICATIONS Model SXV70/SXV70ER Slide rail suspension (Rear suspension): Center travel 238 mm (9.37 in) Rear travel 273 mm (10.75 in) Suspension spring rate 12.7 X 29.4 N/mm (1.3 X 3.0 kg/mm, 73 X 168 lb/in) Front 27.44 X 47.04 N/mm (2.8 X 4.8 kg/mm, 157 X 269 lb/in) Rear Spring wire diameter Front...
  • Page 142 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model SXV70/SXV70ER Frame: Frame material Aluminum Seat height 730 mm (28.7 in) Luggage box location Rear side of seat Steering: Lock-to-lock angle (left) 29.4_ (R ski) 34.7_ (L ski) (right) 34.7_ (R ski) 29.4_ (L ski) Ski alignment Toe-out 0 X 15 mm (0 X 0.59 in)
  • Page 143 Electric starter system (SXV70ER): Type Bendix type T.P.S. (throttle position sensor) Model/Manufacturer 5FL/MIKUNI 4 X 6 KΩ at 20_C (68_F) Resistance (Green/Yellow – Red/Yellow) 0 X 4 KΩ at 20_C (68_F) (Green/Yellow – Gray/Black) Y.P.V.S servo motor: Model/Manufacture 8DF/YAMAHA –137–...
  • Page 144 5.2 X 6.4 kΩ at 0_C (34_F) Resistance 0.300 X 0.364 kΩ at 80_C (176_F) 0.170 X 0.208 kΩ at 100_C (212_F) 90 X 110_C (194 X 230_F) Indicator light (ON) 85 X 105_C (185 X 221_F) (OFF) Speed sensor: Model/Manufacture 8EK/YAMAHA –138–...

  • Page 145: High Altitude Settings

    SPEC HIGH ALTITUDE SETTINGS HIGH ALTITUDE SETTINGS SXV70/SXV70ER Tempera- – 40_C – 29_C – 18_C – 7_C 16_C ture (– 40_F) (– 20_F) (0_F) (20_F) (40_F) (60_F) Altitude MJ #160 MJ #158.8 MJ #157.5 MJ #156.3 MJ #155 MJ #153.8 0 X 100 m PJ #45 PJ #45...

  • Page 146: Tightening Torque

    SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Crankcase (M8 80) (1st) Tighten the bolts in two Crankcase (M8 (2nd) stages. Crankcase (M8 Engine bracket (front) and frame Engine bracket damper Engine bracket (front) and engine Engine bracket right (rear) and engine...
  • Page 147 SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Primary sheave (1st) 12.0 Tighten the bolts in two Primary sheave (2nd) stages. See NOTE. Spider and sliding sheave 20.0 Left-hand thread. Primary sheave cap and sliding sheave Roller and weight (primary sheave) Starter motor driven gear...
  • Page 148 SPEC TIGHTENING TORQUE Tightening torque Parts be tightened Parts be tightened Remarks Remarks mSkg ftSlb  Wheel bracket shaft and sliding frame Apply LOCTITE Set bolt (front axle) Speed sensor Gear unit (speed sensor) NOTE: Tightening steps: 1. Tighten the bolt to a torque at 120 Nm (12 mSkg, 85 ftSlb). 2.
  • Page 149 SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Handlebar holder Steering column Upper Lower Steering column and relay rod Relay rod and relay arm Relay arm and tie rod Tie rod and steering arm Relay arm ...

  • Page 150: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (nut) (bolt) (bolt) This chart specifies torque for standard fasteners mSkg ftSlb with standard I.S.O. pitch threads. Torque speci- 10 mm 6 mm fications for special components or assemblies 12 mm 8 mm are included in the applicable sections of this...

  • Page 151: Cable Routing

    SPEC CABLE ROUTING –145–...
  • Page 152 SPEC CABLE ROUTING CABLE ROUTING 1 Thermo sensor Ignition coil coupler T.O.R.S. coupler CDI magneto coupler cover Clamp the CDI magneto cou- pler, harness and T.P.S. lead. Pass the starter (choke) throttle and oil pump cables through the holder of intake silencer. T.P.S.
  • Page 153 SPEC CABLE ROUTING –147–...
  • Page 154 SPEC CABLE ROUTING Clamp the side frame rein- forcement with the harness wire, the wire harness, the starter relay lead and the wire harness. Align the clamp with the positioning white tape. Clamp the wire harness, starter relay lead, wire harness and side frame.
  • Page 155 SPEC CABLE ROUTING –149–...
  • Page 156 SPEC CABLE ROUTING 1 Clamp the fuel hose using the frame directly attached clamp. Clamp the oil hose using the frame directly attached clamp. Lay the fuel tank breather hose along the steering gate. Lay the oil tank breather hose along the steering gate.
  • Page 157 SPEC CABLE ROUTING –151–...
  • Page 158 SPEC CABLE ROUTING Compression spring Variable resistor coupler Frame directly attached clamp Fuel hose Pulser hose Oil delivery hose Headlight relay (dimmer) (black) Load control relay (white) DC back buzzer Situate the C.D.I. unit coupler in the footrest. CDI unit –152–...
  • Page 159 SPEC CABLE ROUTING –153–...
  • Page 160 SPEC CABLE ROUTING 1 Speedometer coupler Headlight harness Align the clamp with the white tape on the harness. Clamp the headlight harness. Route it behind the shroud stopper. Stay Hook Assemble the starter lever so that it will be in this range. –154–...
  • Page 161 SPEC CABLE ROUTING –155–...
  • Page 162 SPEC CABLE ROUTING 1 Handle bar holder Thumb warmer coupler Engine stop switch coupler Pass the throttle and oil pump cables through the holder. Grip warmer coupler Brake light switch coupler Dimmer switch coupler Parking brake cable Clamp the brake light switch, dimmer switch and grip warmer leads.
  • Page 163 SPEC CABLE ROUTING –157–...
  • Page 164 SPEC CABLE ROUTING Clamp the wire harness using the frame directly attached clamp. Clamp the coolant hose and wire harness. Align the white tape on the wire harness with the white tape on the coolant hose. Coolant hose Lay the wire harness beside the coolant hose.
  • Page 165 SPEC CABLE ROUTING –159–...
  • Page 166 SPEC CABLE ROUTING Clamp the wire harness, fuel tank breather hose and oil tank breather hose. Main switch Stareter (choke) lever Oil pump cable Clamp the oil tank breather hose, grip warmer lead, thumb warmer lead, engine stop switch lead. Do not pass the throttle and oil pump cables through.
  • Page 167 SPEC CABLE ROUTING –161–...
  • Page 168 SPEC CABLE ROUTING 1 Clamp the wire harness, cool- ant hose and T.P.S. coupler. Di- rect the front end of clamp to- ward the intake silencer side. As for the T.P.S. coupler, clamp it only the side having the T.P.S. lead (the front side of the ve- hicle).
  • Page 169 SPEC CABLE ROUTING –163–...
  • Page 170 SPEC CABLE ROUTING Secondary clutch Speed sensor coupler Do not slack to the clutch side. Slack should be to the instru- ment panel side. Speed sensor Speed sensor lead Coolant hose Frame directly attached clamp Pass the wire harness under the carburetor heater hose.
  • Page 172 A.C. Magneto Rectifier / regulator Main switch Battery* Fuse (MAIN)* Starter relay* Starter motor* Engine stop switch Throttle switch Carburetor switch CDI unit Y.P.V.S. Servo motor T.P.S. Variable resistor (thumb warmer) Variable resistor (grip warmer) Ignition coil Spark plug Engine earth Body earth Thumb warmer Grip warmer...
  • Page 173 01 06 0.8E. ITP PRINTED ON RECYCLED PAPER...

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