Yamaha VX600ERG Service Manual
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Yamaha VX600ERG Service Manual

Yamaha VX600ERG Service Manual

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SERVICE MANUAL
VX600ERG
SX600G
MM600G
VT600G
LIT-12618-02-20
8EA-28197-10
981059

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Summary of Contents for Yamaha VX600ERG

  • Page 1 SERVICE MANUAL VX600ERG SX600G MM600G VT600G LIT-12618-02-20 8EA-28197-10 981059...
  • Page 2 NOTICE HOW TO USE THIS MANUAL This manual was written by the Yamaha Motor Com- pany primarily for use by Yamaha dealers and their Particularly important information is distinguished in qualified mechanics. It is not possible to put an entire this manual by the following notations: mechanic’s education into one manual, so it is as-...

  • Page 3: Periodic Inspection And

    ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information POWR 2 Periodic inspection and adjustment CHAS 3 Chassis 4 Power train 5 Engine 6 Cooling system 7 Carburetion...
  • Page 4 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTION AND INSP ADJUSTMENT CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB – ELECTRICAL ELEC SPECIFICATIONS SPEC...

  • Page 5: Table Of Contents

    CHAPTER 1. POWER TRAIN ..........2-16 GENERAL INFORMATION SHEAVE DISTANCE AND OFFSET ADJUSTMENT ......... 2-16 DRIVE V-BELT ......... 2-18 MACHINE IDENTIFICATION ......1-1 ENGAGEMENT SPEED CHECK ..... 2-20 FRAME SERIAL NUMBER ......1-1 PARKING BRAKE PAD INSPECTION ..2-20 ENGINE SERIAL NUMBER ....... 1-1 PARKING BRAKE ADJUSTMENT ...
  • Page 6 SKI ..............3-8 BRAKE MASTER CYLINDER VX600ER/VT600 ........3-8 ASSEMBLY ..........4-37 SX600/MM600 ..........3-9 INSTALLATION ........4-37 INSPECTION ..........3-10 INSTALLATION SLIDE RAIL SUSPENSION ......4-38 (VX600ER/VT600) ........3-10 VX600ER/SX600 ........4-38 VT600 ............4-39 FRONT SUSPENSION ........3-11 MM600 ............
  • Page 7 CHAPTER 6. THROTTLE OVERRIDE SYSTEM (T.O.R.S.) ........... 8-8 COOLING SYSTEM HANDLEBAR SWITCH (RIGHT) ....8-8 CARBURETOR SWITCH ......8-9 HEAT EXCHANGER ........6-1 MAIN SWITCH ........... 8-9 VX600ER/SX600/VT600 ......6-1 LOAD CONTROL RELAY ......8-10 MM600 ............6-2 EMERGENCY ENGINE STARTING INSPECTION ..........
  • Page 8 PASSENGER GRIP WARMER (VT600) .. 8-43 PASSENGER GRIP WARMER SWITCH (VT600) ........8-44 RESISTOR (VT600) ......... 8-44 PASSENGER GRIP WARMER RELAY (VT600) ............. 8-45 FAULT LOCATION TABLE ......8-46 CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS ......9-1 MAINTENANCE SPECIFICATIONS ....9-4 ENGINE ............

  • Page 9: Chapter 1. General Information

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number is located on the right-hand side of the frame (just SEA1010 below the front of the seat). ENGINE SERIAL NUMBER The engine serial number is located on the right-hand side of the crankcase.

  • Page 10: Important Information

    SEA1070 ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments. SEA1080...

  • Page 11: Gaskets, Oil Seals, And O-Rings

    IMPORTANT INFORMATION INFO GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

  • Page 12: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. NOTE: Be sure to use the correct part number when ordering the tool, since the part number may differ according to country.

  • Page 13: For Engine Service

    SPECIAL TOOLS INFO FOR ENGINE SERVICE • Piston pin puller P/N: YU-01304 (for U.S.A./Canada) 90890-01304 (for Europe) This tool is used to remove the piston pin. SEA1170 • Rotor holding puller P/N: YU-33270 1 (for U.S.A./Canada) 90890-01362 2 (for Europe) This tool is used to remove the magneto rotor.

  • Page 14: For Carburetion Service

    SPECIAL TOOLS INFO • YXR clutch bushing jig kit P/N: YS-39752 This tool is used for removal and installation of primary clutch weight and roller bushings. SEA1250 • Clutch bushing press P/N: YS-42424 This tool is used for removing and installing the post bushings (primary sheave cap bush, sliding sheave bush and torque cam bush).

  • Page 15: Periodic Inspection And Adjustment

    INSP INTRODUCTION/PERIODIC MAINTENANCE TABLE PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale.
  • Page 16 INSP PERIODIC MAINTENANCE TABLE Every Initial Pre- 1 month Seasonally operation Item Remarks check 800 km 3,200 km (Daily) (500 mi) (2,000 mi) (40 hr) (160 hr) Check oil level. Drive chain oil Replace. Check deflection. Initial at 500 km (300 mi) and every 800 km Drive chain Adjust if necessary.

  • Page 17: Engine

    INSP SPARK PLUGS ENGINE SPARK PLUGS 1. Remove: • Spark plug caps • Spark plugs 2. Inspect: • Electrodes 1 Damage/wear → Replace the spark plug. • Insulator color 2 SEA2010 3. Measure: • Spark plug gap a Out of specification → Regap. Use a wire thickness gauge.

  • Page 18: Oil Pump

    INSP OIL PUMP OIL PUMP Air bleeding CAUTION: The oil pump and oil delivery line must be bled in the following cases: • Any portion of the oil system has been disconnected. • The machine has been turned on its side. •...
  • Page 19 INSP OIL PUMP 14. Install: • Gasket (bleed bolt) • Bleed bolt 15. Install: • Rear bracket (right) M8 mounting bolt (rear): 33 Nm (3.3 m · kg, 24 ft · lb) M10 mounting bolt (rear): 57 Nm (5.7 m · kg, 41 ft · lb) 16.

  • Page 20: Fuel Line Inspection

    INSP FUEL LINE INSPECTION/COOLING SYSTEM FUEL LINE INSPECTION 1. Remove: • Intake silencer Refer to “FUEL PUMP” in CHAPTER 7. 2. Inspect: • Fuel hose 1 • Fuel delivery hoses 2 Cracks/damage → Replace. 3. Install: SEA2090 • Intake silencer Refer to “FUEL PUMP”...
  • Page 21 INSP COOLING SYSTEM 4. Remove: • Coolant filler cap 1 WARNING Do not remove the coolant filler cap 1 when the engine is hot. Pressurized scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, place a thick rag or a towel over the coolant filler cap.
  • Page 22 INSP COOLING SYSTEM 9. Disconnect: • Coolant hoses 1 Å VX600ER/SX600/VT600 ı MM600 10. Drain the coolant. NOTE: Lift up the front of the machine to drain the coolant completely. SEA2150 WARNING Coolant is poisonous. It is harmful or fatal if swallowed.
  • Page 23 INSP COOLING SYSTEM 18. Inspect: • Gasket (coolant drain bolt) Damage → Replace. 19. Install: • Gasket • Coolant drain bolt 1 Coolant drain bolt: 13 Nm (1.3 m · kg, 9.4 ft · lb) SEA2130 20. Install: • Exhaust joint •...
  • Page 24 INSP COOLING SYSTEM 22. Bleed the air from the cooling system. 23. Inspect: • Cooling system Decrease of pressure (leaks) → Repair as required. Inspection steps: • Attach the cooling system tester 1 to the coolant filler 2. Cooling system tester: 90890-01325, YU-24460-01 •...
  • Page 25 INSP COOLING SYSTEM Air bleeding steps: • Lift up the tail of the machine. • Remove the bleed bolt 1 on the heat exchanger. • While slowly adding coolant to the coolant filler, drain the coolant until no more air bubbles ap- pear.

  • Page 26: Carburetor Synchronization

    COOLING SYSTEM/ INSP CARBURETOR SYNCHRONIZATION • Remove the coolant filler cap and bleed the cooling system again, as described above. No air bubbles → OK. • Add coolant to the specified level. • Pour coolant into the coolant reservoir 3 until the coolant level reaches the “FULL”...

  • Page 27: Engine Idle Speed Adjustment

    ENGINE IDLE SPEED ADJUSTMENT/ INSP THROTTLE CABLE FREE PLAY ADJUSTMENT ENGINE IDLE SPEED ADJUSTMENT 1. Adjust: • Engine idle speed Adjustment steps: • Start the engine and let it warm up. • Turn the throttle stop screw 1 in or out until the specified engine idle speed is obtained.

  • Page 28: Throttle Override System (T.o.r.s.) Check

    THROTTLE CABLE FREE PLAY ADJUSTMENT/ INSP THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK 2. Adjust: • Throttle cable free play Adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 in or out until the specified free play is obtained. Turning in →...

  • Page 29: Starter (Choke) Cable Free Play Adjustment

    STARTER (CHOKE) CABLE FREE PLAY ADJUSTMENT/ INSP EXHAUST SYSTEM INSPECTION STARTER (CHOKE) CABLE FREE PLAY ADJUSTMENT 1. Measure: • Starter cable free play a Out of specification → Adjust. Starter cable free play: 0.5 ~ 1.5 mm (0.02 ~ 0.06 in) SEA2330 2.

  • Page 30: Power Train

    INSP SHEAVE DISTANCE AND OFFSET ADJUSTMENT POWER TRAIN SHEAVE DISTANCE AND OFFSET ADJUSTMENT 1. Open the shroud. 2. Remove: • Drive V-belt guard • Drive V-belt 3. Measure: • Sheave distance a Use the distance gauge. Out of specification → Adjust. Sheave distance: 267 ~ 270 mm (10.52 ~ 10.62 in) Distance gauge:...
  • Page 31 INSP SHEAVE DISTANCE AND OFFSET ADJUSTMENT 5. Adjust: • Sheave distance Adjustment steps: • Loosen the mounting bolts (front) 1 and mount- ing bolts (rear) 2. • Adjust the position of the engine so that the sheave distance is within the specification. •...

  • Page 32: Drive V-Belt

    INSP DRIVE V-BELT DRIVE V-BELT 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 33 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 edge to Not necessary –0.5 mm (–0.02 in)

  • Page 34: Engagement Speed Check

    ENGAGEMENT SPEED CHECK/ INSP PARKING BRAKE PAD INSPECTION ENGAGEMENT SPEED CHECK 1. Place the machine on a level surface of hard- packed snow. 2. Check: • Clutch engagement speed Checking steps: • Start the engine, and open the throttle lever gradually.

  • Page 35: Parking Brake Adjustment

    PARKING BRAKE ADJUSTMENT/ INSP BRAKE LEVER ADJUSTMENT (VX60ER/SX600/VT600) PARKING BRAKE ADJUSTMENT 1. Measure: • Clearance a Out of specification → Adjust. Clearance: 1.2 ~ 1.3 mm (0.047 ~ 0.051 in) 2. Adjust: SEA2480 • Clearance a Adjustment steps: • Loosen the locknuts 1. •...

  • Page 36: Brake Fluid Level Inspection

    BRAKE FLUID LEVEL INSPECTION/ INSP BRAKE PAD INSPECTION BRAKE FLUID LEVEL INSPECTION 1. Place the machine on a level surface. 2. Check: • Fluid level Fluid level is under the “LOWER” level line a → Fill to the proper level. Recommended brake fluid: DOT 4 SEA2510...

  • Page 37: Brake Hose Inspection

    BRAKE HOSE INSPECTION INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE HOSE INSPECTION 1. Inspect: • Brake hose Cracks/damage/wear → Replace. 2. Check: • Fluid leakage Apply the brake lever several times. Fluid leakage → Replace the defective parts. AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) WARNING Bleed the brake system in the following cases:...

  • Page 38: Drive Chain

    AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP DRIVE CHAIN d. Tighten the bleed screws when the brake lever limit has been reached, then release the lever. • Repeat steps (a) to (d) until all of the air bubbles have disappeared from the fluid. •...
  • Page 39 INSP DRIVE CHAIN CAUTION: There is a magnet attached to the end of the dipstick. It is used to remove any metal particles that may accumulate in the drive chain housing. Be sure to: • Pull the dipstick out slowly and gently so the metal particles do not fall off the magnet back into the drive chain housing.
  • Page 40 INSP DRIVE CHAIN Oil replacement Oil replacement steps: • Place the oil pan under the drain hole. • Remove the oil drain bolt 1 and drain the oil. CAUTION: Be sure to remove any oil from the heat protec- tor. SEA2545 •...

  • Page 41: Track Tension Adjustment

    DRIVE CHAIN/ INSP TRACK TENSION ADJUSTMENT 3. Install: • Battery bracket (VX600ER/VT600) • Battery (VX600ER/VT600) CAUTION: • Connect the positive lead to the battery termi- nal first. • Make sure the battery leads are connected properly. Reversing the leads can seriously damage the electrical system.

  • Page 42: Track Tension Adjustment

    INSP TRACK TENSION ADJUSTMENT 3. Adjust: • Track deflection Adjustment steps: • Place the machine onto a suitable stand to raise the track off of the ground. • Loosen the rear axle nut 1. NOTE: It is not necessary to remove the cotter pin 2. SEA2565 a.

  • Page 43: Slide Runner Inspection

    INSP SLIDE RUNNER INSPECTION SLIDE RUNNER INSPECTION 1. Inspect: • Slide runner 1 Cracks/damage/wear → Replace. 2. Measure: • Slide runner thickness a Out of specification → Replace. Slide runner wear limit: SEA2590 10 mm (0.39 in) 2-29...

  • Page 44: Maximizing Drive Track Life

    Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible damage, consult your stud manu- facturer for installation and stud pattern recommen- dations. Yamaha does not recommend track studding. 2-30...

  • Page 45: Chassis

    INSP SKI/SKI RUNNER CHASSIS SKI/SKI RUNNER 1. Inspect: • • Ski runner Damage/wear → Replace. 2. Measure: • Ski runner wear limit a • Plastic ski wear limit b SEA2595 Out of specification → Replace. Ski runner wear limit: 8 mm (0.31 in) Plastic ski wear limit: VX600ER/VT600: 13 mm (0.51 in)

  • Page 46: Steering System

    INSP STEERING SYSTEM STEERING SYSTEM Free play check 1. Check: • Steering system free play Move the handlebar up and down and back and forth. Turn the handlebar slightly to the right and left. Excessive free play → Check that the handle- bar, tie rod ends and relay rod ends are in- SEA2615 stalled securely in position.
  • Page 47 INSP STEERING SYSTEM/LUBRICATION 3. Adjust: • Ski toe-out Adjustment steps: • Loosen the locknuts (tie rod) 1. • Turn the tie rods 2 in or out until the specified toe- out is obtained. • Tighten the locknuts (tie rod) 1. SEA2625 Locknut (tie rod): 25 Nm (2.5 m ·...

  • Page 48: Lubrication

    INSP LUBRICATION Relay arm (steering) 1. Use a grease gun to inject grease into the nipple 1. Recommended lubricant: ESSO Beacon 325 Grease or Aeroshell Grease #7A SEA2645 Front and rear suspension 1. Use a grease gun to inject grease into the nipples 1.

  • Page 49: Electrical

    INSP HEADLIGHT BEAM ADJUSTMENT ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Place the machine in front of a wall at the recom- mended distance D. Refer to the table below. 3. Measure the distance H from the floor to the SEA2670 center of the headlight and place a mark on the wall at that height.

  • Page 50: Battery Inspection (Vx600Er/Vt600)

    INSP BATTERY INSPECTION (VX600ER/VT600) BATTERY INSPECTION (VX600ER/VT600) WARNING Battery fluid is poisonous and dangerous, causes severe burns, etc. Contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL – Flush with water. INTERNAL – Drink large quantities of water or milk.
  • Page 51 INSP BATTERY INSPECTION (VX600ER/VT600) Replace the battery if: • Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging. • Sulfation of one or more cells occurs, as indicated by the plates turning white, or an accumulation of material exists in the bottom of the cell.

  • Page 52: Battery Charging (Vx600Er/Vt600)

    INSP BATTERY CHARGING (VX600ER/VT600) BATTERY CHARGING (VX600ER/VT600) The battery must be charged properly before using for the first time. This initial charge will prolong the life of the battery. 1. Remove: • Battery WARNING When removing the battery, disconnect the nega- tive lead first.

  • Page 53: Fuse Inspection (Vx600Er/Vt600)

    BATTERY CHARGING (VX600ER/VT600)/ INSP FUSE INSPECTION (VX600ER/VT600) 2. Install: • Battery CAUTION: • Connect the positive lead to the battery termi- nal first. • Make sure the battery leads are connected properly. Reversing the leads can seriously damage the electrical system. •...
  • Page 54 INSP FUSE INSPECTION (VX600ER/VT600) 2. Replace: • Blown fuse Replacing steps: • Set the main switch to “OFF”. • Install a new fuse of the correct amperage. • Set the main switch to “ON” and verify if the electrical circuit is operational. •...

  • Page 55: Tuning

    INSP CARBURETOR TUNING TUNING CARBURETOR TUNING The carburetors are set at the factory to run at temperatures of 0°C ~ –20°C (32°F ~ –4°F) at sea level. If the machine is to be operated under conditions other than those specified above, the carburetors must be properly adjusted.
  • Page 56 Use the chart in CHAPTER 9 to select main jets according to variations in elevation and temperature. NOTE: These jetting specifications are subject to change. Consult the latest technical information from Yamaha to be sure you have the most up-to-date jetting specifications. Clip...
  • Page 57 INSP CARBURETOR TUNING Guide for carburetion SEA2720 2-43...
  • Page 58 INSP CARBURETOR TUNING Standard main jet Main jet whose diameter is 10% smaller than standard Main jet whose diameter is 10% larger than standard SEA2725 position position position SEA2730 CAUTION: If the intake silencer is removed from the carbure- tors, the change in pressure in the intake will create a lean mixture that may cause severe engine damage.
  • Page 59 INSP CARBURETOR TUNING Low-speed tuning The carburetors are built so that low speed tuning can be done by adjusting the pilot mixture screw 2 and throttle stop screw 1. CAUTION: Never run the engine without the air intake si- lencer installed. Severe engine damage may re- sult.
  • Page 60 INSP CARBURETOR TUNING Main jet selection chart Spark plug color Diagnosis Remedy Light tan or gray Carburetors are tuned properly. Dry black or fluffy Mixture is too rich. Replace the main jet with the next smaller size. deposits White or light gray Mixture is too lean.
  • Page 61 INSP CARBURETOR TUNING Trouble Diagnosis Adjustment • Remove the pilot jet, clean it with compressed air, and Poor performance at Clogged or loose pilot jet mid-range speeds: then install it. • Momentary slow re- • Make sure that the pilot jet is fully tightened. sponse to the throttle •...

  • Page 62: Clutch

    INSP CLUTCH CLUTCH G Green High altitude R Red Yellow Specifications Model: VX600ER ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) 1,600 ±...
  • Page 63 INSP CLUTCH G Green Silver Pink Yellow R Red Specifications Model: SX600 ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) 1,600 ±...
  • Page 64 INSP CLUTCH R Red W White Yellow Specifications Model: MM600 ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) 1,600 ±...
  • Page 65 INSP CLUTCH G Green Pink Silver R Red Specifications Model: VT600 ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) 1,600 ±...
  • Page 66 INSP CLUTCH G Green Pink Silver R Red Specifications Model: VT600 ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m Å Elevation (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) ←...

  • Page 67: Gear Selection

    INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the desired han- dling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the machine first begins to move from a complete stop.

  • Page 68: Gear Selection

    INSP GEAR SELECTION 1 Chain and sprocket part number Å Part name ı Teeth & links Ç Part no. Î Standard 18 teeth 89J-17682-80 VT600 for Europe 19 teeth 89J-17682-91 MM600 SX600 20 teeth 89J-17682-00 VT600 for U.S.A./Canada ‰ Drive sprocket 21 teeth 89J-17682-10 VX600ER...
  • Page 69 INSP GEAR SELECTION 5 Torque cam (secondary sheave spring seat) SEA2750 ı Effects Ç Part no. Î Cam angle ‰ Identification mark Ï Standard 8BV-17604-71 47° 8BV71 VX600ER/SX600 8BV-17604-51 45° 8BV51 8BV-17604-31 43° 8BV31 MM600/VT600 8BV-17604-11 41° 8BV11 8BV-17604-91 39° 8BV91 2-55...
  • Page 70 INSP GEAR SELECTION 6 Primary sheave spring SEA2755 Î ‰ Ï Ì Color Ó È Ô  Ò Standard Parts No. Spring rate Preload Wire Outside No. of Free N/mm N (kg) gauge diameter coils length (kg/mm) mm (in) mm (in) mm (in) 90501-551L3 19.6 (2.00)
  • Page 71 INSP GEAR SELECTION 7 Clutch weights Å Standard 8CH-17605-10 35.32 g SEA2760 8CR-17605-10 38.09 g SEA2765 8DG-17605-00 34.30 g VX600ER/ SX600/ MM600/ VT600 SEA2770 8DJ-17605-00 37.77 g SEA2775 8DN-17605-20 42.09 g SEA2780 8EK-17605-00 39.00 g SEA2785 2-57...
  • Page 72 INSP GEAR SELECTION 8 Rollers Å ROLLER with ı OUTSIDE Ç BUSHING Î IDENTIFICATION ‰ Standard Ï EFFECTS BUSHING DIAMETER TYPE (P/N) MARK (Width) PART NUMBER COLLAR OUTSIDE DIAMETER (P/N) 8CR-17624-00 14.5 mm Duralon (0.57 in) 90380-09245 SX600/ VT600 9 mm (0.4 in) 90387-0514U SEA2790 Duralon...

  • Page 73: High Altitude Tuning

    INSP HIGH ALTITUDE TUNING HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below. Check STD settings • Carburetors • Spark plugs ▼ Adjust the main jet size according to the chart ▼...

  • Page 74: Front Suspension

    INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload (VX600ER/MM600/VT600) 1. Adjust: • Spring preload Adjustment steps: • Turn the adjusting ring 1 to the proper position. Spring adjuster SEA2810 position Softer ← → Harder Preload VX600ER/VT600: 1 Standard MM600: 3 CAUTION: Be sure that the left and right spring preload is the same.

  • Page 75: Rear Suspension

    INSP REAR SUSPENSION REAR SUSPENSION Stopper band 1. Adjust: • Stopper band tension CAUTION: Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. NOTE: This adjustment affects the handling characteristics of the machine. Adjustment steps: •...
  • Page 76 INSP REAR SUSPENSION Spring preload (VX600ER/MM600/VT600) 1. Adjust: • Spring preload Adjustment steps: • Turn the adjusting ring 1 to the proper position. Spring adjuster SEA2830 position Softer ← → Harder Preload Å Front Standard VX600ER/MM600/VT600: 3 Spring adjuster position Softer ←...
  • Page 77 INSP REAR SUSPENSION Rear suspension-full rate 1. Adjust: • Full rate adjuster Adjustment steps: Installation position Spring rate Soft Medium Hard and damping SEA2850 Standard NOTE: Be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile. •...
  • Page 78 INSP REAR SUSPENSION Rear suspension position (MM600) 1. Adjust: • Rear suspension position NOTE: Select the rear suspension position according to the snow conditions: a standard; b deep new snow. Bolt (slide rail suspension): 72 Nm (7.2 m · kg, 52 ft · lb) ®...
  • Page 79 INSP REAR SUSPENSION 2-65...

  • Page 80: Chassis

    CHAS STEERING CHASSIS STEERING VX600ER/SX600/VT600 Å 10 Nm (1.0 m · kg, 7.2 ft · lb) ı 23 Nm (2.3 m · kg, 17 ft · lb) SEA3010 Order Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Handlebar removal Handlebar cover Plastic band...

  • Page 81: Mm600

    CHAS STEERING MM600 Å 10 Nm (1.0 m · kg, 7.2 ft · lb) ı 23 Nm (2.3 m · kg, 17 ft · lb) SEA3020 Order Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Handlebar removal Handlebar cover Plastic band...
  • Page 82 CHAS STEERING Å 23 Nm (2.3 m · kg, 17 ft · lb) ı 25 Nm (2.5 m · kg, 18 ft · lb) Ç 35 Nm (3.5 m · kg, 25 ft · lb) Î 43 Nm (4.3 m · kg, 31 ft · lb) ‰...

  • Page 83: Inspection

    CHAS STEERING INSPECTION 1. Inspect: • Handlebar 1 (VX600ER/SX600/VT600) • Handlebar 2 (MM600) • Steering column 3 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent column. SEA3040 This may dangerously weaken the column. 2. Inspect: • Bearings (steering column) 1 •...

  • Page 84: Installation

    CHAS STEERING INSTALLATION 1. Install: • Bushings 1 NOTE: Mount the bushing with clearance a to the end of the relay arm 2. a Approx. 1 mm (0.04 in) SEA3090 2. Install: • Tie rod 1 • Locknut 2 • Joints 3 Å...
  • Page 85 CHAS STEERING 4. Install: • Relay rod 1 NOTE: Make sure that the end of the relay rod with the indentation a is connected to the relay arm. CAUTION: Always use new cotter pins. SEA3130 Nut (relay rod): 35 Nm (3.5 m · kg, 25 ft · lb) 5.
  • Page 86 CHAS STEERING 6. Install: • Handlebar CAUTION: • For SX600/MM600: Be sure the projection on the handlebar is not installed into the area a shown. • Be sure the side of the holder with the small gap b faces forward. SEA3150 •...

  • Page 87: Vx600Er/Vt600

    CHAS VX600ER/VT600 Å 11 Nm (1.1 m · kg, 8.0 ft · lb) ı 17 Nm (1.7 m · kg, 12 ft · lb) Ç 21 Nm (2.1 m · kg, 15 ft · lb) Î 48 Nm (4.8 m · kg, 35 ft · lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A...

  • Page 88: Sx600/Mm600

    CHAS SX600/MM600 Å 11 Nm (1.1 m · kg, 8.0 ft · lb) ı 21 Nm (2.1 m · kg, 15 ft · lb) ç 48 Nm (4.8 m · kg, 35 ft · lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA3200...
  • Page 89 CHAS INSPECTION 1. Inspect: • Ski 1 • Ski runner 2 • Ski stopper 3 • Ski column lower bracket 4 • Ski handle 5 Wear/cracks/damage → Replace. • Mounting bolt 6 • Collar 7 • Bolts 8 • Collars 9 Wear/damage →...

  • Page 90: Front Suspension

    CHAS FRONT SUSPENSION FRONT SUSPENSION Å 23 Nm (2.3 m · kg, 17 ft · lb) ı 43 Nm (4.3 m · kg, 31 ft · lb) Ç 48 Nm (4.8 m · kg, 35 ft · lb) Î 50 Nm (5.0 m · kg, 36 ft · lb) ‰...

  • Page 91: Handling Notes (Sx600)

    CHAS FRONT SUSPENSION HANDLING NOTES (SX600) WARNING This shock absorber contains highly compressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper han- dling.
  • Page 92 CHAS FRONT SUSPENSION 4. Inspect: • Connecting rod 1 • Stabilizer 2 Cracks/bends/damage → Replace. • Collar 3 Wear/scratches/damage → Replace. SEA3280 5. Inspect: • Front arm 1 Cracks/bends/damage → Replace. SEA3290 3-13...

  • Page 93: Installation

    CHAS FRONT SUSPENSION INSTALLATION 1. Install: • Control rod 1 • Nut 2 • Joint 3 Å Left hand Ç Ì color ı Set length a angle b SEA3300 ‰ Upper 475.5 ± 0.5 mm 93 ± 1° (VX600ER/SX600/ (18.7204 ± 0.0197 in) VT600) Blue Ï...
  • Page 94 CHAS FRONT SUSPENSION 2. Install: • Steering arm 1 NOTE: • Align the punch mark a on the ski column with the punch mark b on the steering arm. • Install sections c without any gaps. Nut (steering arm): 56 Nm (5.6 m · kg, 40 ft · lb) SEA3310 Å...
  • Page 95 CHAS FRONT SUSPENSION Ski spindle camber Place the unit on a level surface and check the ski spindle camber. DO NOT elevate the front end. 1 Using an angle finder, be sure that the unit sits parallel with the floor. Place the angle finder up against the flat aluminum part of the belly pan.
  • Page 96 CHAS FRONT SUSPENSION 4 Install the radius rod onto the trailing arm and tighten the bolt. Tighten the ball joint locknut and apply grease to the ball joint. Repeat the procedure for the other side. SEA3370 CAUTION: When tightening the ball joint locknut, be sure to keep the ball joint outer housing centered with the ball to prevent binding.
  • Page 97 CHAS FRONT SUSPENSION Front arm part number SEA3390 Å Part number ı Caster Ç Control rod Î Shock absorber ‰ ID bracket angle b bracket angle c mark d 8DM-2382E-10 (L/H) VX600ER/VT600 25.5° 3° 10° 8DM-2382F-10 (R/H) 8CR-2382E-20 (L/H) SX600 25.5°...
  • Page 98 CHAS FRONT SUSPENSION Control rod part number SEA3410 Ç Part Number Î Length a ‰ Angle b 439.5 ± 1 mm (17.3031 ± 0.0394 in) 10.8 ± 0.5° Å Upper 8CR-2384E-20 VX600ER/SX600/ 431.6 ± 1 mm (16.9921 ± 0.0394 in) 10.8 ±...

  • Page 99: Chapter 4. Power Train

    POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT Å : 1st 120 Nm (12.0 m · kg, 85 ft · lb) 2nd 60 Nm (6.0 m · kg, 43 ft · lb) SEA4010 Order Job name/Part name Q’ty Remarks Primary sheave removal...
  • Page 100 POWR PRIMARY SHEAVE AND DRIVE V-BELT Å 4 Nm (0.4 m · kg, 2.9 ft · lb) ı 6 Nm (0.6 m · kg, 4.3 ft · lb) Ç 14 Nm (1.4 m · kg, 10 ft · lb) Î 20 Nm (2.0 m ·...

  • Page 101: Removal

    POWR PRIMARY SHEAVE AND DRIVE V-BELT REMOVAL 1. Remove: • Primary sheave assembly 1 NOTE: Use the primary sheave holder 2 and primary sheave puller 3. Primary sheave holder: SEA4030 90890-01701, YS-01880 Primary sheave puller: YS-01881-1, YS-01859-1...

  • Page 102: Disassembly

    POWR PRIMARY SHEAVE AND DRIVE V-BELT DISASSEMBLY 1. Remove: • Fixed sheave 1 • Stopper 2 • Sliding sheave 3 • Bushing 4 • Spider 5 SEA4040 Removal steps: • Immerse the primary sheave assembly in 80°C ~ 100°C (176°F ~ 212°F) water for several minutes. •...

  • Page 103: Inspection

    POWR PRIMARY SHEAVE AND DRIVE V-BELT INSPECTION 1. Inspect: • Spider 1 • Sliding sheave 2 • Fixed sheave 3 • Primary sheave cap 4 Cracks/damage → Replace. SEA4080 2. Inspect: • Primary sheave spring 1 Cracks/damage → Replace. 3. Measure: •...
  • Page 104 POWR PRIMARY SHEAVE AND DRIVE V-BELT 5. Inspect: • Weight 1 • Roller 2 • Bushing 3 • Slider 4 • Rivet 5 • Collar Wear/scratches/damage → Replace. • Slider inside clearance SEA4110 Out of specification → Replace the slider. Slider inside clearance = Slider inside clearance: Min.

  • Page 105: Assembly

    POWR PRIMARY SHEAVE AND DRIVE V-BELT NOTE: When replacing the weight and roller bushings, use the YXR clutch bushing jig kit. YXR clutch bushing jig kit: YS-39752 Ç Removing Î Installing SEA4140 ASSEMBLY 1. Install: • Sliding sheave (onto the spider) NOTE: Be sure the sliding sheave match mark (X) is aligned with the spider match mark (X).
  • Page 106 POWR PRIMARY SHEAVE AND DRIVE V-BELT 3. Install: • Fixed sheave stoppers 1 NOTE: Stopper tapered portion should face fixed sheave. 4. Tighten: • Spider Tightening steps: SEA4170 • Finger-tighten the spider until it is stopped by the fixed sheave stopper. •...
  • Page 107 POWR PRIMARY SHEAVE AND DRIVE V-BELT 5. Install: • Weight • Nuts 1 Nut (weight): 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: To maintain the primary sheave balance, the bolts 2 SEA4200 must be installed with their threaded portions pointing in a counterclockwise direction, as illustrated.

  • Page 108: Installation

    POWR PRIMARY SHEAVE AND DRIVE V-BELT INSTALLATION 1. Install: • Primary sheave assembly CAUTION: Be sure to remove any oil or grease from the tapered portion of the crankshaft and spider us- ing a cloth dampened with thinner. SEA4230 2. Apply: •...

  • Page 109: Secondary Sheave

    POWR SECONDARY SHEAVE SECONDARY SHEAVE Å 64 Nm (6.4 m · kg, 46 ft · lb) SEA4260 Order Job name/Part name Q’ty Remarks Secondary sheave removal Remove the parts in the order listed below. V-belt Washer Shim – Refer to “SHEAVE DISTANCE AND OFFSET ADJUSTMENT”...
  • Page 110 POWR SECONDARY SHEAVE Å 4 Nm (0.4 m · kg, 2.9 ft · lb) ı 6.5 Nm (0.65 m · kg, 4.6 ft · lb) Ç 10 Nm (1.0 m · kg, 7.2 ft · lb) Î 23 Nm (2.3 m · kg, 17 ft · lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA4270...

  • Page 111: Disassembly

    POWR SECONDARY SHEAVE DISASSEMBLY WARNING • Use extreme CAUTION when disassembling the secondary sheave since serious injury can occur due to the sudden release of spring ten- sion. Use the sheave compressor to contain the spring tension before removing the nuts (spring seat).

  • Page 112: Assembly

    POWR SECONDARY SHEAVE 5. Measure: • Ramp shoe thickness a Out of specification → Replace the ramp shoe. Wear limit: 1.0 mm (0.04 in) SEA4320 ASSEMBLY 1. Install: • Stopper • Sliding sheave Screw (stopper): 6.5 Nm (0.65 m · kg, 4.6 ft · lb) 2.
  • Page 113 POWR SECONDARY SHEAVE Installation steps: • Hold the spring seat 1 and turn the fixed sheave 2 counterclockwise to the specified angle a. NOTE: The holes in the spring seat should align with the bolts on the sliding sheave. a = (sheave hole number + spring seat hole SEA4350 number) ×...

  • Page 114: Installation

    • Measure the secondary sheave clearance again. Repeat these steps until the clearance is within specification. SEA4380 NOTE: Yamaha recommends keeping the original shims. Shims: Part number Thickness 90201-061H1 0.5 mm (0.02 in) 90201-06037 1.0 mm (0.04 in) INSTALLATION 1.

  • Page 115: Drive Chain Housing

    POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL Å 16 Nm (1.6 m · kg, 11 ft · lb) ı 24 Nm (2.4 m · kg, 17 ft · lb) Ç 48 Nm (4.8 m · kg, 35 ft · lb) Î...

  • Page 116: Inspection

    POWR DRIVE CHAIN HOUSING INSPECTION 1. Inspect: • Drive chain housing 1 • Drive chain housing cover 2 Cracks/damage → Replace. • Oil seals (drive chain housing) Wear/damage → Replace. • Bearings (drive chain housing and cover) 3 Pitting/damage → Replace. SEA4400 •...
  • Page 117 POWR DRIVE CHAIN HOUSING 3. Measure: • 14 link section a of the drive chain 1 2 3 4 5 6 7 8 9 0 A B C D E Using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b. Out of specification →...

  • Page 118: Installation

    POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the following. Å Make sure that the bearing seals face towards the drive chain as shown. ı Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. Be sure to install the spacers in their original positions, otherwise the brake disc and jackshaft will stick.

  • Page 119: With Reverse Model

    POWR DRIVE CHAIN HOUSING WITH REVERSE MODEL Å 10 Nm (1.0 m · kg, 7.2 ft · lb) ı 13 Nm (1.3 m · kg, 9.4 ft · lb) Ç 16 Nm (1.6 m · kg, 11 ft · lb) Î...
  • Page 120 POWR DRIVE CHAIN HOUSING Å 10 Nm (1.0 m · kg, 7.2 ft · lb) ı 13 Nm (1.3 m · kg, 9.4 ft · lb) Ç 16 Nm (1.6 m · kg, 11 ft · lb) Î 24 Nm (2.4 m · kg, 17 ft · lb) ‰...

  • Page 121: Inspection

    POWR DRIVE CHAIN HOUSING INSPECTION 1. Inspect: • Drive chain housing 1 • Drive chain housing cover 2 Cracks/damage → Replace. • Shift fork 3 Pitting/wear/damage → Replace. • Oil seals (drive chain housing) Wear/damage → Replace. SEA4480 • Bearings (drive chain housing and cover) 4 Pitting/damage →...

  • Page 122: Installation

    POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the following. Å Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. ı Make sure that the bearing seals face towards the drive chain as shown.
  • Page 123 POWR DRIVE CHAIN HOUSING 4. Install: • Shift rod 1 5. Adjust: • Shift rod length a Adjustment steps: • Move the shift lever to the “FWD.” position. • Loosen the locknuts 2. • Turn the shift rod 1 so that shift rod free play is SEA4520 0 mm (in direction where a can be shortened appropriately) and then turn back the shift rod...

  • Page 124: Jackshaft

    POWR JACKSHAFT JACKSHAFT Å 8.5 Nm (0.85 m · kg, 6.1 ft · lb) ı 23 Nm (2.3 m · kg, 17 ft · lb) SEA4530 Job name/Part name Order Q’ty Remarks Jackshaft removal Remove the parts in the order listed below. Secondary sheave Refer to “SECONDARY SHEAVE”.

  • Page 125: Inspection

    POWR JACKSHAFT INSPECTION 1. Inspect: • Jackshaft 1 Scratches (excessive)/damage → Replace. • Splines 2 Wear/damage → Replace the jackshaft. • Bearing contact surface 3 Scratches/wear/damage → Replace the jackshaft. SEA4540 2. Inspect: • Bearing holder 1 Cracks/damage → Replace. •...

  • Page 126: Jackshaft And Drive Chain Housing Installation

    POWR JACKSHAFT JACKSHAFT AND DRIVE CHAIN HOUSING INSTALLATION 1. Install: • Drive chain housing • Jackshaft Installation steps: • Install the drive chain housing 1. • Tighten the bolts 2. Bolt (drive chain housing): 48 Nm (4.8 m · kg, 35 ft · lb) •...

  • Page 127: Brake

    POWR BRAKE BRAKE Å 6 Nm (0.6 m · kg, 4.3 ft · lb) ı 48 Nm (4.8 m · kg, 35 ft · lb) SEA4580 Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring...

  • Page 128: Brake Pad Replacement

    POWR BRAKE CAUTION: Disc brake components rarely require disassem- bly. DO NOT: • Do not disassemble components unless abso- lutely necessary. • Do not use solvents on internal brake compo- nents. • Do not use contaminated brake fluid for clean- ing.
  • Page 129 POWR BRAKE 2. Install: • Brake pads • Pad spring Installation steps: • Connect a suitable hose 1 tightly to the caliper bleed screw 2. Put the other end of this hose into an open container. • Loosen the caliper bleed screw and push the SEA4610 pistons into the caliper with your finger.
  • Page 130 POWR BRAKE Å 30 Nm (3.0 m · kg, 22 ft · lb) ı 48 Nm (4.8 m · kg, 35 ft · lb) SEA4620 Order Job name/Part name Q’ty Remarks Brake caliper and parking brake re- Remove the parts in the order listed below. moval Brake fluid Drain.
  • Page 131 POWR BRAKE SEA4630 Job name/Part name Order Q’ty Remarks Brake caliper disassembly Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring Brake pad Shim 1 Shim 2 Bleed screw Piston seal Piston For assembly, reverse the disassembly proce- dure.

  • Page 132: Brake Caliper Disassembly

    POWR BRAKE BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: • Pistons SEA4640 • Piston seals 1 Removal steps: • Using a wood of piece 2, lock the right piston. •...

  • Page 133: Brake Caliper Assembly

    POWR BRAKE 1. Inspect: • Caliper piston 1 Scratches/rust/wear → Replace the caliper assembly. • Caliper cylinder 2 Wear/scratches → Replace the caliper as- sembly. • Caliper body 3 Cracks/damage → Replace. SEA4670 • Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and dust seals when- ever a caliper is disassembled.
  • Page 134 POWR BRAKE Å 14 Nm (1.4 m · kg, 10 ft · lb) ı 30 Nm (3.0 m · kg, 22 ft · lb) å : For VX600ER/SX600/VT600 ∫ : For MM600 : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA4690 Order Job name/Part name...

  • Page 135: Inspection

    POWR BRAKE INSPECTION 1. Inspect: • Master cylinder 1 Wear/scratches → Replace the master cylin- der assembly. • Master cylinder body 2 Cracks/damage → Replace. • Oil delivery passage (master cylinder body) Blow out with compressed air. SEA4700 2. Inspect: •...

  • Page 136: Slide Rail Suspension

    POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION VX600ER/SX600 Å 72 Nm (7.2 m · kg, 52 ft · lb) SEA4730 Job name/Part name Order Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen.

  • Page 137: Vt600

    POWR SLIDE RAIL SUSPENSION VT600 Å 24 Nm (2.4 m · kg, 17 ft · lb) ı : 72 Nm (7.2 m · kg, 52 ft · lb) SEA4740 Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen.
  • Page 138 POWR SLIDE RAIL SUSPENSION Å 4 Nm (0.4 m · kg, 2.9 ft · lb) ı 16 Nm (1.6 m · kg, 11 ft · lb) Ç 24 Nm (2.4 m · kg, 17 ft · lb) Î : 30 Nm (3.0 m · kg, 22 ft · lb) ‰...
  • Page 139 POWR SLIDE RAIL SUSPENSION Å 24 Nm (2.4 m · kg, 17 ft · lb) ı 49 Nm (4.9 m · kg, 35 ft · lb) Ç 72 Nm (7.2 m · kg, 52 ft · lb) å : For SX600 : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA4760...
  • Page 140 POWR SLIDE RAIL SUSPENSION Å 49 Nm (4.9 m · kg, 35 ft · lb) ı 72 Nm (7.2 m · kg, 52 ft · lb) å : For SX600 : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA4770 Job name/Part name Order...
  • Page 141 POWR SLIDE RAIL SUSPENSION Å 24 Nm (2.4 m · kg, 17 ft · lb) ı 72 Nm (7.2 m · kg, 52 ft · lb) Ç 75 Nm (7.5 m · kg, 54 ft · lb) å For SX600 ∫...

  • Page 142: Mm600

    POWR SLIDE RAIL SUSPENSION MM600 Å 72 Nm (7.2 m · kg, 52 ft · lb) SEA4790 Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen.
  • Page 143 POWR SLIDE RAIL SUSPENSION Å 4 Nm (0.4 m · kg, 2.9 ft · lb) ı 16 Nm (1.6 m · kg, 11 ft · lb) Ç 24 Nm (2.4 m · kg, 17 ft · lb) Î : 30 Nm (3.0 m · kg, 22 ft · lb) ‰...
  • Page 144 POWR SLIDE RAIL SUSPENSION Å 24 Nm (2.4 m · kg, 17 ft · lb) ı 49 Nm (4.9 m · kg, 35 ft · lb) Ç 72 Nm (7.2 m · kg, 52 ft · lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA4810 Order...
  • Page 145 POWR SLIDE RAIL SUSPENSION Å 49 Nm (4.9 m · kg, 35 ft · lb) ı 72 Nm (7.2 m · kg, 52 ft · lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA4820 Job name/Part name Order Q’ty Remarks...
  • Page 146 POWR SLIDE RAIL SUSPENSION Å 24 Nm (2.4 m · kg, 17 ft · lb) ı 72 Nm (7.2 m · kg, 52 ft · lb) Ç 75 Nm (7.5 m · kg, 54 ft · lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA4830 Order...

  • Page 147: Inspection

    POWR SLIDE RAIL SUSPENSION INSPECTION 1. Inspect: • Suspension wheel • Guide wheel Cracks/damage → Replace. • Wheel bearing Wheel turns roughly → Replace. SEA4840 2. Inspect: • Stopper band 1 Frayed/damage → Replace. • Pull rod 2 Bends/damage → Replace. •...

  • Page 148: Assembly

    POWR SLIDE RAIL SUSPENSION ASSEMBLY 1. Install: • Shaft 1 (MM600) NOTE: Ensure the rubber collars 2 are not pinched between the shaft and sliding frames 3. Bolt (shaft): SEA4870 72 Nm (7.2 m · kg, 52 ft · lb) LOCTITE ®...
  • Page 149 POWR SLIDE RAIL SUSPENSION Control rod parts number SEA4890 ı Parts number Ç Length a Î Length b Å Control rod 1 8CR-4745A-01 310.5 mm (12.2244 in) 200.0 mm (7.8740 in) Å Control rod 1 8ED-4745A-00 262.5 mm (10.3346 in) 146.0 mm (5.7480 in) Ì...

  • Page 150: Front Axle And Track

    POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK Å 8.5 Nm (0.85 m · kg, 6.1 ft · lb) ı 20 Nm (2.0 m · kg, 14 ft · lb) SEA4900 Order Job name/Part name Q’ty Remarks Front axle and track removal Remove the parts in the order listed below.

  • Page 151: Inspection

    POWR FRONT AXLE AND TRACK INSPECTION 1. Inspect: • Track 1 • Slide metal 2 Wear/cracks/damage → Replace. SEA4910 2. Inspect: • Sprocket wheel 1 Wear/break/damage → Replace. • Front axle 2 Bends/scratches (excessive)/damage → Replace. SEA4920 INSTALLATION 104 mm 123 mm 104 mm (4.09 in)
  • Page 152 POWR FRONT AXLE AND TRACK 2. Place the track in the chassis. NOTE: • For track with a direction of rotation mark a: Install the track with the mark pointing in the direc- tion of track rotation. Å VX600ER, VT600 for U.S.A/Canada ı...

  • Page 153: Engine

    EXHAUST ASSEMBLY ENGINE EXHAUST ASSEMBLY Å 18 Nm (1.8 m · kg, 13 ft · lb) 2nd 27 Nm (2.7 m · kg, 19 ft · lb) SEA5010 Order Job name/Part name Q’ty Remarks Exhaust assembly removal Remove the parts in the order listed below. Shroud Open.

  • Page 154: Installation

    EXHAUST ASSEMBLY INSTALLATION 1. Install: • Gasket 3 • Exhaust joint NOTE: • Install the gasket 3 with its projection a facing the primary sheave side. • Tighten the bolts 1 ~ 6 in a crisscross pattern. SEA5020 Bolt (exhaust joint): 1st: 18 Nm (1.8 m ·...

  • Page 155: Engine Assembly

    ENGINE ASSEMBLY ENGINE ASSEMBLY Å 15 Nm (1.5 m · kg, 11 ft · lb) ı 23 Nm (2.3 m · kg, 17 ft · lb) Ç 33 Nm (3.3 m · kg, 24 ft · lb) Î 57 Nm (5.7 m · kg, 41 ft · lb) ‰...

  • Page 156: Inspection

    ENGINE ASSEMBLY INSPECTION 1. Inspect: • Rear bracket (right) 1 Cracks/damage → Replace. SEA5050 INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUTING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Fasten: SEA5060 • Plastic band 1 NOTE: •...
  • Page 157 ENGINE ASSEMBLY 3. Bleed: • Oil system Refer to “OIL PUMP” in CHAPTER 2. • Cooling system Refer to “COOLING SYSTEM” in CHAPTER 2. 4. Adjust: • Oil pump cable distance a Refer to “OIL PUMP” in CHAPTER 2. Distance: 23 ±...

  • Page 158: Cylinder Head And Cylinder

    CYLINDER HEAD AND CYLINDER CYLINDER HEAD AND CYLINDER Å : 10 Nm (1.0 m · kg, 7.2 ft · lb) ı : 14 Nm (1.4 m · kg, 10 ft · lb) SEA5090 Order Job name/Part name Q’ty Remarks Cylinder head and cylinder removal Remove the parts in the order listed below.
  • Page 159 CYLINDER HEAD AND CYLINDER Å 14 Nm (1.4 m · kg, 10 ft · lb) ı 11 Nm (1.1 m · kg, 8.0 ft · lb) 23 Nm (2.3 m · kg, 17 ft · lb) Ç 20 Nm (2.0 m · kg, 14 ft · lb) Î...

  • Page 160: Removal

    CYLINDER HEAD AND CYLINDER REMOVAL 1. Remove: • Piston pin clip • Piston pin • Piston • Small end bearing NOTE: • Before removing the piston pin clip, cover the SEA5110 crankcase with a clean rag so that you will not accidentally drop the clip into the crankcase.

  • Page 161: Inspection

    CYLINDER HEAD AND CYLINDER INSPECTION 1. Eliminate: • Carbon deposits (from the combustion chamber) Use the rounded scraper 1. CAUTION: Do not use a sharp instrument. Avoid damaging or scratching the surface. SEA5130 2. Inspect: • Cylinder head water jacket Crust of minerals/rust →...

  • Page 162: Cylinder Head And Cylinder

    CYLINDER HEAD AND CYLINDER 7. Eliminate: • Score marks and lacquer deposits (from the piston wall) Use 600 ~ 800 grit wet sandpaper. NOTE: Sand in a crisscross pattern. Do not sand exces- sively. SEA5170 8. Measure: • Piston-to-cylinder clearance Measurement steps: 1st step: •...
  • Page 163 CYLINDER HEAD AND CYLINDER 2nd step: • Measure the piston skirt diameter (P) with a micrometer. a 10 mm (0.39 in) from the bottom edge of the piston Piston size (standard) (P): 64.932 ~ 64.935 mm (2.5564 ~ 2.5565 in) •...
  • Page 164 CYLINDER HEAD AND CYLINDER 10. Install: • Piston ring (into the cylinder) Push in the ring with the piston crown. NOTE: Insert the ring into the cylinder, and push it approxi- mately 20 mm (0.8 in) into the cylinder. Push in the ring with the piston crown so that the ring is at right SEA5220 angles to the cylinder bore.
  • Page 165 CYLINDER HEAD AND CYLINDER 14. Inspect: • Reed valves 1 Bends/cracks/damage → Replace. SEA5260 15. Measure: • Valve stopper height a Out of specification → Replace the valve stop- per. Valve stopper height: 10.3 ~ 10.7 mm (0.41 ~ 0.42 in) SEA5270 16.

  • Page 166: Installation

    CYLINDER HEAD AND CYLINDER INSTALLATION 1. Install: • Reed valves • Reed valve stoppers NOTE: • Place the reed valve 1 with its concave surface facing toward the reed valve seat 2. • Fit the reed valve stopper cut a into the corre- sponding cut b on the reed valve.
  • Page 167 CYLINDER HEAD AND CYLINDER 4. Check: • Piston ring position CAUTION: • Make sure that the ring ends are properly fitted around the ring locating pins in the piston grooves. • Be sure to check that the manufacturer’s marks or numbers stamped on the rings face upward. SEA5330 5.
  • Page 168 CYLINDER HEAD AND CYLINDER 9. Tighten: • Nuts (cylinder head) Tightening steps: • Temporarily tighten the cylinder head nuts 1 ~ E as follows. 1st step: • Tighten the nuts 1 ~ E. Nut (cylinder head): 11 Nm (1.1 m · kg, 8.0 ft · lb) 2nd step: •...

  • Page 169: Oil Pump, Crankcase And Crankshaft

    OIL PUMP, CRANKCASE AND CRANKSHAFT OIL PUMP, CRANKCASE AND CRANKSHAFT Å 8 Nm (0.8 m · kg, 5.8 ft · lb) ı 13 Nm (1.3 m · kg, 9.4 ft · lb) Ç 15 Nm (1.5 m · kg, 11 ft · lb) Î...

  • Page 170: Inspection

    OIL PUMP, CRANKCASE AND CRANKSHAFT INSPECTION 1. Measure: • Runout Use the V-blocks and a dial gauge. Out of specification → Replace or repair the crankshaft. Dial gauge: 90890-03097, YU-03097 SEA5410 Maximum runout: : 0.03 mm (0.0012 in) : 0.04 mm (0.0016 in) : 0.03 mm (0.0012 in) 90 mm (3.54 in) 85 mm (3.35 in)
  • Page 171 OIL PUMP, CRANKCASE AND CRANKSHAFT 3. Inspect: • Crankshaft bearing 1 Pitting/damage → Replace. • Stopper ring 2 Bends/damage → Replace. • Crankshaft oil seals 3 • Impeller drive gear teeth 4 Wear/damage → Replace. SEA5430 CAUTION: Lubricate the bearings immediately after examin- ing them in order to prevent rust.

  • Page 172: Installation

    OIL PUMP, CRANKCASE AND CRANKSHAFT INSTALLATION 1. Install: • Stopper ring 1 [onto the crankshaft bearing 2 (primary sheave side) as shown] 3 Knock pin SEA5470 2. Install: • Crankshaft assembly (onto the upper crankcase Å) NOTE: Turn the bearings and labyrinth seal to set the knock pins 1 on the bearings and labyrinth seal into the pin holes 2 in the upper crankcase Å.
  • Page 173 OIL PUMP, CRANKCASE AND CRANKSHAFT 3. Fill: • Gear room 1 Recommended oil: YAMALUBE 2-cycle Gear room capacity: 25 cm (0.81 Imp oz, 0.77 US oz) SEA5510 CAUTION: Before installing and torquing the crankcase bolts, be sure to check that the crankshaft turns smoothly.
  • Page 174 OIL PUMP, CRANKCASE AND CRANKSHAFT 6. Install: • Oil hose 1 NOTE: Install so that the mark a on the check valve faces the crankcase. SEA5550 5-22...

  • Page 175: Ac Magneto

    AC MAGNETO AC MAGNETO Å 23 Nm (2.3 m · kg, 17 ft · lb) ı 48 Nm (4.8 m · kg, 35 ft · lb) Ç 110 Nm (11 m · kg, 80 ft · lb) SEA5560 Order Job name/Part name Q’ty Remarks AC magneto removal...

  • Page 176: Removal

    AC MAGNETO REMOVAL 1. Remove: • Bolts 1 • Starter pulley 2 • Nut 3 NOTE: Attach the primary sheave holder to hold the primary sheave. SEA5570 Primary sheave holder: 90890-01701, YS-01880 2. Remove: • Magneto rotor 1 NOTE: • Remove the magneto rotor using the rotor puller 2.

  • Page 177: Installation

    AC MAGNETO INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUTING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Install: • Stator coil NOTE: Route the pickup coil lead 1 under and behind the pickup coil 2 as shown. SEA5590 2.
  • Page 178 AC MAGNETO 4. Tighten: • Bolts 1 • Nut 2 Bolt (starter pulley): 23 Nm (2.3 m · kg, 17 ft · lb) Nut (magneto rotor): 110 Nm (11 m · kg, 80 ft · lb) SEA5610 NOTE: Attach the primary sheave holder to hold the primary sheave.

  • Page 179: Recoil Starter

    RECOIL STARTER RECOIL STARTER Å 12 Nm (1.2 m · kg, 8.7 ft · lb) ı 18 Nm (1.8 m · kg, 13 ft · lb) SEA5620 Order Job name/Part name Q’ty Remarks Recoil starter removal Remove the parts in the order listed below. Exhaust silencer Refer to “EXHAUST ASSEMBLY”.

  • Page 180: Removal

    RECOIL STARTER REMOVAL 1. Remove: • Starter handle 1 NOTE: To remove the starter handle, untie the knot 2 in the starter rope and then re-tie a knot 3 in the rope end so that it is not pulled into the recoil starter case 4. SEA5630 SEA5640 INSPECTION...

  • Page 181: Installation

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

  • Page 182: Chapter 6. Cooling System

    COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER VX600ER/SX600/VT600 Å 7 Nm (0.7 m · kg, 5.1 ft · lb) SEA6010 Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAP- TER 2.

  • Page 183: Mm600

    COOL HEAT EXCHANGER MM600 Å 7 Nm (0.7 m · kg, 5.1 ft · lb) SEA6020 Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAP- TER 2.

  • Page 184: Inspection

    COOL HEAT EXCHANGER INSPECTION 1. Inspect: • Coolant hoses 1 • Heat exchangers 2 • Filler cap body 3 • Carburetor heating lever assembly 4 • Carburetor heating hoses 5 Cracks/damage → Replace. Å VX600ER/SX600/VT600 ı MM600 SEA6030 SEA6040...

  • Page 185: Installation

    COOL HEAT EXCHANGER 2. Measure: • Filler cap opening pressure Cap opens with a pressure below the specified pressure → Replace. Cap opening pressure: 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm , 14 ~ 18 psi) SEA6050 Measurement steps: •...

  • Page 186: Water Pump

    COOL WATER PUMP WATER PUMP Å 10 Nm (1.0 m · kg, 7.2 ft · lb) ı 13 Nm (1.3 m · kg, 9.4 ft · lb) Ç 33 Nm (3.3 m · kg, 24 ft · lb) Î 90 Nm (9.0 m · kg, 65 ft · lb) SEA6060 Order Job name/Part name...

  • Page 187: Removal

    COOL WATER PUMP REMOVAL 1. Remove: • Impeller 1 NOTE: Attach the primary sheave holder to hold the primary sheave. Primary sheave holder: SEA6070 90890-01701, YS-01880 INSPECTION 1. Inspect: • Impeller 1 • Water pump cover 2 • Thermostatic cover 3 Cracks/damage →...

  • Page 188: Chapter 7. Carburetion

    CARB CARBURETORS CARBURETION CARBURETORS SEA7010 Order Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Carburetors removal Intake silencer Refer to “FUEL PUMP”. Carburetor heating lever Before removing the carburetors, make sure that the carburetor heating lever is turned to “OFF”. Carburetor switch (T.O.R.S.) lead Throttle cable Starter cable...
  • Page 189 CARB CARBURETORS : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA7020 Order Job name/Part name Q’ty Remarks Carburetor separation Remove the parts in the order listed below. Carburetor heating hose Starter cable holder Collar Spring Screw Loosen. Starter rod Spring Starter lever Breather hose...
  • Page 190 CARB CARBURETORS Å 0.7 Nm (0.07 m · kg, 0.51 ft · lb) ı 1 Nm (0.1 m · kg, 0.7 ft · lb) Ç 1.8 Nm (0.18 m · kg, 1.3 ft · lb) Î 2.5 Nm (0.25 m · kg, 1.8 ft · lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA7030...
  • Page 191 CARB CARBURETORS Å 0.7 Nm (0.07 m · kg, 0.51 ft · lb) ı 1 Nm (0.1 m · kg, 0.7 ft · lb) Ç 1.8 Nm (0.18 m · kg, 1.3 ft · lb) Î 2.5 Nm (0.25 m · kg, 1.8 ft · lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SEA7030...

  • Page 192: Inspection

    CARB CARBURETORS INSPECTION 1. Inspect: • Carburetor body • Fuel passage Contamination → Clean. NOTE: • Use a petroleum based solvent for cleaning. • Blow out all passages and jets with compressed SEA7040 air. 2. Inspect: • Rubber seals 1 •...

  • Page 193: Assembly

    CARB CARBURETORS 5. Inspect: • Throttle valve 1 Wear/damage → Replace. 6. Check: • Throttle valve movement Sticks → Replace carburetor body assembly. SEA7080 ASSEMBLY NOTE: • Before reassembling, wash all parts in clean gaso- line. • Always use new gaskets and O-rings. 1.

  • Page 194: Carburetor Synchronization

    CARB CARBURETORS Measurement and adjustment steps: • Hold the carburetor upside down. • Measure the distance between the carburetor body and top of the floats. NOTE: The float arm should resting on the needle valve without exerting pressure on it. •...

  • Page 195: Fuel Level Adjustment

    CARB CARBURETORS FUEL LEVEL ADJUSTMENT 1. Measure: • Fuel level a Out of specification → Adjust. Fuel level (from the bore center): 36 ~ 38 mm (1.42 ~ 1.50 in) Measurement and adjustment steps: • Place the machine on a level surface. •...

  • Page 196: Installation

    CARB CARBURETORS INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUTING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Fasten: • Carburetor heating hose 2 1 NOTE: Fasten the carburetor heating hose 2 with a clamp 2 at the white mark a.

  • Page 197: Fuel Pump

    CARB FUEL PUMP FUEL PUMP VX600ER/VT600 Å 5 Nm (0.5 m · kg, 3.6 ft · lb) ı 10 Nm (1.0 m · kg, 7.2 ft · lb) SEA7160 Order Job name/Part name Q’ty Remarks Fuel pump removal Remove the parts in the order listed below. Carburetor heating lever assembly Air filter element Screw...

  • Page 198: Sx600/Mm600

    CARB FUEL PUMP SX600/MM600 Å 5 Nm (0.5 m · kg, 3.6 ft · lb) ı 10 Nm (1.0 m · kg, 7.2 ft · lb) SEA7170 Q’ty Remarks Order Job name/Part name Fuel pump removal Remove the parts in the order listed below. Carburetor heating lever assembly Air filter element Screw...

  • Page 199: Inspection

    CARB FUEL PUMP INSPECTION SEA7180 1. Inspect: • Fuel hose 1 • Fuel delivery hoses 2 • Vacuum hose 3 • Oil delivery hose 4 Clogs/damage → Replace. 2. Check: • Fuel pump operation Checking steps: • Connect the Mity vac 1 to the vacuum hose 2. Mity vac: 90890-06756, YS-42423 SEA7190...

  • Page 200: Chapter 8. Electrical

    – ELEC SWITCH INSPECTION ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for conti- nuity. If the continuity is faulty at any point, replace the switch. Pocket tester: 90890-03112, YU-03112 NOTE: • Set the pocket tester to “0” before starting a test. •...
  • Page 201 – ELEC IGNITION SYSTEM SEA8030...

  • Page 202: Ignition System

    – ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM 1 AC magneto 2 Rectifier/regulator ∗1 3 Condenser ∗2 4 Main fuse ∗2 6 Battery 8 Main switch 9 Engine stop switch 0 Throttle switch C Carburetor switch E CDI unit H Ignition coil I Spark plug J Engine ground K Frame ground...

  • Page 203: Troubleshooting

    – ELEC IGNITION SYSTEM TROUBLESHOOTING NO SPARK OR WEAK SPARK. For VX600ER/VT600: Check the main fuse and “IGNITION” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or “IGNITION” fuse. For VX600ER/VT600: Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2.
  • Page 204 – ELEC IGNITION SYSTEM For SX600/MM600: Check the lighting, signal and meter system. Refer to “LIGHTING SYSTEM” and “SIGNAL SYSTEM”. FAULTY Repair the lighting system and/or signal system and/or meter system. Correct the connection and/or replace the rectifier/regulator and/or CDI unit. NOTE: For SX600/MM600: If a short circuit occurred in the lighting system, the...

  • Page 205: Condenser (Sx600/Mm600)

    – ELEC IGNITION SYSTEM CONDENSER (SX600/MM600) 1. Disconnect: • Condenser 1 SEA8040 2. Connect: • Condenser (to the LCR meter) 3. Measure: • Condenser capacity Out of specification → Replace. Condenser capacity: ° ° 6,800 µF at 20 C (68 AC MAGNETO 1.

  • Page 206: Spark Plug

    – ELEC IGNITION SYSTEM SPARK PLUG 1. Remove: • Spark plugs 2. Measure: • Spark plug gap Standard spark plug: BR9ES (NGK) Spark plug gap: SEA8070 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) SPARK PLUG CAP 1. Remove: • Spark plug cap 2.

  • Page 207: Throttle Override System (T.o.r.s.)

    – ELEC IGNITION SYSTEM THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should malfunction during operation, T.O.R.S. will operate when the throttle lever is released. T.O.R.S. is designed to interrupt the ignition and keep the engine revolutions between 2,800 and 3,000 r/min if the carburetor fails to return to idle when the lever is released.

  • Page 208: Carburetor Switch

    – ELEC IGNITION SYSTEM 4. Check: • Throttle switch continuity Faulty → Replace the handlebar switch (right). Ω × 1 Throttle switch Continuity position – B/Y B/W Throttle lever is operated. Throttle lever is not operated. SEA8160 CARBURETOR SWITCH SEA8170 1.

  • Page 209: Load Control Relay

    – ELEC IGNITION SYSTEM LOAD CONTROL RELAY 1. Inspect: • Load control relay (with the white coupler) 1 Inspection steps: • Disconnect the load control relay from the cou- pler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the load control relay terminals as SEA8200 shown.

  • Page 210: Electrical Starting System (Vx600Er/Vt600)

    – ELEC ELECTRICAL STARTING SYSTEM SCH8230 8-11...

  • Page 211: Troubleshooting

    – ELEC ELECTRICAL STARTING SYSTEM TROUBLESHOOTING (VX600ER/VT600) STARTER MOTOR DOES NOT OPERATE. WARNING Before starter motor operation, push the engine stop switch to “OFF”. 1. Connect: • Starter relay terminals (battery side and starter motor side) Check the battery and connectors. Refer to “BATTERY INSPECTION”...

  • Page 212: Main Switch

    – ELEC ELECTRICAL STARTING SYSTEM FAULTY Check the main fuse and “IGNITION” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or “IGNITION” fuse. FAULTY Check the main switch. Replace the main switch. Correct the connection. MAIN SWITCH 1.
  • Page 213 – ELEC ELECTRICAL STARTING SYSTEM STARTER MOTOR (VX600ER/VT600) Å : 7 Nm (0.7 m · kg, 5.1 ft · lb) SEA8260 Job name/Part name Order Q’ty Remarks Starter motor disassembly Remove the parts in the order listed below. Starter motor removal Refer to “ENGINE REMOVAL”...
  • Page 214 – ELEC ELECTRICAL STARTING SYSTEM Inspection 1. Inspect: • Commutator (outer surface) Dirty → Clean with #600 grit sandpaper 1. Hold the armature in a vise 2 and copper or aluminium plate 3. CAUTION: Lightly grip the armature with a vise. SEA8270 2.
  • Page 215 – ELEC ELECTRICAL STARTING SYSTEM 4. Measure: • Armature coil resistance (insulation/continuity) Defect(s) → Replace the starter motor. Inspecting steps: • Connect the pocket tester for the continuity check 1 and the insulation check 2. • Measure the armature coil resistances. SEA8300 Armature coil resistance: Continuity check:...
  • Page 216 – ELEC ELECTRICAL STARTING SYSTEM Assembly Reverse the “Disassembly” procedure. Note the following points. 1. Before installing the front bracket and rear bracket, apply bearing grease to the bearings of the front bracket and rear bracket. 2. Make sure the front bracket and rear bracket cover are fitted with O-rings.

  • Page 217: Charging System (Vx600Er/Vt600)

    – ELEC CHARGING SYSTEM SEA8340 8-18...

  • Page 218: Troubleshooting

    – ELEC CHARGING SYSTEM TROUBLESHOOTING (VX600ER/VT600) BATTERY IS NOT CHARGED. 1. Connect: • Pocket tester (to the battery terminals) OUT OF SPECIFICATIONS 2. Measure: • Battery voltage • Fluid gravity • Check the battery. Battery voltage: ° ° more than 12 V at 20 C (68 Refer to “BATTERY INSPECTION”...

  • Page 219: Battery

    – ELEC CHARGING SYSTEM BATTERY Inspection 1. Inspect: • Battery fluid level Refer to “BATTERY INSPECTION” in CHAP- TER 2. 2. Check: • Specific gravity Less than 1.280 → Recharge battery. Battery Storage The battery should be stored if the vehicle is not going to be used for a long period.
  • Page 220 – ELEC CHARGING SYSTEM 8-21...
  • Page 221 – ELEC LIGHTING SYSTEM SEA8370 8-22...

  • Page 222: Lighting System

    – ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 1 AC magneto 2 Rectifier/regulator ∗1 3 Condenser ∗2 4 Main fuse ∗2 6 Battery 8 Main switch E CDI unit K Frame ground T Tail/brake light Z High beam indicator light [ Speedometer light \ Tachometer light a Headlight...

  • Page 223: Troubleshooting

    – ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT AND/OR METER LIGHT DO NOT COME ON. Check the bulb(s). NO CONTINUITY Replace the bulb(s). For VX600ER/VT600: Check the main fuse, “IGNITION” fuse and “HEAD” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION”...
  • Page 224 – ELEC LIGHTING SYSTEM TAIL LIGHT DOES NOT COME ON. Check the bulb(s). NO CONTINUITY Replace the bulb(s). For VX600ER/VT600: Check the main fuse, “IGNITION” fuse and “TAIL” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION” fuse and/or “TAIL” fuse.

  • Page 225: Bulb(S)

    – ELEC LIGHTING SYSTEM BULB(S) SEA8380 1. Remove: • Headlight bulb a • Tail/brake light bulb b • Meter light bulb c 2. Connect: • Pocket tester (to the bulb terminals) WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot. Do not touch the bulb until it cools down.

  • Page 226: Headlight Relay

    – ELEC LIGHTING SYSTEM HEADLIGHT RELAY 1. Inspect: • Headlight relay (with the black coupler) 1 SEA8410 Inspection steps: • Disconnect the headlight relay from the coupler. • Connect the pocket tester (Ω × 1) to the head- light relay terminals as shown. Positive tester probe →...
  • Page 227 – ELEC SIGNAL SYSTEM SEA8440 8-28...

  • Page 228: Signal System

    – ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 1 AC Magneto 2 Rectifier/regulator ∗1 3 Condenser ∗2 4 Main fuse ∗2 6 Battery 8 Main switch D Water temperature sensor E CDI unit K Frame ground ∗2 Q DC back buzzer ∗2 R Gear position switch S Brake light switch...

  • Page 229: Troubleshooting

    – ELEC SIGNAL SYSTEM TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. Check the tail/brake light bulb. Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb. For VX600ER/VT600: Check the main fuse, “IGNITION” fuse and “TAIL” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION”...
  • Page 230 – ELEC SIGNAL SYSTEM WATER TEMPERATURE AND/OR OIL LEVEL INDICATOR LIGHTS DO NOT COME ON. Check the water temperature and/or oil level indicator light bulb(s). Refer to “LIGHTING SYSTEM”. NO CONTINUITY Replace the bulb(s). For VX600ER/VT600: Check the main fuse, “IGNITION”...
  • Page 231 – ELEC SIGNAL SYSTEM FUEL METER DOES NOT OPERATE. For VX600ER/VT600: Check the main fuse, “IGNITION” fuse and “HEAD” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION” fuse and/or “HEAD” fuse. For VX600ER/VT600: Check the battery. Refer to “BATTERY INSPECTION”...
  • Page 232 – ELEC SIGNAL SYSTEM BACK BUZZER DOES NOT SOUND. (VX600ER/VT600) Check the main fuse, “IGNITION” fuse and “TAIL” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION” fuse and/or “TAIL” fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.

  • Page 233: Brake Light Switch

    – ELEC SIGNAL SYSTEM BRAKE LIGHT SWITCH SEA8450 1. Disconnect: • Brake light switch coupler 1 2. Connect: • Pocket tester (to the brake light switch coupler) 3. Check: • Brake light switch continuity Faulty → Replace. Switch position Continuity Brake lever operates Brake lever does...

  • Page 234: Water Temperature Sensor

    – ELEC SIGNAL SYSTEM WATER TEMPERATURE SENSOR 1. Disconnect the water temperature sensor cou- pler 1 and remove the water temperature sen- sor. CAUTION: Handle the water temperature sensor with spe- cial care. Never subject it to shock or allow it to be dropped.

  • Page 235: Oil Level Switch

    – ELEC SIGNAL SYSTEM OIL LEVEL SWITCH 1. Remove: • Intake silencer Refer to “FUEL PUMP” in CHAPTER 7. • Oil level switch 1 SEA8520 2. Connect: • Pocket tester (to the oil level switch coupler) 3. Check: • Oil level switch continuity Faulty →...
  • Page 236 – ELEC SIGNAL SYSTEM 8-37...
  • Page 237 – ELEC GRIP WARMER SYSTEM SEA8560 8-38...

  • Page 238: Grip Warmer System

    – ELEC GRIP WARMER SYSTEM GRIP WARMER SYSTEM CIRCUIT DIAGRAM 1 AC magneto 2 Rectifier/regulator ∗1 3 Condenser ∗2 4 Main fuse ∗2 6 Battery 8 Main switch A Grip warmer B Thumb warmer E CDI unit F Variable resistor (thumb warmer) G Variable resistor (grip warmer) K Frame ground ∗3...

  • Page 239: Troubleshooting

    – ELEC GRIP WARMER SYSTEM TROUBLESHOOTING GRIP WARMER AND THUMB WARMER DO NOT OPERATE. For VX600ER/VT600: Check the main fuse and “IGNITION” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or “IGNITION” fuse. For VX600ER/VT600: Check the battery.
  • Page 240 – ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER DOES NOT OPERATE. (VT600) Check the main fuse, “IGNITION” fuse and “TAIL” fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, “IGNITION” fuse and/or “TAIL” fuse. Check the battery. Refer to “BATTERY INSPECTION”...

  • Page 241: Grip And Thumb Warmer Coil

    – ELEC GRIP WARMER SYSTEM GRIP AND THUMB WARMER COIL SEA8570 1. Disconnect: • Grip warmer leads 1 • Thumb warmer coupler 2 2. Connect: • Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads) 3. Check: •...

  • Page 242: Variable Resistor (Grip Warmer)

    – ELEC GRIP WARMER SYSTEM VARIABLE RESISTOR (GRIP WARMER) 1. Disconnect: • Variable resistor coupler 1 2. Connect: • Pocket tester (to the variable resistor coupler) SEA8610 3. Check: • Variable resistor resistance When pulley is turned once. Ω × 1 Out of specification →...

  • Page 243: Passenger Grip Warmer Switch (Vt600)

    – ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER SWITCH (VT600) 1. Disconnect: • Passenger grip warmer switch coupler 1 2. Connect: • Pocket tester (to the passenger grip warmer switch coupler) SEA8650 3. Check: • Passenger grip warmer switch continuity Faulty →...

  • Page 244: Passenger Grip Warmer Relay (Vt600)

    – ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER RELAY (VT600) SEA8700 1. Inspect: • Passenger grip warmer relay 1 Inspection steps: • Disconnect the passenger grip warmer relay from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the passenger grip warmer relay termi- nals as shown.

  • Page 245: Fault Location Table

    – ELEC FAULT LOCATION TABLE FAULT LOCATION TABLE NOTE: When more than one problem is detected, the water temperature indicator light flashes in the pattern of the lowest numbered problem. After that problem is corrected, the water temperature indicator light flashes in the pattern of the next lowest numbered problem.
  • Page 246 – ELEC FAULT LOCATION TABLE Patterns Condition Reference Shorting of grip warmer is Refer to “GRIP Repeats detected. WARMER SYSTEM”. 0.75 s 0.25 s 3.5 s SEA8760 Discontinuity of the Refer to “VARI- Repeats variable resistor (thumb ABLE RESIS- warmer) is detected. TOR (THUMB WARMER)”.

  • Page 247: Chapter 9. Specifications

    8,250 r/min Maximum torque r/min Starting system Recoil hand starter (SX600/MM600) Electric and recoil hand starter (VX600ER/VT600) Lubrication system Separate lubrication (YAMAHA AUTOLUBE) Engine oil: YAMALUBE 2-cycle oil Type 3.0 L (2.6 Imp qt, 3.2 US qt) Tank capacity Drive chain housing oil: Type Gear oil API “GL-3”...
  • Page 248 SPEC GENERAL SPECIFICATIONS Model VX600ER/SX600/MM600/VT600 Fuel: R + M Type Regular unleaded gasoline (Pump Octane ; 88 or higher) Research Octane; 93 or higher (for Europe) 44.3 L (9.7 Imp gal, 11.7 US gal) Tank capacity Carburetor: Type/Quantity TM31/3 MIKUNI Manufacturer Spark plug: BR9ES...
  • Page 249 SPEC GENERAL SPECIFICATIONS Model VX600ER/SX600/MM600/VT600 Bulb wattage × Quantity: 12 V, 60 W/55 W × 2 Headlight 12 V, 8 W/23 W × 1 Tail/Brake light 12 V, 1.7 W × 1 Tachometer light 12 V, 1.7 W × 1 Speedometer light 12 V, 1.7 W ×...

  • Page 250: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model VX600ER/SX600/MM600/VT600 Cylinder head: 18.7 ~ 19.3 cm Volume (with spark plug) (1.14 ~ 1.18 cu.in) <0.03 mm (0.0012 in)> <Warp limit> ∗Lines indicate straight edge measurement. Cylinder: Aluminum alloy with dispersion coating Material 65.000 ~ 65.014 mm Bore size (2.5591 ~ 2.5596 in)
  • Page 251 SPEC MAINTENANCE SPECIFICATIONS Model VX600ER/SX600/MM600/VT600 Crankshaft: Crank width “A” 55.95 ~ 56.00 mm (2.203 ~ 2.205 in) 291.75 ~ 292.30 mm (11.486 ~ 11.508 in) Crank width “B” Maximum runout “C” : C 0.03 mm (0.0012 in) 0.04 mm (0.0016 in) 0.03 mm (0.0012 in) Measuring points: 90 mm (3.54 in)
  • Page 252 SPEC MAINTENANCE SPECIFICATIONS Model VX600ER/SX600/MM600/VT600 Carburetor: Type/Quantity TM31/3 MIKUNI Manufacturer I.D. mark 8DG100 #1: 136.3 Main jet (M.J) #2, #3: 133.8 Pilot jet (P.J) #42.5 6DHN50-3 Jet needle (J.N) Needle jet (N.J) #1: Q-4 #2, #3: Q-2 ø1.0 Pilot air jet (P.A.J) Pilot outlet (P.O)

  • Page 253: Power Train

    SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model VX600ER/SX600/MM600/VT600 Transmission: V-belt automatic Type 3.8 ~ 1.0 :1 Range of ratio 4,000 ± 200 r/min (3,800 ~ 4,200 r/min) (VX600ER) Engagement speed r/min (VT600 for U.S.A./Canada) 4,200 ± 200 r/min (4,000 ~ 4,400 r/min) (SX600) 4,600 ±...
  • Page 254 SPEC MAINTENANCE SPECIFICATIONS VX600ER/SX600/MM600/VT600 Model Primary sheave weight arm: 8DG-17605-00 Part number (with bushing) 34.30 g (1.211 oz) Weight Rivet: Outer 90261-06028 (VX600ER/MM600) Part number 90261-06015 (SX600) 90261-06034 (VT600) Aluminum (VX600ER/MM600) Material Steel (SX600/VT600) 10.3 mm (0.41 in) (VX600ER/SX600/MM600) Size 13.9 mm (0.55 in) (VT600) Quantity Hole quantity...
  • Page 255 SPEC MAINTENANCE SPECIFICATIONS VX600ER/SX600/MM600/VT600 Model Drive chain: REXNORD S37TNB13 Type 68 L Number of links Track: 8DY-47110-00 (VX600ER) Part number 8EA-47110-10 (SX600) 8ED-47110-01 (MM600) 8DM-47110-00 (VT600 for U.S.A./Canada) 8CC-47110-11 (VT600 for Europe) 381 mm (15.0 in) Width 3,072 mm (120.9 in) (VX600ER/SX600) Length 3,584 mm (141.1 in) (MM600) 3,456 mm (136.1 in) (VT600)
  • Page 256 SPEC MAINTENANCE SPECIFICATIONS Model VX600ER/SX600/MM600/VT600 Suspension setting position: Hook setting length ∗ 15 ± 0.5 mm (0.59 ± 0.02 in) (VX600ER) 25 ± 0.5 mm (0.98 ± 0.02 in) (SX600/VT600) 10 ± 0.5 mm (0.39 ± 0.02 in) (MM600) Full rate adjusting position ∗∗ Shock absorber: Damping force Front 720 N/0.3 m/s (73 kg/0.3 m/s, 161 lb/0.3 m/s) (VX600ER)

  • Page 257: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model VX600ER/SX600/MM600/VT600 Frame: Aluminum Frame material 730 mm (28.7 in) (VX600ER/SX600/VT600) Seat height 700 mm (27.6 in) (MM600) Rear side of seat Luggage box location Steering: Lock-to-lock angle (left) 29.4° (R ski) 34.7° (L ski) (VX600ER/SX600/VT600) 34.7°...

  • Page 258: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model VX600ER/SX600/MM600/VT600 Voltage 12 V Ignition system: 18° at 1,500 r/min Ignition timing (B.T.D.C.) Advanced type Digital type Ignition coil: Model/Manufacturer F6T535/MITSUBISHI 6 mm (0.236 in) or more Minimum spark gap 0.36 ~ 0.48 Ω at 20°C (68°F) Primary coil resistance 5.4 ~ 7.4 kΩ...
  • Page 259 SPEC MAINTENANCE SPECIFICATIONS VX600ER/SX600/MM600/VT600 Model Starter motor (VX600ER/VT600): Model/Manufacturer DB4XF/DENSO Output 12 V-0.6 kW Armature coil resistance 0.014 ~ 0.018 Ω at 20°C (68°F) Continuity check Insulation check More than 100 kΩ at 20°C (68°F) Brush Overall length 12 mm (0.47 in) <Wear limit>...

  • Page 260: High Altitude Settings

    SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS Tempera- –40°C –29°C –18°C –7°C 4°C 16°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 MJ #2#3 #140 MJ #2#3 #137.5 MJ #2#3 #135 MJ #2#3 #132.5...

  • Page 261: Tightening Torque

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m · kg ft · lb Crankcase (M8 × 80) (1st) Tighten the bolts in two (2nd) stages. Crankcase (M8 × 35) Engine bracket (front) and frame Engine bracket damper (front/rear) Engine bracket (front) and engine Engine bracket right (rear) and engine...
  • Page 262 SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Tightening torque Parts to be tightened Remarks m · kg ft · lb Primary sheave (1st) 12.0 Tighten the bolts in two (2nd) stages. See NOTE. Spider and fixed sheave 20.0 Left-hand thread. Apply LOCTITE ®...
  • Page 263 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Parts to be tightened Remarks m · kg ft · lb Rear pivot arm and bracket Shock absorber and rear pivot arm Rear pivot arm and pull rod Apply LOCTITE ® ® Rear suspension bracket and pull rod Apply LOCTITE Shock absorber and rear suspension bracket ®...
  • Page 264 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Tightening torque Parts to be tightened Remarks m · kg ft · lb Handlebar holder Steering column Upper Lower Steering column and relay rod Relay rod and relay arm Relay arm and tie rod Tie rod and steering arm Relay arm Apply LOCTITE ®...

  • Page 265: General Torque Specifications

    SPEC GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (bolt) This chart specifies torque for standard fasteners m · kg ft · lb with standard I.S.O. pitch threads. Torque specifica- 10 mm 6 mm tions for special components or assemblies are in- 12 mm 8 mm cluded in the applicable sections of this book.
  • Page 266 SPEC GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITS 9-20...

  • Page 267: Cable Routing

    SPEC CABLE ROUTING SEA9010 9-21...

  • Page 268: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Water temperature sensor coupler 2 Fasten the carburetor switch leads and water temperature sensor leads and ignition coil leads to the coolant hose with a plastic band. For the VX600ER/ VT600, include the starter motor and battery negative leads.
  • Page 269 SPEC CABLE ROUTING SEA9010 9-23...
  • Page 270 SPEC CABLE ROUTING D Connectors of the gear position switch (VX600ER/VT600) E Route the main switch wire harness under the oil tank breather hose and fuel tank breather hose. F Install the main switch coupler behind the instrument panel. G Make sure that the main switch wire harness is on the inside of the instrument panel screw (away from the engine).
  • Page 271 SPEC CABLE ROUTING SEA9020 9-25...
  • Page 272 SPEC CABLE ROUTING 1 Brake hose 2 Oil pump cable 3 Throttle cable 4 Wire harness 5 Starter cable 9-26...
  • Page 273 SPEC CABLE ROUTING SEA9030 9-27...
  • Page 274 SPEC CABLE ROUTING 1 Wire harness 2 Ensure this is not kink. 3 50 mm (1.97 in) 4 Make sure that the oil tank cap and oil tank breather hose do not touch each other. 5 Route the fuel tank breather hose over the main switch wire harness.
  • Page 275 SPEC CABLE ROUTING SEA9030 9-29...
  • Page 276 SPEC CABLE ROUTING K Fuel tank breather hose L Ground lead M Install the clamp so that it does not come into contact with the ground lead terminal. N Route the fuel tank breather hose behind the condenser. (SX600/ MM600) O Condenser (SX600/MM600) P Fasten the CDI unit leads with a plastic band.
  • Page 277 SPEC CABLE ROUTING SEA9040 9-31...
  • Page 278 SPEC CABLE ROUTING 1 Speedometer coupler 2 Tachometer coupler 3 Plastic band 4 Clamp 5 Headlight leads 6 Speedometer cable 7 Fasten the wire harness and speedometer cable at the white tape mark, with a plastic band. 8 Route the wire harness and speedometer cable under the shroud’s stopper wire.
  • Page 279 SPEC CABLE ROUTING SEA9050 9-33...
  • Page 280 SPEC CABLE ROUTING 1 Oil pump cable 2 Throttle cable 3 Do not fasten the throttle cable and oil pump cable. 4 Pass only the throttle, and oil pump cables through the inside of the cable holder. 5 Thumb warmer coupler 6 Engine stop switch coupler 7 Connectors of the grip warmer 8 Brake light switch coupler...
  • Page 281 SPEC CABLE ROUTING SEA9050 9-35...
  • Page 282 SPEC CABLE ROUTING O To the carburetor P Vacuum hose Q Oil delivery hose R To the oil pump S When fastening the wire harness with the attaches clamp, bend the clamp inward to fasten. T Do not fasten. U Fasten the wire harness at the white tape mark, with a clamp.
  • Page 283 SPEC CABLE ROUTING SEA9060 9-37...
  • Page 284 SPEC CABLE ROUTING 1 Make sure a plastic band is routed through the projection located on the silencer, when fastening it around the wire harness and the starter cable. (VX600ER/VT600) 2 Starter cable 3 Make sure the plastic bands are routed through the projection located on the silencer, when fastening them around the wire...
  • Page 286 AC magneto COLOR CODE Rectifier/regulator B ..... Black Br ....Brown ∗1 Condenser Ch ....Chocolate ∗2 G ....Green Main fuse Gy ....Gray ∗2 Starter relay L ..... Blue Lg ....Light green ∗2 Battary O ....Orange ∗2 P .....
  • Page 287 PRINTED ON RECYCLED PAPER Printed in USA (E) CR...

This manual is also suitable for:

Sx600gMm600gVt600g

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