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Yamaha VK540EF Service Manual

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Service manual (211 pages)

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VK540EF

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Summary of Contents for Yamaha VK540EF

Page 1 VK540EF...
Page 2 NOTICE HOW TO USE THIS MANUAL...
Page 3 ILLUSTRATED SYMBOLS (REFER TO THE ILLUSTRATION)
Page 4 INDEX...
Page 8 CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER...
Page 9 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY...
Page 10 ALL REPLACEMENT PARTS GASKETS, OIL SEALS, AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS...
Page 11 CIRCLIPS LOCTITE®...
Page 12 SPECIAL TOOLS FOR TUNE UP FOR ENGINE SERVICE...
Page 13 FOR POWER TRAIN SERVICE...
Page 14 FOR CARBURETION SERVICE FOR ELECTRICAL SERVICE...
Page 16 CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION PERIODIC MAINTENANCE TABLE...
Page 18 ENGINE SPARK PLUGS...
Page 19 OIL PUMP...
Page 21 OIL FILTER INSPECTION ENGINE OIL LINE INSPECTION...
Page 22 FUEL LINE INSPECTION FUEL FILTER INSPECTION...
Page 24 COOLING FAN BELT TENSION ADJUSTMENT...
Page 25 ENGINE IDLE SPEED ADJUSTMENT THROTTLE CABLE FREEPLAY ADJUSTMENT...
Page 26 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK...
Page 27 STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT EXHAUST SYSTEM INSPECTION...
Page 28 POWER TRAIN DRIVE V-BELT...
Page 31 SHEAVE DISTANCE AND OFFSET ADJUSTMENT...
Page 33 ENGAGEMENT SPEED CHECK ADJUSTING THE BRAKE...
Page 34 BRAKE PAD INSPECTION DRIVE CHAIN...
Page 36 TRACK TENSION ADJUSTMENT...
Page 37 SLIDE RUNNER INSPECTION...
Page 38 CHASSIS SKI/SKI RUNNER STEERING SYSTEM...
Page 40 LUBRICATION...
Page 42 ELECTRICAL HEADLIGHT BEAM ADJUSTMENT...
Page 43 BATTERY INSPECTION...
Page 45 FUSE INSPECTION...
Page 46 TUNING CARBURETOR TUNING...
Page 53 CLUTCH...
Page 54 GEAR SELECTION...
Page 58 HIGH ALTITUDE TUNING...
Page 59 REAR SUSPENSION...
Page 63 CHAPTER 3. CHASSIS STEERING...
Page 65 INSPECTION...
Page 66 INSTALLATION...
Page 69 INSPECTION...
Page 70 FRONT SUSPENSION...
Page 71 HANDLING NOTES INSPECTION...
Page 72 INSTALLATION...
Page 74 CHAPTER 4. POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT...
Page 76 R E M O V A L...
Page 77 DISASSEMBLY...
Page 78 INSPECTION...
Page 80 ASSEMBLY...
Page 82 INSTALLATION...
Page 83 SECONDARY SHEAVE...
Page 85 DISASSEMBLY...
Page 86 INSPECTION...
Page 87 ASSEMBLY...
Page 88 INSTALLATION...
Page 89 DRIVE CHAIN HOUSING...
Page 91 INSPECTION...
Page 95 INSTALLATION...
Page 96 SECONDARY SHAFT (JACKSHAFT)
Page 98 INSPECTION INSTALLATION...
Page 99 BRAKE...
Page 100 BRAKE PAD REPLACEMENT...
Page 103 BRAKE CALIPER INSPECTION...
Page 104 INSTALLATION...
Page 106 SLIDE RAIL SUSPENSION...
Page 110 INSPECTION INSTALLATION...
Page 111 FRONT AXLE AND TRACK...
Page 113 INSPECTION INSTALLATION...
Page 114 CHAPTER 5. ENGINE EXHAUST ASSEMBLY...
Page 115 INSPECTION...
Page 116 ENGINE ASSEMBLY...
Page 117 INSPECTION INSTALLATION...
Page 118 CYLINDER HEAD AND CYLINDER...
Page 119 R E M O V A L INSPECTION...
Page 124 INSTALLATION...
Page 127 OIL PUMP, CRANKCASE AND CRANKSHAFT...
Page 128 INSPECTION...
Page 129 OIL PUMP STROKE ADJUSTMENT...
Page 131 INSTALLATION...
Page 132 OIL PUMP...
Page 133 CDI MAGNETO...
Page 134 R E M O V A L...
Page 135 INSTALLATION...
Page 136 ENGINE COOLING FAN...
Page 137 R E M O V A L...
Page 138 INSPECTION...
Page 139 INSTALLATION...
Page 140 RECOIL STARTER...
Page 141 R E M O V A L INSPECTION...
Page 142 INSTALLATION...
Page 144 CHAPTER 6. CARBURETION CARBURETOR...
Page 146 INSPECTION...
Page 147 ASSEMBLY...
Page 148 INSTALLATION...
Page 149 FUEL PUMP...
Page 150 INSPECTION INSTALLATION...
Page 151 CHAPTER 7. ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION INSPECTING A SWITCH SHOWN IN THE MANUAL...
Page 152 IGNITION SYSTEM CIRCUIT DIAGRAM...
Page 153 TROUBLESHOOTING...
Page 154 SPARK PLUG CAP IGNITION COIL SOURCE COIL/PULSER COIL...
Page 155 SPARK PLUG THROTTLE OVERRIDE SYSTEM (T.O.R.S.)
Page 156 HANDLEBAR SWITCH (RIGHT) CARBURETOR SWITCH...
Page 157 MAIN SWITCH...
Page 158 LIGHTING SYSTEM CIRCUIT DIAGRAM...
Page 159 TROUBLESHOOTING BULB(S)
Page 160 HEADLIGHT BEAM SWITCH LIGHTING COIL SIGNAL SYSTEM...
Page 161 CIRCUIT DIAGRAM TROUBLESHOOTING...
Page 162 TROUBLESHOOTING...
Page 163 TAIL/BRAKE LIGHT BULB...
Page 164 BRAKE LIGHT SWITCH GEAR POSITION SWITCH BACK BUZZER GRIP WARMER SYSTEM...
Page 165 CIRCUIT DIAGRAM TROUBLESHOOTING...
Page 166 GRIP AND THUMB...
Page 167 WARMER COIL GRIP WARMER SWITCH...
Page 168 ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM...
Page 169 TROUBLESHOOTING...
Page 170 MAIN SWITCH RECTIFIER...
Page 171 STARTER MOTOR...
Page 174 CHARGING SYSTEM CIRCUIT DIAGRAM...
Page 175 TROUBLESHOOTING...
Page 176 BATTERY CHARGING COIL...
Page 177 CHAPTER 8. SPECIFICATIONS GENERAL SPECIFICATIONS...
Page 179 MAINTENANCE SPECIFICATIONS ENGINE...
Page 182 POWER TRAIN...
Page 185 CHASSIS...
Page 186 ELECTRICAL...
Page 188 HIGH ALTITUDE SETTINGS...
Page 189 TIGHTENING TORQUE...
Page 191 GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS...
Page 192 CABLE ROUTING...
Page 206 COLOR CODE...
Page 207 WIRING DIAGRAM...

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