Page 1 General Information Troubleshooting Lubrication, Maintenance and Tune-up Engine Fuel and Exhaust Systems Electrical System Oil Injection System Cooling System Recoil Starter Drive System Brakes Chaincase, Jackshaft and Front Axle Front Suspension and Steering Track and Rear Suspension Off-season Storage Index Wiring Diagrams...
Page 2: Table Of Contents
CHAPTER ONE ........GENERAL INFORMATION ..1 ........Manual organization Precision measuring tools .
Page 3 CHAPTER FOUR ............ENGINE ......Engine number identification Cylinder ..Piston.
Page 4 CHAPTER ELEVEN BRAKES Hydraulic brake pad replacement Brake hose replacement Brake caliper Brakedisc Brake master cylinder Bleeding the brake system Parking brake 2 10 CHAPTER TWELVE CHAINCASE, JACKSHAFT AND FRONT AXLE 2 1 5 Drive chain and sprockets Chaincase (Except VT6OO, VT700, VX6OOER and Jackshaft VX7OOXTCD models) 2 15...
Page 7: Chapter One
Troubleshooting procedures discuss typical symptoms Tables 1-11 are at the end of this chapter. and logical methods to pinpoint the trouble. Table 1 lists the Yamaha models covered in this man- Chapter Three explains all routine maintenance neces- ual. sary to keep the snowmobile operating well. Chapter Table 2 lists vehicle length.
Page 8: Warnings. Cautions And Notes
CHAPTER ONE Well-equipped mechanics may be able to substitute simi- lar tools or fabricate a suitable replacement. However, in some cases, the specialized equipment or expertise required may make it impractical for the home mechanic to attempt the procedure. When necessary, such opera- tions arc identified in the text with the recommendation to have a dealership or specialist perform the task.
Page 9: Serial Numbers
GENERAL INFORMATION Cleaning Parts Cleaning parts is one of the more tedious and difficult service jobs performed in the home garage. There are many types of chemical cleaners and solvents available for shop use. Most are poisonous and extremely flamma- ble.
Page 10: Fasteners
CHAPTER ONE FASTENERS Proper fastener selection and installation is important to ensure that the vehicle operates as designed, and can be serviced efficiently. The choice of original equipment fas- teners is not arrived at by chance. Make sure replacement fasteners meet all the same requirements as the originals. Threaded Fasteners Threaded fasteners secure most of the components on the vehicle.
Page 11 GENERAL INFORMATION Self-locking fasteners offer greater holding strength than standard fasteners, which improves their resistance to vibration. Most self-locking fasteners cannot be reused. The materials used to form the lock become distorted after the initial installation and removal. It is a good practice to discard and replace self-locking fasteners after their re- moval.
Page 12: Shop Supplies
Chapter Three. SHOP SUPPLIES NOTE Lubricants Fluids The injection oil used by Yamaha snowmo- bile engines also be able to flow at must Periodic lubrication helps ensure a long service life for temperatures of -40º C (-40º F). See Chap- any type of equipment.
Page 13 GENERAL INFORMATION fluid Brake Brake fluid is the hydraulic fluid used to transmit hy- draulic pressure (force) to the wheel brakes. Brake fluid is classified by the Department of Transportation (DOT). support Current designations for brake fluid are DOT 3, DOT 4 areas and DOT 5.
Page 14: Basic Tools
CHAPTER ONE Most solvents are used in a parts washing cabinet for in- dividual component cleaning. For safety, use only non- flammable or high flash point solvents. Gasket Sealant Sealants are used in combination with a gasket or seal and are occasionally alone. Follow the manufacturer's recommendation when using sealants.
Page 15 GENERAL INFORMATION pair or replace worn or damaged screwdrivers. A worn tip may damage the fastener, making it difficult to remove. Wrenches Box-end, open-end and combination wrenches (Figure 10) come in a variety of types and sizes. The number stamped on the wrench refers to the dis- tance between the work areas.
Page 16 CHAPTER ONE As with wrenches, a 6-point socket provides supe- rior-holding ability, while a 12-point socket needs to be moved only half as far to reposition it on the fastener. Sockets are designated for either hand or impact use. Impact sockets are made of thicker material for more du- rability.
Page 17 GENERAL INFORMATION To recalculate a torque reading when using a torque adapter, use the following formula, and refer to Figure 18. TW is the torque setting or dial reading on the is the torque specification and the actual amount of torque that will be applied to the fastener. A is the amount that the adapter increases (or in some cases re- duces) the effective lever length as measured along the centerline of the torque wrench (Figure 19).
Page 18: Precision Measuring Tools
CHAPTER ONE HOW TO MEASURE TORQUE WRENCH EFFECTIVE LENGTH Effective length (E) Effective length (E) No calculation needed Snap Ring Pliers Hammers Various types of hammers (Figure 23) are available to fit a number of applications. A ball-peen hammer is used Snap ring or snap ring pliers (Figure 22) are specialized to strike another tool, such as a punch or chisel.
Page 19 GENERAL INFORMATION factured to close tolerances, and obtaining consistently accurate measurements is essential to determining which components require replacement or further service. Each type of measuring instrument is designed to mea- sure a dimension with a certain degree of accuracy and within a certain range.
Page 20 CHAPTER ONE Calipers Calipers (Figure 25) are excellent tools for obtaining inside, outside and depth measurements. Although not as precise as a micrometer, they allow reasonable precision, typically to within 0.05 mm (0.001 in.). Most calipers have a range up to 150 mm (6 in.). Calipers are available in dial, vernier or digital versions.
Page 21 GENERAL INFORMATION Movable 0.50 mm Reading on fixed scale 10.00 mrn 2. Reading on movable scale 0.50 mm Total reading 10.50 mrn NOTE If a thimble mark doesnot align exactly with the sleeve line, estimate the amount between the lines. accurate readings in ten-thousandths of an inch (0.0001 in.), a vernier...
Page 22 STANDARD INCH MICROMETER Sleeve line ..Ratchet Thimble Sleeve 1. Largest number visible on the sleeve line 0.200 in. Number on sleeve marks visible between the numbered sleeve mark and the thimble edge 0.025 in. 3. Thimble mark that aligns with sleeve line Total reading 0.231 in.
Page 23 GENERAL INFORMATION VERNIER INCH MICROMETER Vernier scale Vernier scale Thimble Vernier scale 1 . Largest number visible on the sleeve line 0.100 in. Number on sleeve marks visible between the numbered sleeve mark 0.050 in. and the thimble edge 3. Thimble is between 0.018 and 0.019 0.018 in.
Page 24 CHAPTER ONE STANDARD METRIC MICROMETER Locknut Anvil Ratchet Thimble marks consists of five lines marked 0, 2, 4, 6, and 8. These lines identified with a number. The number sequence depends on the size of the micrometer. A 0-25 mm micrometer, for run parallel to the thimble lines and represent 0.002-mm example, has sleeve marks numbered 0 through 25 in 5 increments.
Page 25 GENERAL INFORMATION Sleeve Thimble 5.0 mm. 1. Reading on upper sleeve line 0.50 mm. 2. Reading on lower sleeve line 3. Thimble line coinciding with 0.18 sleeve line Total reading 5.68 Sleeve Thimble VERNIER METRIC MICROMETER Vernier scale a. Place the standard gauge between the spindle and 1.
Page 26 CHAPTER Vernier scale 1. Reading on upper sleeve line 4.0 mm 2. Reading on lower sleeve line 0.5 mm Thimble is between 0.15 and 0.16 lines on the sleeve line 0.15 mm 4. Vernier line coinciding with thimble line 0.008 mm Total reading 4.658 mm Sleeve...
Page 27 Dial indicators are available in various ranges and grad- nations and with three basic types of mounting bases: magnetic, clamp, or screw-in stud. When purchasing a dial indicator, select the magnetic stand type (Figure 40) with a continuous dial. Cylinder Bore Gauge A cylinder bore gauge is similar to a dial indicator.
Page 28: Electrical System Fundamentals
CHAPTER ONE Results may vary if using a meter not recommend by the manufacturer is used. Such requirements are noted when applicable. Ohmmeter (analog) calibration Each time an analog ohmmeter is used or the scale is changed, the ohmmeter must be calibrated. Digital ohmmeters do not require calibration.
Page 29 GENERAL INFORMATION tions. This is due to the low voltage (6-9 volts) that the meter uses to test the circuit. The voltage in an ignition Voltage coil secondary winding can be several thousand volts. Such high voltage can cause the coil to malfunction, even though it tests acceptable during a resistance test.
Page 30: Special Tools
damage to the meter. Connect the red test lead to the elec- trical source and the black test lead to the electrical load. SPECIAL TOOLS Some of the procedures in this manual require special tools. These are described in the appropriate chapter and are available from either the manufacturer or a tool sup- plier.
Page 31 GENERAL INFORMATION 20. Use grease to hold small parts in place if they tend to REMOVING BROKEN fall out during assembly. Apply grease to electrical or SCREWS AND BOLTS brake components. Removing Frozen Fasteners If a fastener cannot be removed, several methods may be used to loosen it.
Page 32 CHAPTER ONE Bearing puller Stud Removal/lnstallation A stud removal tool is available from most tool suppli- ers. This tool makes the removal and installation of studs Spacer easier. If one is not available, thread two nuts onto the stud Shaft and tighten them against each other.
Page 33 GENERAL INFORMATION NOTE Unless otherwise specified, install bearings with the manufacturer's mark or number facing outward. Removal While bearings are normally removed only when dam- Spacer aged, there may be times when it is necessary to remove a bearing that is in good condition. However, improper bearing removal does damage the bearing and maybe the shaft or case half.
Page 34 CHAPTER ONE a shaft and into a housing at the same time, a tight fit is re- quired for both outer and inner bearing races. In this situa- tion, install a spacer underneath the driver tool so that pressure is applied evenly across both races. See Figure 58.
Page 35: Snowmobile Operation
GENERAL INFORMATION Driver Spacer due to heat expansion. This makes bearing installa- Bearing tion easier. Shaft Housing NOTE Always install bearings with the manufac- turer mark or number facing outward. e. While the housing is still hot, install the new bear- ing(~) into the housing.
Page 36 CHAPTER ONE 14. Check the skis for proper alignment (Chapter Three). ever, because snowmobiles are often operated in extreme Check the ski pivot bolt for tightness or damage. weather conditions, over rough terrain, and in remote ar- eas, they should be checked before each ride and main- WARNING tained on a periodic basis.
Page 37: Snowmobile Safety
GENERAL INFORMATION Emergency Survival Techniques or other loose clothing while the engine is running or when starting the engine. I f the 1. Do not panic in the event of an emergency. Relax, scarf or clothing should catch in the drive belt or clutch, severe injury or death could think the situation over, then decide on a course of action.
Page 38 VX700 *Yamaha designates model year by including a suffix letter in the model number. For instance, a unit with model number VT700B would indicate it is a 1998 model. The mode! year suffix letters are as follows: A- 1997,B- 1998, C — 1 9 9 9 , D- 2000, F- 2001, G—2002.
Page 39 GENERAL INFORMATION Table 2 VEHICLE LENGTH (continued) Model 1998 MM700 VT700 VX700SX VX700SX VX700XT VX700XTC VX700XTCD VX700XTCP 1999 VT600 VX600ER VX600SX MM700 W O O VX700 VX700ER VX700SX 2000 MM600 VT600 VX600 VX600SX MM700 VT700 VX700 VX700SX 2001 and 2002 MM600 SX600 VT600...
Page 40 CHAPTER ONE Table VEHICLE WIDTH (continued) Model 1999 VT600 47.2 VX600ER 47.2 VX600SX 46.1 MM700 45.5 VT700 47.2 VX700 47.2 VX700ER 47.2 VX700SX 46.1 2000 MM600 43.8 VT600 47.2 VX600 47.2 46.1 43.8 47.2 47.2 46.1 2001 and 2002 43.8 46.1 47.2 47.2...
Page 41 GENERAL INFORMATION Table 4 VEHICLE HEIGHT (continued) Model 2000 2001 and2002 only) Table 5 VEHICLE WEIGHT Model...
Page 42 CHAPTER ONE Table 6 DECIMAL AND Decimal Metric Decimal Metric Fractions Fractions 1 164 0.01 5625 0.39688 33/64 0.51 5625 13.09687 1 /32 0.03125 0.79375 17/32 0.53125 13.49375 13.89062 3/64 0.046875 1.19062 35/64 0.546875 1/16 0.0625 1.58750 0.5625 14.28750 37/64 0.578125 14.68437 5/64...
Page 43 GENERAL INFORMATION Table 7 CONVERSION FORMULAS (continued) Multiply: To get the equivalent of: Fluid volume (continued) U.S. ounces 0.03381 4 Milliliters Cubic centimeters 1 . 0 Milliliters Liters 0 . 0 0 1 Torque Newton-meters Foot-pounds 1.3558 Meters-kilograms Foot-pounds 0 . 1 38255 0 .
Page 44 CHAPTER ONE BTDC Before top dead center Celsius (Centigrade) Cubic centimeters Capacitor discharge ignition cu. In. Cubic inches Fahrenheit Foot-pounds gal. Gallons High altitude Horsepower Inches Kilogram kg/cm Kilograms per square centimeter Kilogram meters Kilometer Liter Meter Magneto Milliliter Newton-meters Ounce Pounds per square inch Power take off...
Page 45: Testing Electrica1 Components
Electrical specifications are listed in Tables 1-3 at the tested by a Yamaha dealership to verify the test result be- end of this chapter. fore purchasing a new component.
Page 46: Ignition System Troubleshooting
If basic checks fail to locate the prob- lem, take the snowmobile to a Yamaha dealership and have them troubleshoot the electrical system. Ohmmeter readings should be made when the engine is cold.
Page 47 TROUBLESHOOTING Check: Engine does not start, but fuel *Defective or dirty spark plug and spark are good *Spark plug gap set too wide *Incorrect ignition timing *Broken piston ring(s) Cylinder, crankcase or cylinder sealing faulty *Worn or damaged crankcase sea&) Damaged CDI unit *Damaged generating coil(s) Check:...
Page 48 CHAPTER TWO individual metal terminals in both the male and fe- male plastic connectors. d. Make sure all electrical terminals within the con- nector are clean and free of corrosion. Ifnecessary, clean connectors with a spray electrical contact cleaner. Bent e.
Page 49 TROUBLESHOOTING PRIMARY COIL TEST Ignition coils (SECONDARY CIRCUIT) Ignition high-tension coil 1. Open the shroud and locate the ignition high tension coils on the airbox. Refer to Figure 6 for typical coil in- stallation. (PRIMARY CIRCUIT) 2. Disconnect the two primary connectors from the high tension coil.
Page 50 Only an operational spark test can indicate whether a coil is producing an adequate spark from the input voltage. A Yamaha dealership may have the equipment to test the coil's output. I f not, substitute a known good coil and check engine operation.
Page 51 TROUBLESHOOTING COIL SOURCE TESTS CHARGING SYSTEM Rectifier Fuse 4. Connect the negative voltmeter lead to the negative battery terminal and the positive voltmeter lead to the pos- itive battery terminal. See Figure 12. Battery 5. Start the engine. Gradually increase engine speed to 3000 rpm and note the voltmeter reading.
Page 52: Electric Starting System
CHAPTER TWO 3. Connect an ohmmeter between the white and black COIL CHARGE TEST wire terminals from the charge coil (Figure 13). 4. Compare the reading to the specification in Table 2. If the reading is not within specifications, replace the stator assembly as described in Chapter Six.
Page 53 TROUBLESHOOTING Troubleshooting Before troubleshooting the starting circuit, make sure: 2. Battery cables are the proper size and length. Replace cables that are undersized or damaged. All electrical connections are clean and tight. 4. The wiring harness is in good condition. with no worn or frayed insulation or loose harness sockets.
Page 54: Fuel System
CHAPTER TWO Positive lead Starter motor heavy duty jumper cable (Figure 19). Interpret the results as follows: a. If the starter motor ran, test the main switch and en- gine stop switch as described in Chapter Six. b. If the starter motor did not run, the starter relay is faulty.
Page 55: Engine
TROUBLESHOOTING Jumper cable Jumper cable Starter motor 4. Flat spots are felt during operation that feel much like Preignition the engine is trying to run out of gas. Preignition is the premature burning of fuel and is 5. Engine power is reduced. caused by hot spots in the combustion chamber (Figure 21).
Page 56 CHAPTER TWO FUEL SYSTEM TROUBLESHOOTING No fuel at carburetor Check: *Defective fuel pump Clogged fuel filter screen Clogged or leaking pulse line Clogged or damaged fuel line Flooding at carburetor Check: Excessive fuel pump pressure Damaged fuel inlet valve *Dirty fuel inlet valve Check: Dirt or water In fuel *Incorrect float level...
Page 57 TROUBLESHOOTING (continued) Engine misfires Check: Dirty carburetor Dirty or defective inlet seat or needle *Starting valve out of adjustment *Incorrect carburetor adjustment Engine backfires Check: Poor quality fuel Incorrect carburetor adjustment Check: *Insufficient oil in fuel Poor quality fuel *Lean carburetor mixture Check: Incorrect spark plug heat range *Fuel mixture too rich...
Page 58 CHAPTER TWO PREIGNITION Flame fronts collide Total expansion and result in very occurs near top Ignited by hot deposit Regular ignition spark rapid expansion of stroke is also present. Unnoticed detonation is often the cause of rect ignition timing, which can result in a power loss. engine damage that occurs for no apparent reason.
Page 59: Two-Stroke Pressure Testing
TROUBLESHOOTING DETONATION Little expansion after Very rapid combustion Early expansion causes TDC results in power knock blowby loss Excessive Vibrations proper engine operation is impossible. Any other source of leakage such as porous or cracked crankcase castings Excessive vibrations may be caused by loose engine, results in the same conditions.
Page 60 CHAPTER TWO LOW ENGINE POWER Check: Ignition system trouble *Faulty ignition coil Incorrect Ignition timing Incorrect spark plug heat range Loose wiring connector Fuel system trouble Check: *Contaminated fuel filter *Contaminated fuel filter screen *Throttle valve does not open fully *Clogged high speed nozzle *Clogged pulse line *Leaking pulse line...
Page 61 TROUBLESHOOTING ABNORMAL ENGINE NOISE Plnging Check: *Faulty ignition system component Incorrect spark plug heat range Execessive carbon buildup in combustion chamber *Incorrect fuel/oil mixture ratio *Poor quality fuel Abnormal noise during engine Check: idle with a cold engine Excessive piston clearance Excessive piston ring wear Excessive piston skirt wear *Bent or damaged connecting rod...
Page 62: Power Train
CHAPTER TWO small brush and soapsuds solution. Possible leakage points are listed below: a. Crankshaft seals. b. Spark plug(s). c. Cylinder head joint. d. Cylinder base joint. e. Carburetor base joint. f. Crankcase joint. POWER TRAIN The following items provide a starting point from 5.
Page 63: Skis And Steering
TROUBLESHOOTING 4. Worn spindle bushings. Drive Clutch Engages Before Engagement RPM 5. Stripped spindle splines. 1. Worn spring. 2. Incorrect weight. Unequal Steering Drive Clutch Engages After Engagement RPM 2. Improperly installed steering arms. 1. Incorrect spring. 3. Damaged steering components. 2.
Page 64 CHAPTER TWO Table 2 CHARGING SYSTEM TEST SPECIFICATIONS Charging coil voliage 13.3-14.3 volts at 3000 rpm Charging coil resistance 0.31 -0.37 ohms Lighting coil voltage 11 volts at 3000 rpm Lighting coll resistance...
Page 65: Fluid Checks
Chapter Three This chapter covers all the regular maintenance re- FLUID CHECKS quired to keep a snowmobile in top shape. Regular main- tenance is the best guarantee of a trouble-free, Check vital fluids daily or before each ride to ensure long-lasting vehicle.
Page 66: Maintenance Schedules
CHAPTER THREE make sure the injection system is working (oil level di- minishing), Do not continue to use a 3U:I pre-mix ajkr the first tank unless the snowmobile is oper- ating in weather conditions where the ambi- ent temperature is -26O C (-IJO F} or c o l d e ~ Under these conditions, the 50:l pre-mzk tion.
Page 67 Proper Fuel Selection The two-stroke engines used in Yamaha siiowmobiles are lubricated by oil that circulates through the crankcase The chain housing oil level is checked with the dipstick and eventually into the combusiion chamber with the &el.
Page 68 CHAPTER T H m E with new oil when preparing the machine for summer storage. 1. Park the snowmobile on a level surface. 2. Open the shroud. 3. Place an old carpet scrap or several shop cloths under the chainrase drain plug to absorb spilled oil. the snowmobile.
Page 69: Scheduled Maintenance
LUBRICATION, MAINTENANCE AND TUNE-UP Lubricate the ski pivot pins and bushings (Figure 8) seasonally or every 2000 miles with a low-temperature grease. Refer to Chapter Thirteen and remove each ski for access to the pivot pin and bushing. Steering Column Lubricate the steering column bearings seasonally or every 2000 miles with a low-temperature grease.
Page 70 CHAPTER THREE Drive Belt Check A worn or damaged drive belt reduces engine perfor- mance and may fail during engine operation. With the en- gine OFF, open and secure the shroud and remove the drive belt cover. Check the drive belt (Figure 11) for cracks, fraying or unusual wear as described in Chapter Ten.
Page 71 LUBRICATION, MAINTENANCE AND TUNE-UP is not visible, refer to Chapter Eleven and replace the brake pads. Parking Brake Inspection Periodically check the operation of the parking brake. Refer to Chapter Eleven and measure brake pad thickness as described. Throttle and Oil Cable Inspection The throttle lever on the handlebar actuates the carbure- tor throttle cable and the oil injection pump control cable.
Page 72 CHAPTER THREE After performing throttle free play adjustment, check the oil pump cable adjustment as described in this section. Oil Pump Adjustment The oil pump injects lubricating oil into the engine. Throttle position determines the amount of oil injected. Control cable adjustment is necessary because cables wear and stretch during normal use.
Page 73 LUBRICATION, MAINTENANCE AND TUNE-UP Inspect the rubber on the guide wheels for wear and damage (A, Figure 18). Replace the wheels if they are in poor condition. Refer to Chapter Fourteen. Inspect the front limiter straps (B, Figure 18) for fray- ing, tearing or other damage.
Page 74 CHAPTER T H W E clear of the ground. 2. Clean ice, snow and dirt from the track and suspension. 3. Attach a spring scale to the track at approximately the middle of the track slider (Figure 19). Pull the scale to de- flect the track away from the slider shoe until a force of 10 kg.
Page 75 LUBRICATION, MAINTENANCE AND TmE-UP Metal Metal Metal clips FORWARD TRACK CORRECTLY TRACK SHIFTED TRACK SHIFTED ALIGNED TO RIGHT TO LEFT Drive Chain Adjustment Check the drive chain tension monthly. To adjust drive chain tension, proceed as follows: 2. Turn the adjuster (B, Figure 24) counterelockwise 3.
Page 76 CHAPTER T H W E Recoil Starter Pull out the starter rope (Figure 25) and inspect it for fraying. If its condition is questionable, replace the rope as described in Chapter Nine. Check the action of the starter. It should be smooth, and when the rope is released, it should return all the way.
Page 77 LUBRICATION, MAINTENm-CE AND TUNE-UP Completely drain and refill the cooling system once a year. Use only a high qzdulity ethylene glycol anti- freeze specz$cully lubeled for use with a h - Perform the following procedure when the engine is cold. Do not spill u~tfreeze on painted surfaces d.
Page 78 CHAPTER T H m E 9. With an assistant's help, lift up the rear of the snowmo- bile to drain as much coolant as possible. phon the coolant from the coolant recovery 27) into a suitable container. Do not s@hon cuofant by mouth and a hose. The coolant mixture is poisonous and in- very small amount may cause sickness.
Page 79: Unscheduled Maintenance
LUBRICATION, MAINTENANCE AND TUNE-UP 6. Remove carbon from the exhaust system as described in Chapter Five. 7. Wipe surfaces with a soft cloth moistened with solvent level Coolant to remove any carbon residue. 8. Reassemble the engine. UNSCHEDULED MAINTENANCE Check the following service items frequently and ser- vice as required.
Page 80: Engine Tune-Up
CHAPTER THREE Electrical Connectors each tune-up, record the compression of each cylinder, then compare the current compression with test results Inspect the high tension leads to the spark plugs for from earlier tune-ups. The first step is to record the mea- cracks and breaks in the insulation and replace the leads if sured compression of each cylinder and the date, so it can they arc not perfect.
Page 81 LUBRICATION, MAINTENANCE AND TUNE-UP Correct Spark Plug Heat Range penetrating oil and let it soak into the threads again. 3. Remove the spark plug with a 14 mm spark plug maximum performance and reliability. The condition of a wrench. used spark plug can tell a trained mechanic a lot about en- gine condition and carburetion.
Page 82 CHAPTER THREE SPARK PLUG CONDITIONS OIL FOULED CARBON FOULED GAP BRIDGED OVERHEATED SUSTAINED PREIGNITION WORN OUT...
Page 83 LUBRICATION, MAINTENANCE AND TUNE-UP Reach Reading Spark Plugs Too short Correct Too long Because the firing end of a spark plug operates in the combustion chamber, it reflects the operating condition of the engine. Much information about engine and spark plug performance can be determined by careful examina- tion of the spark plug.
Page 84 CHAPTER THREE 3. Over-retarded ignition timing. 4. Ignition component failure. 5. Low engine compression. fouled The tip of an oil fouled plug has a black insulator tip, a damp oily film over the firing end and a carbon layer over the entire nose.
Page 85 LUBRICATION, MAINTENANCE AND TUNE-UP 2. Rotate the idle speed screw (A, Figure 40) so the throt- tle valve height (Figure 41) on the center carburetor (B, Figure 40) is 1.2 mm (0.047 in.). 3. Check the throttle valve height on both outer carbure- tors (C, Figure 40).
Page 86 CHAPTER THREE mixture. Turning the pilot mixture screw counterclock- wise richens the fuel mixture. 1. Open the shroud. NOTE Figure 45 shows the carburetors removed for clarity. 2. Locate the pilot mixture screw on the underside of each carburetor (Figure 45). 3.
Page 87 LUBRICATION, MAINTENANCE AND TUNE-UP High speed tuning Mid-range speed tuning Low speed tuning other than those specified, adjust the carburetors accord- NOTE It is important to note that the following jet- ingly. ting guidelines are guidelines only. Individ- ual adjustments vary because of altitude, Figure 47 illustrates the different carburetor circuits temperature and snow conditions.
Page 88 CHAPTER THREE Throttle valve Clip Jet needle Needle jet Main Mid-range tuning The jet needle and needle jet control the mixture at me- dium speeds, from approximately 114 to 3!4 throttle (Fig- ure 47). The tapered bottom half of the jet needle extends into the needle jet (Figure 49).
Page 89 LUBRICATION, MAINTENANCE AND TUNE-UP Clip Clip position position Clip Shim a. Refer to Table 17 and Table 18 and find the temper- ature and altitude range in which the snowmobile will be operated. Then cross reference the altitude and temperature to obtain the new main jet size. NOTE Number one carburetor is at PTO (clutch) end o f engine;...
Page 90: High-Altitude Clutch Tuning
Less optimum snow conditions or more rugged terrain require more reduction. Refer to the recommended sprockets in Table 14. Replacement sprockets and chains can be purchased through Yamaha dealerships. Refer to Chapter Twelve for sprocket and chain replacement procedures.
Page 91 Front Suspension Spring Preload Springs with different spring pressure ratings are avail- able on some models. Consult with a Yamaha dealership. The front suspension shock absorber spring is provided with a threaded adjusting nut to adjust spring preload. The...
Page 92 CHAPTER THREE spring pressure ratings are available on some models. Consult with a Yamaha dealership. The shock absorber is charged with nitro- gen gas under high pressure. Do not attempt expose the shock absorber to high heat or flames. Spring rise The rear suspension bracket supports the front end of the rear shock absorber (Figure 59).
Page 93 LUBRICATION, MAINTENANCE AND TUNE-UP Rear Suspension Limit Straps Rear Suspension Mounting Position The front arm of the rear suspension system is equipped with limit straps. See Figure 62. The limit straps control weight transfer during acceleration. When the straps are The position of the rear suspension in the tunnel may be longer, the track lead angle can be greater and more adjusted on MM600 and MM700 models after 1999 to ac-...
Page 94 CHAPTER THREE Table SEASONAL MAINTENANCE SCHEDULE {continuedl Lubricate steering column Lubricate steering spindle Change cooiant in cooling system Check exhaust system for leakage or other signs of damage Check shock absorbers for leakage or damage Check ski alignment Check ski wear bar for looseness or damage Check front suspension for loose or damaged components Check rear suspension rail wear strips for wear and damage Check for loose, damaged or missing fasteners...
Page 95 LUBRICATION, MAINTENANCE AND TUNE-UP Table 7 MAINTENANCE TORQUE SPECIFICATIONS Cylinder head nuts Engine mounts Refer to Chapter Four Spark plug Table SPARK PLUGS All models NGK BR9ES Table PILOT MnXTUUE SCREW INITIAL SETTING All 593 cc models 2 turns out All 698 cc models 1 112 turns out Table 10 RECOMMENDED IDLE SPEED SETTING...
Page 96 CHAPTER THREE Table 12 HIGH-ALTITUDE CLUTCH SPEClFiCATiONS-4500-7000 FT. (continued) Model Shift weight (outer) Shift weight [inner) Spring Aluminum 10.3 Steel 13.9 Aluminum 10.3 Steel 13.9 Aluminum 10.3 Steel 13.3 None Steel 10.3 Aluminum 10.3 Steel 10.3 None Steel 10.3 Aluminum 10.3 Pink Aluminum 10.3 Sieef 13.9...
Page 97 LUBRICATION, MAINTENANCE AND TUNE-UP Table I 4 CHAINCASE SPROCKET S P E C I F I C A T I O N ~ O O O = ~ O Upper Bower sprocket Model (number of teeth) Chain links Table 15 CHAINCASE SPROCKET SPEClFlCATlOMS-4500-7000 FT. Upper !lower sprocket Model (number af teeth)
Page 98 CHAPTER THREE Table 17 MAIN JET, CLIP POSIT!ON AND PILOT JET (593 ENGINES)* Temperature Altitude 0-330 and No. Clip Pilot jet No. I and No. Clip Pilot jet 1600-3300 and No- Clip Pilot jet 3300-4900 and No. Clip Pilot jet No.
Page 99 LUBRICATION, MAINTENANCE AND TUNE-UP Table 18 MAIN JET, CLIP POSITION AND PILOT JET (698 ENGINES) (continued) Temperature Altitude No. 1 No. 2 No. 3 Pilot jet 3300-5000 No. 1 No. 3 Clip Pilot jet 5000-6700 ft. No. 2 No. 3 Clip Pilot j e t...
Page 100: Chapter Four
Chapter Four Engine This chapter describes service procedures for the lists for service (especially during the fall and winter sea- son), this practice can reduce the time a unit is in the shop. The engine is equipped with ball-type main crankshaft If much of the preliminary work is done, the repairs can be scheduled and performed much quicker.
Page 101: Engine Lubrication
Using makeshift tools can damage the components and may cause serious injury. Where special snowmobile tools are required, they may be purchased through any Yamaha dealership. Other tools can be purchased through the dealership, from a motorcy- REAR cle store or from an auto parts store.
Page 102: Servicing Engine In Frame
CHAPTER FOUR 7. Refer to Table 4 at the end of this chapter for torque specifications. Proper torque is essential in ensuring long life and satisfactory service from snowmobile compo- nents. 8. Apply a small amount of heat resistant grease to the in- ner lips of each new oil seal to prevent damage when first starting the engine.
Page 103: Engine Installation
ENGINE 18. If so equipped, remove the electric starter motor as described in Chapter Six. 19. With at least one assistant, lift the engine up and re- move it from the frame. Carry it to a workbench for fur- ther disassembly. ENGINE INSTALLATION 1.
Page 104 CHAPTER FOUR ENGINE MOUNTS...
Page 105: Engine Top End
ENGINE 8. If equipped with a battery, connect the negative battery cable to the engine. lowing: 9. Attach the crankcase pulse hose (Figure 10). a. Open the shroud. 10. Attach the oil hoses to the oil pump (B. Figure b. Drain the cooling system as described in Chapter 11.
Page 106 CHAPTER FOUR TOP END 1. Screw 14. Head gasket 2. Gasket 15. Nut 16. Cylinder 3. Screw 4. Washer 17. Stud 5. Coolant outlet 18. Dowel 6. Washer 19. Gasket 20. Upper piston ring 7. Seal 8. Coolant fitting 21. Lower piston ring 9.
Page 107 ENGINE 2. After removing the spark plug. check the spark plug threads in the cylinder head for any carbon buildup or cracking. The carbon can be removed with a 14 rnm spark plug thread chaser. After cleaning the threads, reinstall the spark plug and make sure it can be threaded into the cylin- der head completely.
Page 108: Cylinder
CHAPTER FOUR rial from the cylinder head mating surface will change the compression ratio and clearance of the squish area around the outside edge. 4. Check the cylinder head water passages for coolant residue and sludge buildup. Clean passages thoroughly with solvent and allow to dry thoroughly.
Page 109 ENGINE a. Remove the cylinder head studs as described in Chapter One. onto a piece of thick plate glass or surface plate (Figure 18). ure-eight pattern on the sandpaper. d. Rotate the cylinder several times to avoid removing too much material from one side. Chapter One.
Page 110: Piston. Piston Pin, And Piston Rings
CHAPTER FOUR 5. Make sure the end gaps of the piston rings are aligned with the locating pins in the ring grooves (Figure 23). Lu- bricate the piston rings and the inside of each cylinder bore lightly with injection oil. (Figure 6.
Page 111 ENGINE Washer Pipe Threaded connecting rod. I f the piston pin does not push out by hand, remove it as described in Step 6. 6. If the piston pin is tight, use a puller as shown in Fig- ure 26. The tool can be fabricated as shown. Assemble the tool onto the piston and pull the piston pin from the piston.
Page 112 (some side-to-side special tools and technicians trained and sliding is normal), have a Yamaha dealership check the experienced at rebuilding the crankshaft as- crankshaft further to see if it is satisfactory for further use.
Page 113 ENGINE area below the piston pin bore are usually caused by a lack of lubrication, rather than overheating. b. If the piston has seized and appears very dry (appar- ent lack of lubrication on the piston), a lean fuel mixture probably caused the overheating. Over- heating can result from incorrect jetting, air leaks or over-advanced ignition timing.
Page 114 CHAPTER FOUR ure 33, typical) and compare to the specified gap in Table 2 or Table 3. as a set. NOTE When installing new rings, measure the end gap as described in Step 6. I f the gap is less than specified, make sure they are the cor- rect piston rings.
Page 115 ENGINE conditions, the engine may be experiencing preignition or detonation. Both conditions are discussed in Chapter Two. CAUTION Do not clean piston skirts or ring lands us- ing a wire brush. The wire brush removes aluminum that will increase piston cleur- the ring lands causing decreased support for the piston rings.
Page 116 CHAPTER FOUR der bore is worn. Because the cylinder bores their original cylinder location (PTU, MAG are hard-surfaced, resizing is not possible. or CEN) and the direction the exhaust I f the cylinder bore is excessively worn, ei- port. The manufacturer 3 mark (arrow) cast therreplace the cylinder or machine it to ac- into the piston should point to the exhaust cept a cast iron liner.
Page 117: Reed Valve Assembly
ENGINE opening must not align with the slot in the piston pin bore of the piston. CAUTION Always install new piston pin clips and make sure clips snap securely into piston grooves. A weak or improperly installed clip could disengage during engine operation and cause excessive engine damage.
Page 118: Crankcase And Crankshaft
CHAPTER FOUR 8. Install a new gasket onto the crankcase and position the reed assembly into the crankcase opening. 9. Install the spacer (Figure 46) into the reed valve hous- ing. 10. Install the carburetor adapter onto the reed valve housing.
Page 119 ENGINE light coat of RTV high temperature silicone sealant Crankshaft service includes disassembling the crank- shaft, replacing unsatisfactory parts and accurate crank- shaft alignment. Special measuring and alignment tools, a hydraulic press and experience are necessary to disassem- ble, assemble and accurately align the crankshaft assem- bly.
Page 120 CHAPTER FOUR 10. Loosen the crankcase screws in two or more stages by reversing the sequence shown in Figure 53. Remove all crankcase screws, including the outer screws not shown in Figure 53. CAUTION Do not the cases apart with a screw- pry' driver or any other sharp tool;...
Page 121 a. Tape a piece of 400-600 grit wet emery paper onto a piece of plate glass or a surface plate. b. Move the case half slowly in figure-eight patterns on the sandpaper. See Figure 55, typical. surface is flat. d. Rotate the case half several times to avoid removing too much material from one spot.
Page 122 CHAPTER FOUR CRANKSHAFT ASSEMBLY 1. Nut 15. Crankshaft 16. Crankshaft 2. Lockwasher 3. Seal 17. Ball bearing 4. Roller bearing 18. Labyrinth seal 5. Collar 19. Spring pin 6. Key 20. Crankshaft 7. Crankshaft 21. Washer 22. Crankshaft Washer Connecting rod 23.
Page 123 ENGINE NOTE The V-blocks can be made of hardwood to perform the following checks. 6. Rotate each connecting rod around the crankshaft by hand, while checking for excessive noise or roughness. 7. Carefully examine the condition of the crankshaft main bearings. Clean the bearings with solvent and allow them to dry thoroughly.
Page 124 CHAPTER FOUR crank wheels, the crankshaft must be disas- sembled. Refer service to a qualified dealer- ship or crankshaft specialist. NOTE Do not check crankshaft runout with the crankshaft placed between lathe centers. Use V-blocks as described in Step 9. 9.
Page 125 ENGINE Attach a puller as shown in Figure 70, then use the on the crankshaft. It is critical to properly puller to remove the bearing assemblies. install the bearings. 5. Install the roller bearing at the flywheel end of the seal and spacer.
Page 126 CHAPTER FOUR bearing race into the bearing rollers are lubrication holes. CA UT10N Make sure the roller bearing is installed with the lubrication holes and locating dowel pinhole positioned as shown in Fig- w e 71. Incorrect bearing installation causes bearing failure because of the lack of lubrication.
Page 127 ENGINE a. Rotate the crankshaft ball bearings to align their lo- cating pins with the pin recesses in the upper crank- case. See Figure 75, typical. bearing (A, Figure 71) aligns with the pin in the up- per crankcase half (Figure 76). 73) engages both grooves in the upper and lower crankcase halves.
Page 128: Coolant Pump And Oil Injection Pump Drive Shaft
CHAPTER FOUR quently while tightening the bolts to make sure the crank- shaft continues to turn freely. 10. Install the pistons and cylinders as described in this chapter. 11. Install the oil pump as described in this chapter. 12. Install the coolant pump as described in Chapter Eight.
Page 129 ENGINE Table 1 ENGINE IDENTIFICATION (continued) Engine Displacement Model cooling type mm (in.) Liquid 70.5 x 59.6 (42.6) Liquid 70.5 x 59.6 (2.78 x 2.35) (42.6) Table 2 593 CC ENGINE SERVICE SPECIFIGAATIONS mm (in.) Piston diameter Distance measured from skirt bottom 1 0 (0.39) Piston ring end gap 0.35-0.55 (0.01 4-0.022)
Page 130 CHAPTER FOUR Crankshaft runout (maximum)* Inner bearings 0.04 (0.001 6) Crankshaft ends 0.03 (0.0012) Cylinder head warpage (max.) 0.03 (0.0012) Cylinder bore 70.50-70.52 (2.775-2.776) Out of round (maximum) 0.1 (0.0004) Taper (maximum) 0.5 (0.002) Reed stop height ' S ee text for measuring point Table 4 TORQUE SPECIFICATIONS Carburetor adapter Crankcase bolts...
Page 131: Air Box
Fuel and Exhaust Systems The fuel system consists of the fuel tank, fuel pump, carburetors and air box. There are slight differences 1. Open the shroud. among the various models and they are noted in the vari- 2. Remove the air filter element (B, Figure 1, typical). ous procedures.
Page 132: Intake Tubes
CHAPTER FIVE INTAKE TUBES The carburetor is supported by a rubber intake tube (Figure 2, shown with carburetor removed). Periodically inspect the tubes for cracks or other damage which may cause an air leak, causing a lean air/fuel mixture. CARBURETOR All engines are equipped with slide-valve type Mikuni carburetor specifications and models.
Page 133: Carburetor Service
FUEL AND EXHAUST SYSTEMS CARBURETOR OPERATION (THROTTLE OPENING CARBURETOR OPERATION (THROTTLE OPENING 0 TO 118) Pilot outlet Pilot jet (Figure 4). As the throttle is opened further, the air stream begins to siphon fuel through the main jet and needle jet. The tapered needle increases the effective flow capacity of the needle jet as it rises with the throttle valve, in that it occupies decreasingly less of the area of the needle jet...
Page 134 CHAPTER FIVE CARBURETOR OPERATION 5. Disconnect the connector leads to the throttle override switch (Figure 10). 6. Loosen the jam nut (Figure 11) on the starter cable, then unscrew and disconnect the starter cable. 7. Disconnect the throttle cable (Figure 12). 8.
Page 135 FUEL AND EXHAUST SYSTEMS 3. Detach the starter cable bracket (A, Figure 16)? then remove the collar (B) and spring (C) from the starter rod. 4. Loosen thc clamp screw (D, Figure 161 on each starter rod a m . Remove the arm (A, Figure 17) and spring (B) from the end of the rod.
Page 136 Screw Top cover 3. Gasket 4. Screw Starter cable bracket 7. Hose Collar 9. Spring Lower mounting bracket bracket 15. Spring...
Page 137 FUEL AND EXHAUST SYSTEMS...
Page 138 CHAPTER FIVE CARBURETOR Clip 2. Shim 4. Jet needle 5. Body 7. Throttle lever 10. Screw 14. Gasket 18. Throttle cable bracket 20. Washer 21. Nut 22. Sprlng 23. TORS switch 24. Idle speed screw 26. Spring seat 27. Throttle shaft 28.
Page 139 FUEL AND EXHAUST SYSTEMS 7. Remove the needle jet through the top of the carburetor (Figure 29). 8. Remove the float pin (A, Figure 30). NOTE Be careful when removing the float. The fuel inlet valve and clip can fazll offthefloat tang when removing the float.
Page 140 CHAPTER FIVE Good 10. Unscrew the retaining screw (A, Figure 31) and re- move the fuel inlet valve seat (B) and O-ring. CA UTION 11. Remove the pilot jet (Figure 32) and sleeve. Do not use wire or a drill bit to clean carbu- 12.
Page 141 FUEL AND EXHAUST SYSTEMS 10. Check the float for fuel saturation, deterioration or excessive wear where it contacts the float arm. Replace as required. If the float is in good condition, check it for leak- age as follows. Fill the float bowl with water and push the floats down.
Page 142: Carburetor Adjustments
CHAPTER FIVE 10. Install the spring, washer and O-ring onto the pilot mixture screw (Figure 39). Install the pilot mixture screw into the carburetor body. Then back the screw out the same number of turns noted during disassembly. 11. Install the starter assembly (Figure 40).
Page 143: Fuel Pump
FUEL AND EXHAUST SYSTEMS Drain screw level ally affects the engine cooling system through the loss of engine coolant. Heater Valve Coolant flow through the heating system is controlled by a manual control valve mounted on the air box (Figure 44).
Page 144 CHAPTER FIVE CARBURETOR HEATER SYSTEM Carburetor heater control valve...
Page 145: Fuel Tank
FUEL AND EXHAUST SYSTEMS hoses oftttztil qfier removing the clamps. 4. Loosen the hose clamps. Then detach the hoses from the pump. Plug the hoses to prevent fuei leakage or con- tamination. 5. Remove the nuts holding the fuel pump to the frame and remove the fuel pump.
Page 146 CHAPTER FIVE FUEL TANK Clamp 4. Fitting Fuel cap 6. Gasket 8. Washer Gasket Hose 14. Screw 16. Hose system may cause decreased engine performance as well as excessive noise levels. the exhaust system i s hot, waif until it cools before removing it.
Page 147: Exhaust System
FUEL AYD EXHAUST SYSTEMS EXHAUST SYSTEM 2. Muffler 3. Spring 4. Protector 5. Protector Gasket Spring Spring 9. Exhaust pipe 12. Exhaust manifold 13. Bolt Gasket Cleaning tach a piece of discarded control cable to an electric &ill (Figure Fray the loose end of the cable and insert the cable into the pipe.
Page 148 be easily repaired if welding equipment, some simple body tools, and a slide hammer are available. Drill a small hole in the center of the dent. Screw the end of the slide hammer into the hole. 2. Heat the area around the dent evenly with a torch. 3.
Page 149 FUEL AND EXHAUST SYSTEMS Table 2 CARBURETOR SPECIFICATIONS-MM700, SX700, VT700, AND VX700SX/SXS/XT/XTC/XTCD/XTCP Throttle valve cutaway Float height Fuel level 36-38 mm (1.42-1.50 in.) Pilot air screw 1 1/2 turns out...
Page 150: Battery
Chapter Electrical System This chapter provides service procedures for the igni- weather for long periods, remove the battery and store it in tion system, lights and other electrical equipment. Electri- a warm place. cal troubleshooting procedures are described in Chapter CAUTION Two.
Page 151 ELECTRICAL SYSTEM with a stiff wire brush. Replace excessively worn or dam- aged cables. NOTE Do not overfill the battery cells in Step 9. The electrolyte expands because of heat from charging and will overflow i f the level is above the upper level line. 9.
Page 152 CHAPTER SIX NEEDS FULLY CHARGING CHARGED Take reading eye level Float Do not suck much in too electrolyte Hold must Float tube be free vertical Weight Hold the hydrometer vertically and note the number in the specific gravity varies more than 0.050 from cell to line with the surface of the electrolyte (Figure 3).
Page 153 ELECTRICAL SYSTEM Charging Maintain a good state of charge in batteries used for starting. When charging the battery, the cells will show signs of gas bubbling. If one cell has no gas bubbles or if its specific gravity is low, the cell is probably shorted. ter charging or if the specific gravity drops quickly, the battery is defective.
Page 154: Capacitor Discharge Ignition (Cdi)
CHAPTER SIX CAPACITOR DISCHARGE IGNITION (CDI) 2. Lockwasher 3. Bolt 4. Starter pulley 5. Spacer 6. Flywheel 7. Bolt Washer 9. Stator 10. Key 11. Crankshaft 12. Screw 13. Plate 14. Screw 15. Bracket 16. Pickup coil New Battery Installation tery, make sure it has been properly charged.
Page 155 ELECTRICAL SYSTEM Refer to Figures 7-12 when performing procedures in this section. Troubleshooting Refer to Chapter Two. Flywheel The flywheel must be removed to service the stator coils. Flywheel replacement is usually necessary only if the magnets have been damaged by mechanical heat or shock.
Page 156: Cdi Box
CHAPTER SIX 2. Remove the frame crossmember (Figure 7). 14. Hold the primary sheave to prevent crankshaft rota- tion. Then tighten the flywheel nut to 11 0 W m (8 1 &.-lb.). NOTE 15. Install the water pump drive belt as described in The engine has been removed for clarity.
Page 157 ELECTRICAL SYSTEM 3. Disconnect the ignition coil electrical connectors, 4. Remove the screws holding the ignition coils to the fore connecting the wire connectors, make sure both con- nector halves arc clean of all dirt and moisture residue. Use electrical contact cleaner to clean the connectors. Spark Plug Caps Replace the spark plug caps by pulling the old caps off the coil's high tension wire.
Page 158 CHAPTER SIX STARTER 1. Throughbolt Washers 13. Armature Washer 3. End cap 14. Washer Grommet 15. Frame 16. O-ring 17. Drive housing 6. O-ring 7. Brush spring Drive assembly Positive brush 19. Washer 20. Spring 9. Grommet 10. O-ring Pinion stopper Snap ring...
Page 159 Have an assistant on hand to help with its removal and purchase a new clip from a Yamaha dealership before disassembling the starter motor. 6. If necessary, remove the pinion gear as follows: a.
Page 160 CHAPTER SIX Clip Vise-grip Clip Pinion gear 0.35-0.40 (9-10 Pinion stopper 7. If it is necessary to remove the brush plate lift the bmsh plate out of the end cap including the negative brush (Fig- Return spring ure 19). The positive brush will remain in the end cap (Figure 20).
Page 161 4. Check the fiber washer(s) and replace if worn, cracked or damaged in any way. If this washer is not available from a Yamaha dealership, check with an automotive electrical repair shop. 5. Check the metal thrust washers for damage. Replace if necessary.
Page 162: Switches
the commutator serviced by a dealership or electrical re- pair shop. 8. Inspect the commutator copper bars (Figure 24) for discoloration. If a pair of bars is discolored, grounded ar- mature coils are indicated. 9. Measure the commutator outside diameter with a ver- nier caliper and compare to specifications in Table 3.
Page 163 ELECTRICAL SYSTEM SWITCHES CARBURETOR SWITCH BRAKELIGHT SWITCH HEADLIGHT SWITCH THROTTLE SWITCH MAIN SWITCH...
Page 164 (Figure 33). If ei- ther switch is damaged, replace the complete right handle- 1. Remove the rear handlebar cover. bar switch assembly; individual switches are not available from Yamaha. nector. 3. Loosen the Phillips screw at the bottom of the switch NOTE housing and turn the housing over.
Page 165: Instrument Panelwarning Light Check
ELECTRICAL SYSTEM 3. Disconnect the main switch electrical connector and remove the main switch. Installation is the reverse of the preceding steps. Carburetor Switch Refer to Throttle Override System in this chapter. Throttle Switch Refer to Throttle Override System in this chapter. INSTRUMENT PANEL WARNING LIGHT CHECK The instrument panel (Figure 35) is equipped with a...
Page 166: Oil Level Sender Testing
CHAPTER SIX To test the fuel level sender, disconnect the sender lead The ohmmeter should read 4-10 ohms when the fuel tank is full and 90-100 ohms when the fuel tank is empty. To replace the fuel level sensor, follow these steps: 1.
Page 167: Throttle Override System
Refill the cooling system as described in Chapter Three. THROTTLE OVERRIDE SYSTEM All models are equipped with the Yamaha Throttle Override System (TORS). The TORS system monitors the throttle and carburetor lever positions using The TORS system consists of a microswitch at the throttle lever and a microswitch at the carburetor (Figure 40).
Page 168 Aiming surface 2. Geometric center a. The ohmmeter should read zero ohms when operat- 5. Connect the ohmmeter to the black/yellow and black ing the throttle lever. terminals on the carburetor switch connector. Test as fol- lows: b. The ohmmeter should read infinity with the throttle a.
Page 169: Lighting System
ELECTRICAL SYSTEM 1. Open the shroud. 2. Disconnect the electrical connector at the headlight bulb (A, Figure 42). 3. Remove the rubber cover (B, Figure 42). 4. Detach the bulb holder and remove the headlight bulb. 5. Reverse the removal steps to install the headlight bulb. Make sure the bulb holder is securely in position.
Page 170 CHAPTER SIX Table 1 BATTERY Model Battery type Table 2 STATE OF CHARGE Specific State gravity of charge Discharged One-quarter charged One-half charged Threequarters charged Fully charged Table 3 STARTER SPECIFICATIONS Armature coil resistance 0.014-0.018 ohms Brush wear limit 8.5 mm (0.33 in.) Commutator outside diameter 28 mm (1.10 in.) Wear limit...
Page 171 ELECTRICAL SYSTEM Table BULBS (MM700 [PRIOR TO 20001, VT700, VX700SX [PRIOR TO 20001) Headlight Tachometer light Speedometer light High beam Indicator light Water temperature light Oil level indicator light...
Page 172: Oil Pump Service
Oil Injection System This chapter covers complete oil injection system ser- vice. All models are equipped with the Yamaha Autolube oil injection system (Figure 1). The system consists of a me- chanical gear-driven pump (Figure 2, typical), external oil tank (Figure 3, typical), hoses, throttle/oil pump cable assembly and a dash mounted low oil level warning light.
Page 173: Component Replacement
OIL INJECTION SYSTEM 4. Remove the bleed screw and gasket (Figure 4). 5. Drain the oil from the screw hole until the oil is free of air bubbles. 6. Reinstall the bleed screw and gasket. 7. Reinstall the carburetors. COMPONENT REPLACEMENT Oil Reservoir Tank Open the shroud.
Page 174 CHAPTER SEVEN PUMP Oil pump control cable 2. Bleed screw Gasket 5. Socket head screw Clamp 7. Protective spring 8. O-ring 9. Oil pump 10. Oil hose 11. Check valve...
Page 175: Oil Pump
OIL INJECTION SYSTEM 2. Detach the outlet lines from the pump. to the crankcase. 4. Pull the pump away from the crankcase. NOTE The oil pump is driven by the cross-shaft in the crankcase thai also drives the water pump impeller. The cross-shaft is accessible after disassembling the crankcase.
Page 176 Chapter Eight Cooling System This chapter covers service procedures for the water The cooling system must cool before removing any pump, connecting hoses and heat exchangers. component of the system. Cooling system flushing procedures are in Chapter Coolant Pump Three. The cooling system is a closed, liquid cooling system.
Page 177 COOLING SYSTEM Engine Right heat heat exchanger Center exchanger 4. Remove the right, front engine mounting bracket (Fig- NOTE The engine is shown removed/or clarity. 5. Remove the water pump cover (Figure 3). NOTE When unscrewing the impeller retaining bolt it may be necessary to hold the primary sheave so the impeller driveshaft does not rotate.
Page 178 CHAPTER EIGHT COOLANT PUMP 1. Bolt 11. Bolt 12. Washer 2. Washer 3. Bolt 13. Pump cover 4. Engine mount 14. O-ring 5. Bolt 15. Bolt 6. Bolt 16. Washer 7. Coolant hose 17. Impeller 18. Driveshaft 8. Clamp 9. Carburetor heating hose 19.
Page 179 COOLING SYSTEM Remove the impeller retaining bolt (A, Figure 7) and remove the impeller (B). Inspection 1. Remove the O-ring (A, Figure 8) from the pump cover. Install a new O-ring during assembly. 2. Inspect the impeller cavity (B, Figure 8) in the pump cover.
Page 180 CHAPTER EIGHT Hoses rubbing against another item. Make sure these guards are installed on the new hose. Hoses deteriorate with age and should be replaced peri- 2. Loosen the hose clamps from the hose to be replaced. odically or whenever they start cracking or leaking. To be Slide the clamps along the hose and out of the way.
Page 181 Chapter Nine Recoil Starter Rewind starters are relatively trouble-free. A broken or frayed rope is the most common malfunction. Starter Housing 2. Remove the handle as follows. a. Pull out the starter handle. b. Slide the rope through the handle (A, Figure 1). NOTE rope after removing the handle in substep This chapter covers removal and installation of the...
Page 182 CHAPTER NINE Leave 1/4-1/2 in. reserve length at end of rope RECOIL STARTER 1. Screw 11. Cam guide 2 . Washer 12. Spring 3. Bushing Drive pawl 14. Washer 4. Collar 5. Starter housing 15. Drive plate 16. Nut 6. Handle 7.
Page 183 RECOIL STARTER 4. Installation is the reverse of the preceding steps. Ob- serve the following: a. Apply Loctite 242 (blue) to the threads of the three retaining screws. screws. d. Reinstall the recoil starter housing as described in this chapter. Starter Housing c.
Page 184 CHAPTER NINE 8. Remove the cam guide (C, Figure 7) and spring (D). 9. Remove the sheave (Figure 8) and rope assembly from the starter housing. 10. If replacing the rope, remove the rope from the sheave. Be careful ifthe rewind spring (A, Figure 9) has remained in the cavity of the housing, because it may unwind suddenly and vio- lently, cawing serious injury.
Page 185 RECOIL STARTER Starter Housing Assembly Refer to Figure 4. Wear safety glasses and gloves while in- stalling the recoil spring. 1. Install the recoil spring (A, Figure 9) as follows: a. Lubricate the rewind spring and the cavity of the starter housing with a low-temperature grease.
Page 186 CHAPTER NINE the sheave slightly to make sure the sheave and the end of the spring arc engaged. 4. Install the pawl spring as shown in Figure 17. NOTE 5. Install the pawl (A, Figure 18). Make sure the spring The rope should be too long to wind com- engages the pawl.
Page 187 Chapter Ten Drive System contains a speed reduction on all models. It also contains the reverse gears of models so equipped. A front axle fit- ted with track drive sprockets exits from the chaincase. WARNING Never lean into a snowmobile engine cum- loose clothing when the engine is running or when the driver is starting the engine.
Page 188: Primary Sheave Assembly
High-speed Low-speed (Primary) Driven sheave (Secondary) wide enough for the V-belt to drop down between the Figure 2. sides of the sheave. There is no engagement because the width of the belt is less than the space between the sides of The shift sequence is determined by a combination of the primary sheave.
Page 189: Secondary Sheave
DRIVE SYSTEM Tapered surfaces SECONDARY SHEAVE NOTE slightly different than the one shown in. Fig- ure 6. Operation of both types is simiia~: Re- fer to the appropriate paragraphs of this against the sides of the rear (driven) sheave, it compresses chapter when servicing.
Page 190 PRIMARY SHEAVE 1. Bolt 15. Slider 2. Starter gear (electric 16. Pin 17. Locknut start models) 3. Fixed sheave half 18. Bushing Washer 4. Split collar 5. Sliding sheave half 20. Bushing 6. Locknut 21. Roller 7. Collar 22. Bolt 23.
Page 191 DRIVE SYSTEM SECONDARY SHEAVE 1. Screw 2. Cover (if so equipped) Bushing 4. Flange bolt 5. Shim Sliding sheave Stud 8. Screw 9. Holder stopper 10. Fixed sheave 11. Ramp shoe 12. Cover 13. Screw 14. Spring 15. Spring seatfcam 16.
Page 192: Drive Belt
Correct center-to-center distance ensures correct belt nance and the type of snowmobile operation. Inspect the tension and reduction ratio. The correct Yamaha align- belt at the intervals listed in Chapter Three. Early belt fail- ment bar or equivalent is necessary for checking the off-...
Page 193 Different alignment bars are used for the various models. Check with a Yamaha Inspection dealership for the availability of the correct alignment bar for the appropriate model.
Page 194 CHAPTER TEN lent primary sheave engagement. This is an indica- tion of a defective or improperly installed primary sheave. 5. Replace a worn or damaged belt immediately. Always carry a spare belt on the snowmobile for emergency pur- poses. Drive Belt Height Adjustment For a 1: 1 sheave ratio to occur, the drive belt must move to the outer edges of the secondary sheave (A, Figure 14) when the sheave halves are closed together (neutral posi-...
Page 195 1 if the desired nominal their equivalents are required to accurately adjust the sheave offset is 1 5 mrn. Use Yamaha gauge YS-4242 1-2 if sheave distance, offset and parallelism (Figure 17). These the desired nominal sheave offset is 20 mm. Position the...
Page 196: Primary Sheave Service
CHAPTER TEN gauge against the sheaves (Figure 21). The gauge should contact each sheave in at least two places at the same time. If it does not, perform the following: a. Loosen the front and rear engine mounting bolts (Figure 19 and Figure 20). See Chapter Four. specified in Table 3.
Page 197 (Figure 22) assembly. Disassembly The primary sheave is under spring pres- sure. Use the Yamaha special tool or an equivalent tool during disassembly and re- assembly, or refer service to a dealership. 1. Attach the sheave compressor (Yamaha sheave com- pressor part No.
Page 198 CHAPTER TEN b. Unscrew the pivot bushing retaining setscrews (B, Figure 30). c. Remove the weight, washers and bushing (Figure 31). 7. If further disassembly of the spider, fixed sheave and sliding sheave is necessary, take the assembly to a rotate the components during disassembly and reassem- bly.
Page 199 DRIVE SYSTEM Stamped side Weight Rivet NOTE To maintain primary sheave bafance, install the roller bolts so the threaded endfaces in a counterclockwise direction as shown in Fig- 3. Install the spider roller assemblies (Figure 28). Tighten the nut to 6 N-m (53 in.-lb.). Check that each roller turns smoothly.
Page 200 CHAPTER TEN PRIMARY SHEAVE 15. Slider 1. Bolt 2. Starter gear (electric 16. Pin start models) 17. Locknut 3. Fixed sheave half Bushing 4. Split collar 19. Washer 5. Sliding sheave half 20. Bushing 6. Locknut 21. Roller 7. Collar 22.
Page 201: Secondarysheave Service
DRIVE SYSTEM 5. Perform the Secondary Sheave Free Play Adjustment in this chapter. Secondary Sheave Free Play Adjustment 1 Remove the drive belt as described in this chapter. 2. The secondary sheave must have side clearance when installed on the jackshaft with the sheave bolt tightened. Check free play by moving the sheave back and forth by hand.
Page 202 CHAPTER TEN 3. Bushing Shim 7. Stud 8. Screw 14. Spring 17. Bushing 18. Collar (if so equipped) 19. ShIms 20. Washer...
Page 203 DRIVE SYSTEM 3. Check the sheave drive belt surfaces for rubber or sust buildup. For proper operation, the sheave surfaces must be clean. Remove mbber or rust debris with a coarse grade Check the splines in the fixed sheave half for cracks or damage.
Page 204 CHAPTER TEN Reassembly b. Refer to Table 17 and install the spring into the fixed sheave halfby inserting the spring end into the numbered hole specified. (Figure 44) and onto the spring so the spring end resides in the num- shims into the sliding sheave half.
Page 205 DRIVE SYSTEM Peak Model speed rprn rpm range 4400-4800 8250-8750 3800-4200 8050-8550 4500-4900 8050-8550 3700-41 00 8050-8550 3800-4200 8250-8750 3900 8300 4000 Table 2 DRIVE BELT SPECIFICATIONS Model Part Nom Circumference New width Wear limit $12.4 cm 35.0 mm (1 -26 in.) (44.3 in*) (1.38 in.) All other models (after 1997)
Page 206 CHAPTER TEN Table 7 PRIMARY SHEAVE SPRING lMM700 PRIOR TO 2000) Color code Green-Pin k-Green 48 mm (1 -89 in.) Inside diameter Wire diameter 5.8 mm (0.23 in.) Preload 300 N (67 lb.) Spring rate 27.5 N/mm (357 lb./in.) Number of coils 4.64 76.3 mm (3.0 in.) Free length...
Page 207 DRIVE SYSTEM Table 13 SECONDARY SHEAVE SPRING (MM700, SX700, VT700, Color code Green Outside diameter 69.5 mm (2.736 in.) Wire diameter 5.5 mm (0.21 7 in.) Spring rate 8.7 N/mm (50 Ib./i n .) Number of coils 5.53 Free length 75 mm (2.95 in.) Table 14 PRIMARY SHEAVE SPECIFICATIONS Slider halves max.
Page 208: Chapter Eleven
Chapter Eleven Brakes 2. Use only DOT 4 brake fluid from a sealed container. This chapter covers service procedures for the hydrauli- cally activated disc brake system and the mechanically Do not intermix silicone based (DOT Refer to Chapter Three for brake adjustment and brake because it can cause brake corn- fluid fluid level and filling procedures.
Page 209: Hydraulic Brake Pad Replacement
HYDRAULIC BRAKE PAD REPLACEMENT the friction surface on both pads face each other. There is no recommended time interval for changing c. Install the pad retaining spring plate (Figure 10) so the brake pads on the main brake. Pad wear depends the tabs fit into the recesses in the caliper.
Page 210: Brake Caliper
CHAPTER ELEVEN BRAKE CALIPER 2. Pad retaining pin 3. Allen screw 4. Caliper half 5. Bleed valve screw 6. Cap 7. Caliper half 8. Piston 9. Seals 10. Piston 11. Spring plate 12. Outer shim 13. Inner shim 14. Brake pad...
Page 211 BRAKES Wear limit...
Page 212 Caliper Overhaul This procedure describes complete overhaul of the brake caliper assembly. Yamaha does not provide service specifications for any caliper component; replace any part e. Direct compressed air in short spurts into the bleed that appears worn or damaged.
Page 213: Brake Master Cylinder
3. Unscrew the brake lever pivot bolt nut (A, Figure 16) and washer. Remove the brake switch (B). Then reinstall the washer and nut to prevent loss. CAUTION Cover the area around the master c-ylinder with a heavy cloth or plastic tarp to protect it from accidental brake fluid spills.
Page 214 CHAPTER ELEVEN MASTER CYLINDER 1. Screw 16. Parking brake lever 2. Cover 17. Washer Dowel pin 3. Gasket 4. Diaphragm 19. Screw 5. Body 20. Screw 6. Brake line 7. Fitting 22. Parking brake cable Jam nut 23. Brake switch Pivot bolt 24.
Page 215 BRAKES Disassembly Refer to Figure 14. 1. Remove the master cylinder as described in this chap- ter. 2. If not already removed, remove the screws securing the cover and remove the cover and diaphragm; pour out any residual brake fluid and discard it. Never reuse brake fluid.
Page 216: Parking Brake 2
CHAPTER ELEVEN 2. Inspect the hand lever pivot hole. If worn or elongated, replace the lever. body for cracks or elongation. If damaged, replace the master cylinder assembly. 4. Make sure the passage (Figure 22) in the bottom of the body reservoir is clear.
Page 217 BRAKES PARKING BRAKE Jam nut 2. Flange nut 3. Spring 4. Collar 5. Spring 6. Bolt 7. Caliper leg 9. Cotter pin 12. Cotter pin 13. Parking brake cable on the hydraulic brake master cylinder operates the park- ing brake. Refer to Chapter Three to adjust the parking brake.
Page 218: Brake Hose Replacement
CHAPTER ELEVEN than the specified wear limit. Refer to Parking Brake Dis- 4. Inspect the brake pad for damage and, if required, re- place the caliper brake leg. Parking Brake Disassembly/Reassembly Refer to Figure 24. legs. 2. Remove the cable guide pins and cotter pins. 3.
Page 219: Bleeding The Brake System
3. Remove the brake disc (B, Figure 29). 4. If necessary, remove the drive key (Figure 30) from the jackshaft. NOTE Measure brake disc thickness where the pads contact the disc, not at the edge ofthe disc. 5. Measure the thickness of the brake disc. Replace the brake disc if the thickness is less than 9.5 mm (0.374 in.) or the disc is damaged.
Page 220 CHAPTER ELEVEN cause brake failure. Do not intermix differ- ent brands or types as they may not be com- patible. Do not intermix a silicone based (DOT brake fluid as it can cause brake component damage leading to brake system failure.
Page 221: Chapter Twelve
Chapter Twelve This chapter describes complete service procedures for 7. Have an assistant apply the hydraulic brake. Loosen the drive sprocket nut (A, Figure 5) and the driven the chaincase, jackshaft and front axle. VT600, VT700, sprocket bolt (B). 8. Remove the drive sprocket nut (A, Figure 5) and equipped with a reverse gear.
Page 222 CHAPTER TWELVE 1. Bolt 14. Spacer 27. Snap ring 2. Cover 15. Washer 28. Bearing 16. Bearing 29. Bolt 3. Bearing 4. Nut 17. Roller 30. Dipstick 31. Chain tensioner bolt 5. Washer 18. Snap ring 32. Nut 6. Drive sprocket 20.
Page 223 CHAINCASE, JACKSHAFT AND FRONT AXLE and replace if necessary. Reverse to assemble the tensioner. Installation Refer to Figure 1. 1. Install the spacers onto the jackshaft and front axle (Figure 6). 2. Install the chain and sprockets. The necked side of the driven sprocket (Figure 7) must contact the spacer on the front axle.
Page 224: Drive Chain. Sprockets And Gears
21 8 CHAPTER TWELVE 10. Adjust chain tension as described in Chapter Three. 2. Check the drive and driven sprockets for cracks, deep scoring, excessive wear or tooth damage. Check the splines for the same abnormal conditions. DRIVE CHAIN, SPROCKETS AND GEARS 3.
Page 225: Chaincase
CHAINCASE, JACKSHAFT AND FRONT AXLE 7. Install the drive sprocket nut (A, Figure 14) and 2. Inspect the bearings (A, Figure 31). Ifbearing removal washer. is necessary, remove the snap ring (B) and press or drive 8. Install the spring ( C , Figure 13) and spring seat {B). out the bearing.
Page 226 CHAPTER TWELVE...
Page 227 CHAINCASE, JACKSHAFT AND FRONT AXLE CHAINCASE (WITH REVERSE) 37. Washer 1. Shift assembly 38. Spring seat 2. Rod end 39. Spring 3. Nut 40. Reverse gear 4. Rod 41. Spring 5. Nut 42. Coupler 6. Rod end 43. Snap ring 7.
Page 228 CHAPTER TWELVE...
Page 229 CHAINCASE, JACKSHAFT AND FRONT AXLE...
Page 230 CHAPTER TWELVE...
Page 231 CHAINCASE, JACKSHAFT AND FRONT AXLE 1. Collar 2. O-ring 3. Brake disc 4. Key Washer 6. Snap ring 7. Jackshaft 8. Nut 9. Bearing plate 10. Bolt 11. Setscrew 12. Bearing 13. Bearing plate 14. Bolt 15. Washer...
Page 232: Front Axle
CHAPTER TWELVE 4. Loosen the jackshaft bearing lock collar setscrews Figure 35). 5. Remove the nuts, washers and bolts securing the bear- ing flanges to the bulkhead Figure 351, then remove the bearing and flange assembly. Remove the jackshaft. Inspection 1.
Page 233 CHAINCASE, JACKSHAFT AND FROM' AXLE in.) (7.87 2. Remove the secondary sheave as described in Chapter Inspect the collar for wear where the seal lip contacts Ten. the collar. Replace the collar if worn or damaged. Replace the O-ring in the groove on the inside of the collar (Figure 3.
Page 234 CHAPTER TWELVE 102 mm 123 mm 102 mm 102 mm 123 mm 102 mm in.) (4.84 in.) in.) Installation Figure 42-VT700. Figure 43-VX60OSX. the direction shown in Figure 46. Figure 44-VX7OOSXS. 2. Align the fiont axle so Figure 45 -VX7OOXT/XTC/XTCD/XTCP. right side, then instal1 the front axle.
Page 235 123 mm 104 mm 104 mm (4.84 in.) (4.09 in.) 102 mm 102 mm (4.01 in.) (4.84 in.) (4.01 in.) i n . ) (5.22...
Page 236 CHAPTER TWELVE 123 mm 104 mm (4.09 in.) 111.9 mm (4.41 in.) 201 mm 164 mm (6.46 in.) 123 mm 104 mm 104 mm (4.84 in.) (4.09 in.)
Page 237 CHAINCASE, JACKSHAFT AND FROKT AXLE 23 1 TRACK ALIGNMENT Rear axle Front axle Install the speedometer cable housing, making sure the speedometer drive pin {Figure 47) properly en- gages the holes in the front axle and speedometer gear. Install the retaining nuts and tighten securely. Apply Loetite 242 (blue) to the bearing lock collar setscrews.
Page 238 CHAPTER TWELVE Upper /lower sprocket (number of teeth] Chain links 21139 22/40 23140 20139 22/39 20139 21139 21 J40 23/40 22/40 *Refer to Chapter Three for high-altitude adjustments. Table 3 TORQUE SPECIFfCATIONS Drive sprocket nut Driven socket boEt Front axle lock collar setscrews Reverse axle shaft bolt...
Page 239: Chapter Thirteen
Chapter Thirteen Front Suspension and Steering This chapter describes service to the skis, handlebar, 3. Remove the cotter pin (Figure 3, typical) from the end steering assembly, steering column and tie rods. Ski align- of the ski pivot bolt. Loosen and remove the nut, bolt and ment is described in Chapter Three.
Page 240 CHAPTER THIRTEEN SKI ASSEMBLY 1. Ski stopper Collar 4. Washer 5. Cotter pin 6. Nut 7. Ski 8. Cover 10. Washer Skag 12. Bolt...
Page 241 FRONT SUSPENSION AND STEERING SKI ASSEMBLY 1. Ski stopper Collar 3. Nut 4. Washer 5. Cotter pin 7. Mounting bracket 8. Handle 10. Washer 11. Nut 12. Washer 13. Ski 14. Washer 15. Bolt 16. Skag 17. Bolt 18. Washer 19.
Page 242 CHAPTER THIRTEEN g. Lock the pivot bolt by inserting a new cotter pin through the nut and bolt. Bend the ends of the cotter pin over the edges of the nut. Inspection Refer to Figure 1 or Figure 2. tion. Replace if necessary. 2.
Page 243 FRONT SUSPENSION AND STEERING FRONT SUSPENSION 16. Steering arm 30. Bolt 1. Nut 2. Bolt 17. Bushing 31. Nut 32. Washer 3. Shock absorber 18. Nut 4. Bushing 19. Bushing 33. Bushing 5. Sway bar 20. Link 34. Bolt 21. Bolt 35.
Page 244 CHAPTER THIRTEEN c. Clean the spindle and trailing arm bushings thor- oughly of all old grease. fore installation. marks (Figure 6) and install the steering arm (C, Figure 7). 56 N*m (40 h. Using a hand-operated grease gun inject grease into the fitting on the spindle housing.
Page 245 FRONT SUSPENSION AND STEERING 1. Support the front of the machine so both skis are off the ground. 2. Remove the outer steering arm and spindle as de- scribed in this chapter. NOTE Note bolt direction before removing the bolt in Step 3 in order to install it in the same di- rection during assembly.
Page 246 4. Installation is the reverse of the preceding steps. Note the following: a. Use high strength rivets to secure the sway bar sup- ports. Contact a Yamaha dealership for rivets. b. Apply low-temperature grease to the bushing in the sway bar link.
Page 247: Shockabsorber
I f a spring compressor is not on hand, refer spring removal to a Yamaha dealer- ship. 4. Install a spring compressor onto the shock absorber following the manufacturer's instructions.
Page 248: Handlebar And Grips
CHAPTER THIRTEEN UPPER SHOCK ABSORBER MOUNT 1. Bushing 2. Nut Mounting bracket 4. Bolt 5. Nut 6. Bolt 7. Bolt 8. Shock absorber rectly, a small amount of resistance should be felt on HANDLEBAR AND GRIPS the compression stroke and a considerable amount of resistance felt on the return stroke.
Page 249 FRONT SUSPENSION AND STEERING HANDLEBAR 1. Bolt 2. Cable guide Clamp 4. Oil tank breather hose 5. Oil pump cable 6. Throttle cable 7. Throttle cable holder Cover 9. Screw 10. Brake lever holder 11. Handlebar 12. Clamp 13. Steering column 14.
Page 250 CHAPTER THIRTEEN The handlebar grips on all models are equipped with a heating element that is molded into the grip. 2. Using a suitable utility knife, cut the grip lengthwise and peel the grip off the handlebar. 3. Clean any adhesive residue off the handlebar. Do not use any grease, soap or other Izibri- cant to install grips.
Page 251 FRONT SUSPENSION AND STEERING STEERING SYSTEM 1. Nut 18. Bearing 19. Collar 2. Lockplate 3. Cable guide 20. Steering arm 4. Collar 21. Cotter pin 22. Nut 6. Steering column 23. Tie rod end 7. Cotter pin 24. Nut 25. Tie rod 8.
Page 252 CHAPTER THIRTEEN e. Tighten the outer tie rod end bolts to 42 N*m (30 f. After installing the tie rods andlor steering relay rod, check ski alignment as described in this chap- ter. Steering Relay Arm Refer to Figure 22. ground.
Page 253 FRONT SUSPENSION AND STEERING 1. Park the snowmobile on a level surface so the skis and the snowmobile are pointing in the same direction. 2. The handlebar should face straight ahead. 3. If the handlebar is not properly aligned, perform the following steps.
Page 254 CHAPTER THIRTEEN FORWARD Angle finder Negative Positive...
Page 255 FRONT SUSPENSION AND STEERING 5. To adjust spindle camber, proceed as follows: The top of the spindle tilts away from the snowmobile if it has positive camber. See Figure 32. a. Loosen the jam nut at the inner end on the lower Adevice to measure spindle angle in degrees is required control arm (Figure to measure spindle camber.
Page 256 CHAPTER THIRTEEN Table 1 TORQUE SPECIFICATIONS (continued) Shock upper mounting bracket Handlebar Steering column bearing holder Steering relay rod Rod end Jam nuts Tie rod Inner tie rod end nuts Outer tie rod end bolts Jam nuts Steering relay arm pivot bolt Table 2 TOE-OUT SPECIFICATIONS Model...
Page 257: Chapter Fourteen
Track and Rear Suspension All models are equipped with a slide rail rear suspen- original location with a marker or paint to facilitate assembly. sion. Refer to Chapter Three to adjust the rear suspension. Torque specifications are in Table 1. Remove the bolts (Figure 3) on each side securing the Refer to Chapter Three for information concerning rear rear suspension assembly to the tunnel.
Page 258: Wear Strips
CHAPTER FOURTEEN mounting bolt on each side, tighten it to 72 N*m (53 on each side, tighten them to 24 N-m (17 ft.-lb.). Inspection 1. Clean all bolts, nuts and threaded holes thoroughly with solvent. 2. Inspect the suspension attaching bolts for thread dam- age or breakage.
Page 259: End Caps
TRACK AND REAR SUSPENSION REAR SUSPENSION FASTENERS bolts Bolt the screw hole in the wear strip aligns with the hole in the rail. d. Install the screw and tighten securely. END CAPS The end caps are attached to the front end of the slide rail with a rivet as shown in Figure 6 .
Page 260: Shockabsorbers
CHAPTER FOURTEEN SHOCK ABSORBERS One shock absorber is located at the front of the rear suspension; the other is located at the rear. The shock ab- sorber is charged with high pressure gas. A coil spring is mounted on each shock absorber. The removal and ser- vice procedure are different for the various models.
Page 261 TRACK AND REAR SUSPENSION Spring retainer Bumper Spring adjuster a. Inspect the damper housing for cracks, dents or 2. Remove the front axle (Figure 13) as described in other damage. Replace the damper housing if dam- Chapter Twelve. aged. Do not attempt to repair or straighten it. 3.
Page 262 CHAPTER FOURTEEN FRONT COMPONENTS REAR SUSPENSION (LATER MM600/MM700) 16. Bushing 31. Bushing 1. Bushing 2. Washer 17. Collar 32. Collar 33. Bolt-30 Ngm (22 ft.-lb.) 3. Shaft 18. Nut 34. Bolt-72 Nem (52 ft.-lb.)* 4. Bolt 19. Washer 5. Eyebolt 20.
Page 263 TRACK AND REAR SUSPENSION FRONT COMPONENTS REAR SUSPENSION (EXCEPT LATER MM600lMM700) Washer 31. Wheel 1. Bushing 32. Washer 2. Shaft 17. Washer 18. Bolt 33. Nut 3. Bolt 19. Strap 34. Front suspension 4. Front pivot arm 20. Nut 35. Bolt Eyebolt 6.
Page 264 CHAPTER FOURTEEN REAR COMPONENTS REAR SUSPENSION (TYPICAL) 30. Mounting bracket 1. Shaft 16. Track tension adjuster 2. Wheel 17. Nut (if so equipped) 31. Bolt-71 N-m (50 ft-lb.) 3. Collar 18. Collar 4 Washer 19. Wheel 32. Collar (if so equipped) 5.
Page 265 TRACK AND REAR SUSPENSION 71. Collar Cotter pin Snap ring Bolt 5 8 . Wheel 7 2 . Washer 59. Shaft Bolt-49 N*m Bushing B o l t 4 9 Nom Wheel Bolt Sliding frame Washer Rear pivot arm 7 5 . N u t 4 9 N-m Bushing 7 6 .
Page 266 CHAPTER FOURTEEN LUG DAMAGE FRONT Track Ground RATCHETING DAMAGE...
Page 267 TRACK AND REAR SUSPENSION OVER-TENSION DAMAGE LOOSE TRACK DAMAGE to open and expose the cord. This frequently hap- pens in more than one place. Impact damage is usu- ally caused by riding on rough or frozen ground or ice. Also, insufficient track tension can allow the track to pound against the track stabilizers inside the IMPACT DAMAGE tunnel.
Page 268 CHAPTER FOURTEEN 1. Using a hand grinder (Figure 24), grind a slit in the 3. Align the new clip onto the track. Then install the clip comer of the clip. See Figure 25. with the clip installation tool (Figure 27). Check the clip 2.
Page 269 TRACK AND REAR SUSPENSION Table 2 CONTROL ARM LENGTH (continued) Upper control a r m Lower control a r m Upper control Lower control arm...
Page 270 Chapter Fifteen Of f-Season Storage One of the most critical aspects of snowmobile mainte- Do not allow water to enter the engine when nance is off-season storage. Proper storage prevents en- gine and suspension damage and fuel system contamination. Improper storage causes deterioration and 4.
Page 271 OFF-SEASON STORAGE NOTE A cloud of smoke will develop in substep 9c. This is normal. d. Spray engine preservative (storage oil) into all car- buretors until the engine smokes heavily or begins to stall. f. Reinstall the airbox. CAUTION To prevent expensive engine damage, clean the area around the sparkplug holes before removing the sparkplugs.
Page 272 CHAPTER FIFTEEN 17. Using a suitable siphon tool, siphon fuel out of the fuel tank and into a gasoline storage tank. 18. When the fuel tank is empty, remove the airbox (Fig- ure 1). Remove the drain screw (Figure 4) on each carbu- retor and drain the carburetors.
Page 273 Index 150-151 Chaincase Air box Daily maintenance schedule drive chain Axle Decimal and metric equivalents and sprockets. except VT600. front . 2 2 6-23 1 Disc. brake . 2 1 2.2 13 Drive belt specifications 2 15-2 18 Drive chain specifications 23 1 and sprockets.
Page 274 INDEX ..... Hose replacement. brake Fluid checks ....Hydraulic brake pad replacement Front axle .
Page 275 INDEX suspension adjustments 84-87 Scheduled maintenance primary sheave ....unscheduled Secondary sheave 183-1 86 spring 199-200 Master cylinder .20 7.2 10 service 195-198 pulley alignment Metric tap drill sizes specifications rear suspension Monthly maintenance schedule .
Page 276 INDEX 593 cc engines Suspension Track .25 5.262 ....... . 698 ec engines rear (continued) end caps...
Page 277 Wiring Diagrams...
Page 278 WIRING DIAGRAMS WITHOUT ELECTRIC STARTER Main switch Engine Variable Thumb stop Throttle switch switch Tachometer assembly * - - - - - - - - - - - - - - - meter Water temp. Condenser switch Left and right sender grip warmer level...
Page 279 WIRING DIAGRAMS Diagram Key connectors Ground Frame ground No connection regulator Black Green Blue Yellow orange Pink Brown Brake light switch Spark plugs...
Page 280 WIRING DIAGRAMS EQUIPPED WITH ELECTRIC STARTER Main switch Engine Variable Thumb resistor warmer Tachometer assembly ,--------------- meter Headlight light Hgh beam indicator light Water temp. Headlight beam switch Condenser Fuel Left and right sender grip warmer level switch...
Page 281 WIRING DIAGRAMS Diagram Key magneto Water Ground Frame ground No connection passenger Color Code Black Green Blue Yellow Orange Pink Brown back Brake light buzzer switch position...
Page 282 NOTES...

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