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SUPPLEMENTARY SERVICE MANUAL

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Summary of Contents for Yamaha SX500D

  • Page 1 SUPPLEMENTARY SERVICE MANUAL...
  • Page 2 OE001 NOTE: NOTICE A NOTE provides key information that can This manual was written by the Yamaha Motor make procedures easier or clearer. Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to MANUAL FORMAT put an entire mechanic’s education into one...
  • Page 3 OE031 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspection and adjustment 3 Chassis 4 Power train 5 Engine overhaul 6 Cooling system 7 Carburetion 8 Electrical 9 Specifications...
  • Page 4: Table Of Contents

    GENERAL INFORMATION SECONDARY SHEAVE ....ASSEMBLY ......MACHINE IDENTIFICATION .
  • Page 5: General Information

    MACHINE IDENTIFICATION/IMPORTANT INFORMATION INFO 1E001 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 6: Periodic Inspections And

    INSP OIL PUMP PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE 2E021 OIL PUMP (500) Air bleeding CAUTION: The oil pump and oil delivery line must be bled on the following occasions: S When any portion of the oil system has been disconnected. S When the machine has been turned on its side.
  • Page 7 INSP OIL PUMP 2E021 OIL PUMP (700) Air bleeding CAUTION: The oil pump and oil delivery line must be bled on the following occasions: S When any portion of the oil system has been disconnected. S When the machine has been turned on its side.
  • Page 8: Cooling System

    INSP COOLING SYSTEM 2E061 COOLING SYSTEM (500) Coolant replacement NOTE: The coolant should be changed at least every season. 1. Place the machine on a level surface. 2. Remove: S Muffler 1 S Exhaust pipe 2 3. Make sure that the carburetor heating lever 1 is turned to “ON”...
  • Page 9 INSP COOLING SYSTEM 5. Place an open container under the coolant drain bolts 1 . 6. Remove: S Coolant drain bolts S Gaskets (coolant drain bolts) 7. Drain the coolant. NOTE: Lift up the tail of the machine to drain the cool- ant.
  • Page 10 INSP COOLING SYSTEM 10. Remove the reservoir tank 1 and drain the coolant. 11. Install: S Reservoir tank 12. Inspect: S Gaskets (coolant drain bolts) Damage ! Replace. 13. Install: S Gaskets (coolant crain bolts) S Coolant drain bolts S Exhaust pipe/gaskets S Muffler Coolant drain bolt: 23 Nm (2.3 mSkg, 17 ftSlb)
  • Page 11 INSP COOLING SYSTEM 16. Inspect: S Cooling system Decrease of pressure (leaks) ! Repair as required. Inspection steps: S Attach the cooling system tester (90890-01325, YU-24460-01) to the coolant filler 2 . S Apply 100 kPa (1.0 kg/cm , 14 psi). S Measure the pressure with gauge.
  • Page 12 INSP COOLING SYSTEM 3. Adjust: S Drive belt deflection Adjustment steps: S Remove the recoil starter 1 . S Use a primary sheave holder (90890–01701, YS–01880) to hold the primary sheave. S Remove the starter pulley 2 . S Remove the screws 3 of the starter pulley. S Adjust the drive belt deflection by adding or removing a shim 4 .
  • Page 13 INSP COOLING SYSTEM 2E061 COOLING SYSTEM (600/700) Coolant replacement NOTE: The coolant should be changed at least every season. 1. Place the machine on a level surface. 2. Remove: S Muffler 1 S Exhaust pipe 2 3. Make sure that the carburetor heating lever 1 is turned to “ON”...
  • Page 14 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 15 INSP COOLING SYSTEM 10. Remove the coolant reservoir/oil tank 1 and drain the coolant. 11. Install: S Coolant reservoir/oil tank 12. Inspect: S Gasket (coolant drain bolt) Damage ! Replace. 13. Install: S Gasket S Coolant drain bolt S Exhaust pipe/gaskets S Muffler Coolant drain bolt: 13 Nm (1.3 mSkg, 9.4 ftSlb)
  • Page 16: Engine Idle Speed Adjustment

    INSP COOLING SYSTEM/ENGINE IDLE SPEED ADJUSTMENT 16. Inspect: S Cooling system Decrease of pressure(leaks) ! Repair as re- quired. Inspection steps: S Attach the cooling system tester (90890-01325, YU-24460-01) to the coolant filler 2 . S Apply 100 kPa (1.0 kg/cm , 14 psi).
  • Page 17: Power Train

    INSP DRIVE V-BELT POWER TRAIN DRIVE V-BELT (600/700) WARNING When installing the new V-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to –0.5 mm (–0.02 in) below the edge a . If the V-belt is not positioned correctly, the clutch engagement speed will be changed.
  • Page 18 INSP DRIVE V-BELT 2. Adjust the position of the V-belt by removing or adding a spacer 1 on each adjusting bolt 2 . V-belt position Adjustment More than 1.5 mm (0.06 in) above the Remove a spacer edge From 1.5 mm (0.06 in) above the Not necessary edge to –0.5 mm...
  • Page 19: Engagement Speed Check

    ENGAGEMENT SPEED CHECK/ INSP BRAKE PAD INSPECTION/SLIDE RUNNER INSPECTION 2E201 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.
  • Page 20: Chassis

    INSP SKI/SKI RUNNER/STEERING SYSTEM 2E212 CHASSIS SKI/SKI RUNNER 1. Check: S Ski S Ski runner Damage/wear ! Replace. Ski runner wear limit 1 : 8 mm (0.31 in) CAUTION: Do not operate the machine without the ski cover to prevent ski wear and damage. 2E221 STEERING SYSTEM 2E232...
  • Page 21: Tuning

    INSP CARBURETOR TUNING TUNING CARBURETOR TUNING Carburetor tuning data 1. Standard specifications MODEL Type TM36 TM31 TM33 Manufacturer MIKUNI I.D. Mark 8CJ10 8DG100 8CH10 Main jet (M.J.) #151.3 #1: 136.3, #2, 3: 133.8 #1: 145, #2, 3: 143.8 Pilot jet (P.J.) #42.5 Main air jet (M.A.J.) ø2.5...
  • Page 22: Clutch

    INSP CLUTCH CLUTCH White Silver Blue High altitude Pink Orange Yellow Green Specifications Model: SX500 X 3,500 ft 3,000 X 5,000 ft 4,500 X 7,000 ft 6,500 X 10,000 ft Elevation Idle speed Approx. 1,600 r/min Clutch engagement Approx. 3,900 r/min 4,000 r/min 4,100 r/min 3,800 r/min...
  • Page 23 INSP CLUTCH White Silver Blue Pink Orange Yellow Green Specifications Model: SX600 X 3,500 ft 3,000 X 5,000 ft 4,500 X 7,000 ft 6,500 X 10,000 ft Elevation Idle speed Approx. 1,600 r/min Clutch engagement Approx. 4,200 r/min 4,100 r/min 4,200 r/min 4,200 r/min Shift speed...
  • Page 24 INSP CLUTCH White Silver Blue Pink Orange Yellow Green Specifications Model: SX700 X 3,500 ft 3,000 X 5,000 ft 4,500 X 7,000 ft 6,500 X 10,000 ft Elevation Idle speed Approx. 1,600 r/min Clutch engagement Approx. 4,000 r/min 3,900 r/min 4,000 r/min 3,900 r/min Shift speed...
  • Page 25 INSP CLUTCH 2E331 The clutch may require tuning depending upon the area of operation and desired handling characteristics. The clutch can be tuned by changing engagement and shifting speed. Clutch engagement speed is defined as the en- gine speed where the machine first begins to move from a complete stop.
  • Page 26: Gear Selection

    INSP GEAR SELECTION GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions. If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions ex- ist, decrease the ratio.
  • Page 27 INSP GEAR SELECTION 3 Secondary spring Spring rate Wire Free No. of Parts No. NSmm/rad Color gauge length Standard coils (kgmm/rad) (mm) (mm) 90508-500B1 6003 (613) BROWN 90508-536A9 7147 (729) 500, 600 90508-556A2 8314 (848) GREEN 90508-556A7 9460 (965) SILVER 4 Secondary spring twist angle Seat Sheave...
  • Page 28 INSP GEAR SELECTION 6 Primary spring Spring rate Preload Wire Outside Free No. of Standard Parts No. N / mm N / mm Color gauge diameter length coils (kg / mm) (kg) (mm) (mm) (mm) 90501-481J1 9.8 (1.0) 196.1 (20) S-B-S 5.16 85.4...
  • Page 29: Front Suspension

    INSP FRONT SUSPENSION FRONT 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 Max. Min. 251.5 mm 261.5 mm 268.0 Length (9.81 in) (10.20 in) (10.45 in) CAUTION:...
  • Page 30: Rear Suspension

    INSP REAR SUSPENSION 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 Max. Min. Length 203 mm 213 mm 215 mm (front) (7.92 in) (8.31 in) (8.39 in) Max.
  • Page 31: Chassis

    CHAS CHASSIS 11 Nm (1.1 mSkg, 8 ftSlb) 21 Nm (2.1 mSkg, 15 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) : ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order below. Cotter pin Ski column lower bracket Ski stopper...
  • Page 32: Inspection

    CHAS INSPECTION 1. Inspect: S Ski 1 S Ski runner 2 S Ski column lower bracket 3 S Ski handle 4 S Ski Stopper 5 Wear/cracks/damage ! Replace. S Mounting bolt 6 S Collar 7 Wear/damage ! Replace. –28–...
  • Page 33: Front Suspension

    CHAS FRONT SUSPENSION FRONT SUSPENSION 600/700 23 Nm (2.3 mSkg, 17 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 78 Nm (7.8 mSkg, 56 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) 56 Nm (5.6 mSkg, 40 ftSlb) : ESSO beacon 325 grease or Aeroshell grease #7A Order...
  • Page 34: Installation

    CHAS FRONT SUSPENSION INSTALLATION 1. Install: S Control rod 1 S Nut 2 S Joint 3 a Set length Left hand Set length angle Color (mm) 475.5 0.5 mm Upper (18.545 0.0197 in) Blue Blue 472.6 0.5 mm Lower (18.431 0.0197 in) Right hand Set length...
  • Page 35: Power Train

    POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT 120 Nm (12.0 mSkg, 87 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 below. V-belt Blind cap Primary sheave assembly...
  • Page 36 POWR PRIMARY SHEAVE AND DRIVE V-BELT 6 Nm (0.6 mSkg, 4.3 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) 200 Nm (20 mSkg, 145 ftSlb) S Clean the threads. 16mm (0.63 in) 30 X 35mm S Apply LOCTITE # 648 as illustrated in .
  • Page 37 POWR PRIMARY SHEAVE AND DRIVE V-BELT INSPECTION 1. Inspect: S Primary sheave spring 1 Cracks/damage ! Replace. 2. Measure: S Primary sheave spring free length a Out of specification ! Replace. Primary sheave spring free length: 88.4 mm (3.1 in) (500) 89.4 mm (3.52 in) (600, 700) 3.
  • Page 38: Secondary Sheave

    POWR SECONDARY SHEAVE SECONDARY SHEAVE 600/700 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...
  • Page 39 POWR SECONDARY SHEAVE ASSEMBLY 1. Install: S Secondary sheave spring 1 NOTE: Hook the end of the secondary sheave spring onto the spring holes in the fixed sheave and in the spring seat. Standard spring position: 2-6 (600) 3-3 (700) Installation steps: S Attach the sheave compressor.
  • Page 40: Drive Chain Housing

    POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING 12 Nm (1.2 mSkg, 8.7 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 below.
  • Page 41: Installation

    POWR DRIVE CHAIN HOUSING INSPECTION 1. Measure: S 14 link section a of the drive chain Using a spring scale, pull on the drive chain with 36 kg ( 80 lbs) of force b . Out of specification ³ Replace the drive chain.
  • Page 42: Brake

    POWR BRAKE BRAKE 6 Nm (0.6 mSkg, 4.3 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in the order below. Cap bolt Retaining pin Pad spring Brake pad For installation, reverse the removal procedure.
  • Page 43: Brake Pad Replacement

    POWR BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: S Disassemble components unless abso- lutely necessary. S Use solvents on internal brake compo- nents. S Use contaminated brake fluid for cleaning. Use only clean brake fluid. S Allow brake fluid to come in contact with the eyes, otherwise eye injury may occur.
  • Page 44 POWR BRAKE 2. Install: S Brake pads S Pad spring Installation steps: S Connect a suitable hose 1 tightly to the cali- per 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.
  • Page 45: Slide Rail Suspension

    POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION 71 Nm (7.1 mSkg, 51 ftSlb) Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order below. Tension abjuster Loosen. Blind caps Bolts Washer Slide rail suspension For installation, reverse the removal procedure.
  • Page 46 POWR SLIDE RAIL SUSPENSION 4 Nm (0.4 mSkg, 2.9 ftSlb) 16 Nm (1.6 mSkg, 11 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) Order Job name/Part name Q’ty...
  • Page 47 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) Order Job name/Part name Q’ty Remarks Suspension wheels Collar Wheel brackets Circlips Suspension wheels Bushings Shaft Rear suspension bracket Spacers Washer plate Collar...
  • Page 48 POWR SLIDE RAIL SUSPENSION 49 Nm (4.9 mSkg, 35 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb) Order Job name/Part name Q’ty Remarks Rear shock absorber Bushings Collar Pull rod Collars Bushings Collars Suspension wheels Control rods Bushings Screw Bushings –44–...
  • Page 49 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) Order Job name/Part name Q’ty Remarks Rear pivot arm Bushings Collar Collar Rear pivot arm bracket Collar Circlips Suspension wheels Wheel bracket Rear axle...
  • Page 50 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 51: Front Axle And Track

    POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK 600/700 9 Nm (0.9 mSkg, 6.5 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) Order Job name/Part name Q’ty Remarks Front axle and track removal Remove the parts in the order listed below.
  • Page 52: 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 53: Engine

    CYLINDER HEAD AND CYLINDER ENGINE CYLINDER HEAD AND CYLINDER 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) Order Job name/Part name Q’ty Remarks...
  • Page 54 CYLINDER HEAD AND CYLINDER INSPECTION 1. Measure: S Valve stopper height a Out of specification ! Replace. Valve stopper height a : 10.4 X 10.8 mm (0.41 X 0.42 in) 2. Measure: S Reed valve bending limit a Out of specification ! Replace. Reed valve bending limit a : less than 0.3 mm (0.012 in) –50–...
  • Page 55 CYLINDER HEAD AND CYLINDER 600/700 14 Nm (1.4 mSkg, 10 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) Order Job name/Part name Q’ty Remarks Cylinder head and cylinder removal Remove the parts in the order listed below.
  • Page 56 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 57 CYLINDER HEAD AND CYLINDER S If out if specification, replace piston and pis- ton rings as a set. 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 58 CYLINDER HEAD AND CYLINDER 3. Measure: S Outside diameter a (piston pin) Out of specification ! Replace the piston pin. Outside diameter a (piston pin): 19.995 X 20.000 mm (0.7872 X 0.7874 in) 4. Measure: S Piston pin-to-piston clearance Out of specification ! Replace the piston. Piston pin-to-piston clearance = Bore size (piston pin) b –...
  • Page 59: 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 below. Coolant Drain. Refer to “COOLANT REPLACEMENT”. Coolant filler cap Coolant hose 1 Filler cap body Clamp Coolant hose 2 Coolant hose 3 Heat exchanger (right) Coolant hose 4...
  • Page 60: Inspection

    COOL HEAT EXCHANGER INSPECTION 1.Measure: S Filler cap opening pressure Cap opens at pressure below the specified pressure ! Replace. Cap opening at pressure: 80 X 100 kPa (0.8 X 1.0 kg/cm 11.44 X 14.30 psi) Measurement steps: S Attach the cooling system tester 1 (90890 -01325, YU-24460-01) to the coolant filler cap S Apply the specified pressure for 10 seconds, and make sure there is no pressure drop.
  • Page 61: Carburetion

    CARB CARBURETORS CARBURETION CARBURETORS * Intake silencer S First, remove the throttle cable from the cable guide on the steering column. S Adjust the throttle cable free play while the cable is in the cable guide. S After adjusting the throttle cable free play, properly install the upper and lower intake silencer plates and seal.
  • Page 62: Assembly

    CARB CARBURETORS ASSEMBLY Reverse the “DISASSEMBLY” procedure. Note the following points. NOTE: S Before reassembling, wash all parts in clean gasoline. S Always use a new gasket and O-ring. 1. Tighten: S Inner parts Pilot air jet/main air jet: 0.7 Nm (0.07 mSkg, 0.5 ftSlb) Screw (valve seat): 1 Nm (0.1 mSkg, 0.7 ftSlb) Pilot jet:...
  • Page 63: Fuel Level Adjustment

    CARB CARBURETORS 3. Install: S Return springs 1 NOTE: Hook the spring hooks 2 to the projections on the connecting lever 3 and carburetor body 4 , while twisting the spring clockwise approxi- mately 315 degrees. S Carburetors FUEL LEVEL ADJUSTMENT 1.
  • Page 64 CARB CARBURETORS * Intake silencer S First, remove the throttle cable from the cable guide on the steering column. S Adjust the throttle cable free play while the cable is in the cable guide. S After adjusting the throttle cable free play, properly install the upper and lower intake silencer plates and seal.
  • Page 65 CARB CARBURETORS Order Job name/Part name Q’ty Remarks Carburetor separation Separation the parts in the order below. Coolant hoses Starter cable holder Collar Spring Screw Loosen Starter rod Spring Starter levers Breather hoses Top covers Gaskets Throttle shaft connecting screws Connecting plate (upper) Connecting plate (lower) For assembly, reverse the separation...
  • Page 66 CARB CARBURETORS ASSEMBLY Reverse the “DISASSEMBLY” procedure. Note the following points. NOTE: S Before reassembling, wash all parts in clean gasoline. S Always use a new gasket and O-ring. 1. Tighten: S Inner parts Pilot air jet/main air jet: 0.7 Nm (0.07 mSkg, 0.5 ftSlb) Screw(valve seat): 1 Nm (0.1 mSkg, 0.7 ftSlb) Pilot jet:...
  • Page 67 CARB CARBURETORS 3. Install: S Return springs 1 NOTE: Hook the spring hooks 2 to the projections on the connecting lever 3 and carburetor body 4 , while twisting the spring clockwise approxi- mately 315 degrees. S Carburetors FUEL LEVEL ADJUSTMENT 1.
  • Page 68: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model SX500D SX600D SX700D Model code number: 8CT2 8EA2 8CH4 Dimensions: Overall length 2,760 mm (108.7 in) Overall width 1,200 mm (47.2 in) Overall height 1,230 mm (48.4 in) Weight: 215 kg (474 lb)
  • Page 69 SPEC GENERAL SPECIFICATIONS Model SX500D SX600D SX700D Carburetor: Type/quantity TM36 TM31 TM33 Manufacturer MIKUNI 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...
  • Page 70: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model SX500D SX600D SX700D Cylinder head: 23.3 X 23.9 cm 18.7 X 19.3 cm 22.9 X 23.5 cm Volume (with spark plug) <Warp limit> <0.03 mm (0.0012 in)> Lines indicate straight edge measurement. 600 / 700...
  • Page 71 SPEC MAINTENANCE SPECIFICATIONS Model SX500D SX600D SX700D Crank shaft: 61.95 X 62.00 mm 55.95 X 56.00 mm 55.95 X 56.00 mm Crank width “A” (2.439 X 2.440 in) (2.203 X 2.205 in) (2.203 X 2.205 in) 179.85 X 180.15 mm 291.75 X 292.30 mm...
  • Page 72 SPEC MAINTENANCE SPECIFICATIONS Model SX500D SX600D SX700D Carburetor: Type /Quantity TM36/2 pcs. TM31/3 pcs. TM33/3 pcs. Manufacturer MIKUNI I.D. mark 8CJ10 8DG1 00 8CH10 Main jet (M.J) 151.3 #1 : 136.3 #1 : 145 #2,3 : 133.8 #2, 3 :143.8 Main air jet (M.A.J)
  • Page 73: Power Train

    SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model SX500D SX600D SX700D Transmission: Type V-belt automatic 3.8 X 1.0 : 1 Range of ratio 3,800 " 200 r/min 4,200 " 200 r/min 3,900 " 200 r/min Engagement r/min (3,600 X 4,000 r/min) (4,000 X 4,400 r/min) (3,700 X 4,100 r/min) 7,800 "...
  • Page 74 SPEC MAINTENANCE SPECIFICATIONS Model SX500D SX600D SX700D Rivet: Outer Part number 90261-06034 90261-06015 90261-06034 Material Steel Size 13.9 mm (0.55 in) 10.3 mm (0.40 in) 13.9 mm (0.55 in) Quantity 3 pcs Hole quantity 3 pcs Inner Part number 90261-06015...
  • Page 75 SPEC MAINTENANCE SPECIFICATIONS Model SX500D SX600D SX700D Track: Part number 8EA-47110-10 8EA-47110-10 8EA-47110-10 Width 381 mm (15.0 in) Length 3,072 mm (120.9 in) Pitch 64 mm (2.52 in) Number of links Height “B” 16 mm (0.63 in) 19 mm (0.75 in)
  • Page 76 SPEC MAINTENANCE SPECIFICATIONS Model SX500D SX600D SX700D Shock absorber: Damping force Front Extension 2,380 N/0.3 m/s Compression 1,950 N/0.3 m/s Rear Extension 2,900 N/0.3 m/s Compression 970 N/0.3 m/s Slide runner: Thickness 17.8 mm (0.70 in) Wear limit 10 mm (0.4 in)
  • Page 77: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model SX500D SX600D SX700D Frame: Frame material Aluminum Seat height 685 mm (26.8 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)
  • Page 78: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model SX500D SX600D SX700D Voltage: 12 V Ignition system: Ignition timing (B.T.D.C) 16_ at 1,600 r/min 18_ at 1,500 r/min 18_ at 1,600 r/min Advanced timing (B.T.D.C) 18_ at 4,500 r/min 20_ at 4,500 r/min 24_ at 4,500 r/min...
  • Page 79 SPEC MAINTENANCE SPECIFICATIONS Model SX500D SX600D SX700D Rectifier/regulator: Model/manufacturer Model/manufacturer 8CR 00/ 8CR-00/ EHU0TR140/ EHU0TR140/ MATSUSHITA MATSUSHITA No load regulated voltage 13 8 X 14 8 V 13.8 X 14.8 V 14.0 X 15.0 V –75–...
  • Page 80: High Altitude Settings

    SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS SX500D Tempera- – 40_C – 29_C – 18_C – 7_C 15_C ture (– 40_F) (– 20_F) (0_F) (20_F) (40_F) (60_F) Altitude 0 X 100 m MJ#155 MJ#153.8 MJ#152.5 MJ#151.3 MJ#150 (0 X 330 ft) JN-2.0...
  • Page 81 SPEC MAINTENANCE SPECIFICATIONS SX600D Tempera- – 40_C – 29_C – 18_C – 7_C 15_C ture (– 40_F) (– 20_F) (0_F) (20_F) (40_F) (60_F) Altitude MJ#1 #142.5 MJ#1 #140 MJ#1 #137.5 MJ#1 #135 MJ#1 #132.5 MJ#1 #130 0 X 100 m MJ#2#3 #140 MJ#2#3...
  • Page 82 SPEC MAINTENANCE SPECIFICATIONS SX700D Tempera- – 40_C – 29_C – 18_C – 7_C 15_C ture (– 40_F) (– 20_F) (0_F) (20_F) (40_F) (60_F) Altitude MJ#1 #148.8 MJ#1 #147.5 MJ#1 #146.3 MJ#1 #145.0 MJ#1 #143.8 MJ#2#3 #147.5 MJ#2#3 #146.3 MJ#2#3 #145.0 MJ#2#3 #143.8 MJ#2#3 #142.5 0 X 100 m...
  • Page 83: Tightening Torque

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks mSkg ftSlb Crankcase (first) Tighten the bolts in two Crankcase (final) stages. Engine bracket (front) and frame 500 Engine bracket (front) and frame 600, 700 Engine bracket damper (front) Engine bracket and engine Engine bracket upper and lower (rear) Engine bracket damper and frame (rear)
  • Page 84 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Parts to be tightened Parts to be tightened Remarks Remarks mSkg ftSlb Sliding frame and slide runner Slide rail suspension mounting bolt Rear pivot arm and bracket Apply LOCTITE Shock absorber and rear pivot arm Rear pivot arm and rod Rear suspension bracket and rod Control rod and sliding frame...
  • Page 85: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING –81–...
  • Page 86 SPEC CABLE ROUTING CABLE ROUTING 1 Wire lead (electrical starter model) 2 Fasten the throttle cable, water temperature sensor lead, carbu- retor switch lead and solenoid lead with a plastic clamp. 3 Carburetor switch coupler 4 Fasten the throttle cable and oil pump cable with a plastic clamp.
  • Page 87 SPEC CABLE ROUTING –83–...
  • Page 88 SPEC CABLE ROUTING Wire harness Guide, wire Route the fuel breather hose along the upper of the main harness. Route the oil breather hose along the upper of the main har- ness. Install the tail / brake light lead behind the instrument panel. Make sure that the oil tank cap and oil breather hose do not touch each other.
  • Page 89 SPEC CABLE ROUTING –85–...
  • Page 90 SPEC CABLE ROUTING Speedometer coupler Tachometer coupler Smoothing condenser coupler Install the smoothing condenser so it is flush with the inner edge of the tab. Clamp Speedometer cable Headlight lead Fasten the headlight lead and speedometer cable at the white tape mark, with a plastic clamp.
  • Page 91 SPEC CABLE ROUTING –87–...
  • Page 92 SPEC CABLE ROUTING Oil pump cable Throttle cable Fasten the wire harness. Do not fasten the throttle cable and oil pump cable. Fasten the throttle cable and oil pump cable with a plastic clamp. Route the cable along the side of the handle holder. Thumb warmer coupler Engine stop switch coupler Grip warmer lead...
  • Page 93 SPEC CABLE ROUTING –89–...
  • Page 94 SPEC CABLE ROUTING Voltage regulator Rectifire regulator Back buzzer coupler (for model with reverse) Back buzzer coupler (for model without reverse) Fasten the wire harness with a plastic clamp. Gear position switch (for model without reverse) Brake hose holder Fasten the wire harness with a plastic clamp.
  • Page 95 SPEC CABLE ROUTING –91–...
  • Page 96 SPEC CABLE ROUTING Wire harness Fasten the wire harness with a plastic clamp. Route the wire harness through the slot on the intake silencer. CDI unit and ECU Fasten the wire harness with a plastic clamp. Route the wire harness through the slot on the intake silencer.
  • Page 97 SPEC CABLE ROUTING CABLE ROUTING 600/700 –93–...
  • Page 98 SPEC CABLE ROUTING CABLE ROUTING 600/700 Fasten the carburetor switch, wa- ter temperature sensor lead, cool- ant hose, wire lead and battery negative lead with a plastic clamp. Clamp Carburetor switch coupler Fasten the wire lead, battery negative lead and coolant hose with a plastic clamp.
  • Page 99 SPEC CABLE ROUTING –95–...
  • Page 100 SPEC CABLE ROUTING Water temperature sensor coupler Oil pump cable Throttle cable 35 X 45 mm (1.37 X 1.76 in) Clamp Silencer (Air box) Ignition coil (#3) –96–...
  • Page 101 SPEC CABLE ROUTING –97–...
  • Page 102 SPEC CABLE ROUTING Wire harness Does not kink. 50 mm (1.97 in) Route the fuel breather hose along the upper of the main switch harness. Route the oil breather hose along the upper of the main switch harness. Install the tail / brake light lead behind the instrument panel.
  • Page 103 SPEC CABLE ROUTING –99–...
  • Page 104 SPEC CABLE ROUTING Speedometer coupler Tachometer coupler Smoothing condenser coupler Install the smoothing condenser so it is flush with the inner edge of the tab. Clamp Headlight lead Speedometer cable Fasten the headlight lead and speedometer cable at the white tape mark, with a plastic clamp.
  • Page 105 SPEC CABLE ROUTING –101–...
  • Page 106 SPEC CABLE ROUTING Oil pump cable Throttle cable Fasten the wire harness. Do not fasten the throttle cable and oil pump cable. Thumb warmer coupler Engine stop switch coupler Route the throttle cable and oil pump cable through the clamp. Grip warmer lead Brake light switch coupler Head light switch coupler...
  • Page 107 SPEC CABLE ROUTING –103–...
  • Page 108 SPEC CABLE ROUTING Voltage regulator Rectifire regulator Back buzzer coupler (for model with reverse) Back buzzer coupler (for model without reverse) Fasten the wire harness with a plastic clamp. Gear position switch (for model without reverse) Brake hose holder Fasten the wire harness with a plastic clamp.
  • Page 109 SPEC CABLE ROUTING –105–...
  • Page 110 SPEC CABLE ROUTING Fasten the wire harness and start- er cable with a plastic clamp. Route the wire harness and starter cable through the slot on the intake silencer. CDI unit Carburetor switch coupler Water temperature sensor coupler Starter relay coupler CDI unit Make sure a plastic-locking tie is routed through wire harnesses...
  • Page 111 WIRING DIAGRAM SX500 CDI magneto Oil level switch Condenser Rectifier/ regulator Brake light switch COLOR CODE Starter relay / fuse Tail / brake light ... . Black ... Green Battery Speedometer assembly...
  • Page 112 WIRING DIAGRAM...
  • Page 113 WIRING DIAGRAM SX600 SX700 CDI magneto Oil level switch Condenser Rectifier/ regulator Brake light switch COLOR CODE Starter relay / fuse Tail / brake light ....Black .
  • Page 114 WIRING DIAGRAM...
  • Page 115 99.06 1.E.ITP PRINTED ON RECYCLED PAPER...

This manual is also suitable for:

Sx600dSx700d

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