Yamaha VT600G 2002 Motorcycle Manuals

Manuals and User Guides for Yamaha VT600G 2002 Motorcycle. We have 3 Yamaha VT600G 2002 Motorcycle manuals available for free PDF download: Service Manual, Manual, Owner's Manual

Yamaha VT600G Service Manual (287 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 4 MB

Periodic Inspection and
3
Table of Contents
5
Chapter 1. General Information

9
Machine Identification

9
- Frame Serial Number
  9
- Engine Serial Number
  9
Important Information

10
- Preparation for Removal and Disassembly
  10
- All Replacement Parts
  10
- Gaskets, Oil Seals, and O-Rings
  11
- Lock Washers/Plates and Cotter Pins
  11
- Bearings and Oil Seals
  11
- Circlips
  11
- Loctite
  11
Special Tools

12
- For Tune up
  12
- For Engine Service
  13
- For Power Train Service
  13
- For Carburetion Service
  14
- For Electrical Service
  14
Chapter 2

15
Periodic Inspection and Adjustment

15
Introduction

15
Periodic Maintenance Table

15
Engine

17
- Spark Plugs
  17
- Oil Pump
  18
- Fuel Line Inspection
  20
- Cooling System
  20
- Carburetor Synchronization
  26
- Engine Idle Speed Adjustment
  27
- Throttle Cable Free Play Adjustment
  27
- Throttle Override System (T.o.r.s.) Check
  28
- Starter (Choke) Cable Free Play Adjustment
  29
- Exhaust System Inspection
  29
Power Train

30
- Sheave Distance and Offset Adjustment
  30
- Drive V-Belt
  32
- Engagement Speed Check
  34
- Parking Brake Pad Inspection
  34
- Parking Brake Adjustment
  35
- Brake Lever Adjustment (Vx600Er/Sx600/Vt600)
  35
- Brake Fluid Level Inspection
  36
- Brake Pad Inspection
  36
- Brake Hose Inspection
  37
- Air Bleeding (Hydraulic Brake System)
  37
- Drive Chain
  38
- Track Tension Adjustment
  41
- Track Tension Adjustment
  42
- Slide Runner Inspection
  43
- Maximizing Drive Track Life
  44
Chassis

45
- Ski/Ski Runner
  45
- Steering System
  46
- Lubrication
  48
Electrical

49
Tuning

55
- Carburetor Tuning
  55
- Clutch
  62
- Gear Selection
  67
- Gear Selection
  68
- High Altitude Tuning
  73
- Front Suspension
  74
- Rear Suspension
  75
Chapter 3

80
Chassis

80
Steering

80
- Vx600Er/Sx600/Vt600
  80
- Mm600
  81
- Inspection
  83
- Installation
  84
- Installation (Vx600Er/Vt600)
  84
- Vx600Er/Vt600
  87
- Sx600/Mm600
  88
Front Suspension

90
- Handling Notes (Sx600)
  91
- Inspection
  91
- Installation
  93
Chapter 4. Power Train

99
Primary Sheave and Drive V-Belt

99
- Removal
  101
- Disassembly
  102
- Inspection
  103
- Assembly
  105
- Installation
  108
Secondary Sheave

109
- Disassembly
  111
- Inspection
  111
- Assembly
  112
- Installation
  114
Drive Chain Housing

115
- Without Reverse Model
  115
- Inspection
  116
- Installation
  118
- With Reverse Model
  119
- Inspection
  121
- Installation
  122
Jackshaft

124
- Inspection
  125
- Jackshaft and Drive Chain Housing Installation
  126
Brake

127
- Brake Pad Replacement
  128
- Brake Caliper Disassembly
  132
- Brake Caliper Inspection and Repair
  132
- Brake Caliper Assembly
  133
- Brake Caliper Installation
  133
- Inspection
  135
- Brake Master Cylinder Assembly
  135
- Installation
  135
Slide Rail Suspension

136
- Vx600Er/Sx600
  136
- Vt600
  137
- Mm600
  142
- Inspection
  147
- Assembly
  148
- Installation
  148
Front Axle and Track

150
- Inspection
  151
- Installation
  151
Chapter 5

153
Engine

153
Exhaust Assembly

153
- Installation
  154
Engine Assembly

155
- Inspection
  156
- Installation
  156
Cylinder Head and Cylinder

158
- Removal
  160
- Inspection
  161
- Cylinder Head and Cylinder
  162
- Installation
  166
Oil Pump, Crankcase and Crankshaft

169
- Inspection
  170
- Installation
  172
Ac Magneto

175
- Removal
  176
- Installation
  177
Recoil Starter

179
- Removal
  180
- Inspection
  180
- Installation
  181
Chapter 6. Cooling System

182
Heat Exchanger

182
- Vx600Er/Sx600/Vt600
  182
- Mm600
  183
- Inspection
  184
- Installation
  185
Water Pump

186
- Removal
  187
- Inspection
  187
- Installation
  187
Chapter 7. Carburetion

188
Carburetors

188
- Inspection
  192
- Assembly
  193
- Carburetor Synchronization
  194
- Fuel Level Adjustment
  195
- Installation
  196
Fuel Pump

197
- Vx600Er/Vt600
  197
- Sx600/Mm600
  198
- Inspection
  199
- Installation
  199
Chapter 8. Electrical

200
Switch Inspection

200
- Inspecting a Switch Shown in the Manual
  200
Ignition System

202
- Circuit Diagram
  202
- Troubleshooting
  203
- Condenser (Sx600/Mm600)
  205
- Ac Magneto
  205
- Spark Plug
  206
- Spark Plug Cap
  206
- Ignition Coil
  206
- Throttle Override System (T.o.r.s.)
  207
- Handlebar Switch (Right)
  207
- Carburetor Switch
  208
- Main Switch
  208
- Load Control Relay
  209
- Emergency Engine Starting (Sx600/Mm600)
  209
Electrical Starting System (Vx600Er/Vt600)

210
- Troubleshooting
  211
- Main Switch
  212
Charging System (Vx600Er/Vt600)

217
- Troubleshooting
  218
- Battery
  219
- Stator Coil
  219
Lighting System

222
- Circuit Diagram
  222
- Troubleshooting
  223
- Bulb(S)
  225
- Headlight Beam Switch
  225
- Headlight Relay
  226
Signal System

228
- Circuit Diagram
  228
- Troubleshooting
  229
- Brake Light Switch
  233
- Gear Position Switch (Vx600Er/Vt600)
  233
- DC Back Buzzer (Vx600Er/Vt600)
  233
- Water Temperature Sensor
  234
- Oil Level Switch
  235
- Fuel Sender
  235
Grip Warmer System

238
- Troubleshooting
  239
- Grip and Thumb Warmer Coil
  241
- Variable Resistor (Thumb Warmer)
  241
- Variable Resistor (Grip Warmer)
  242
- Passenger Grip Warmer (Vt600)
  242
- Passenger Grip Warmer Switch (Vt600)
  243
- Resistor (Vt600)
  243
- Passenger Grip Warmer Relay (Vt600)
  244
Fault Location Table

245
Chapter 9. Specifications

247
General Specifications

247
Maintenance Specifications

250
- Engine
  250
- Power Train
  253
- Chassis
  257
- Electrical
  258
- High Altitude Settings
  260
- Tightening Torque
  261
General Torque Specifications

265
Definition of Units

265
- Cable Routing
  267
Cable Routing

268

Yamaha VT600G Manual (282 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 15 MB

Table of Contents
2
Chapter One
7
General Information
7
Manual Organization
7
Ignition Coils 15
7
Voltage Regulator 15
7
Electric Starting System 15
7
Drive Unit 18
7
Warnings. Cautions and Notes
8
Safety
8
Serial Numbers
9
Fasteners
10
Shop Supplies
12
Basic Tools
14
Precision Measuring Tools
18
Electrical System Fundamentals
28
Special Tools
30
Basic Service Methods
30
Snowmobile Operation
35
Snowmobile Safety
37
Snowmobile Code of Ethics
37
Testing Electrica1 Components
45
Ignition System Troubleshooting
46
Electric Starting System
52
Fuel System
54
Engine
55
Two-Stroke Pressure Testing
59
Power Train
62
Skis and Steering
63
Track Assembly
63
Fluid Checks
65
Break-In Procedure
65
Maintenance Schedules
66
Scheduled Maintenance
69
Unscheduled Maintenance
79
Engine Tune-Up
80
High-Altitude Clutch Tuning
90
Chaincase Sprocket Adjustment
90
Suspension Adjustments
90
Chapter Four
100
Engine
100
Engine Number Identification
100
Engine Lubrication
101
Service Precautions
101
Servicing Engine in Frame
102
Engine Removal
102
Engine Installation
103
Engine Top End
105
Cylinder
108
Piston. Piston Pin, and Piston Rings
110
Reed Valve Assembly
117
Crankcase and Crankshaft
118
Coolant Pump and Oil Injection Pump Drive Shaft
128
Air Box
131
Intake Tubes
132
Carburetor
132
Carburetor Operation
132
Carburetor Service
133
Carburetor Adjustments
142
Carburetor Heating System
142
Fuel Pump
143
Fuel Tank
145
Exhaust System
147
Exhaust System Repair
147
Battery
150
Capacitor Discharge Ignition (CDI)
154
CDI Box
156
Switches
162
Instrument Panelwarning Light Check
165
Fuel Level Sender
165
Oil Level Sender Testing
166
Thermoswitchtesting
166
Throttle Override System
167
Lighting System
169
Oil Pump Service
172
Component Replacement
173
Oil Pump
175
Primary Sheave Assembly
188
Secondary Sheave
189
Drive Belt
192
Primary Sheave Service
196
Secondarysheave Service
201
Chapter Eleven
208
Hydraulic Brake Pad Replacement
209
Brake Caliper
210
Brake Master Cylinder
213
Parking Brake 2
216
Brake Hose Replacement
218
Brakedisc
218
Bleeding the Brake System
219
Chapter Twelve
221
Chaincase, Jackshaft and Front Axle
221
Drive Chain and Sprockets
221
Drive Chain. Sprockets and Gears
224
X700XTCD Models)
224
Chaincase
225
Jackshaft
225
Front Axle
232
Chapter Thirteen
239
Front Suspension and Steering
239
Skis
239
Shockabsorber
247
Handlebar and Grips
248
Chapter Fourteen
257
Track and Rear Suspension
257
Rear Suspension 25
257
Wear Strips
258
End Caps
259
Shockabsorbers
260

Yamaha VT600G Owner's Manual (98 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 9 MB

Table of Contents
6
Yamaha Motor Corporation, U.s.a. Snowmobile Limited Warranty

8
Yamaha Extended Service (Y.e.s.)

11
Location of the Important Labels

12
Safety Information

14
Description

17
Control Functions

19
- Main Switch
  19
- Starter Lever (Choke)
  20
- Throttle Lever
  20
- Throttle Override System (T.O.R.S.)
  20
- Oil Level Warning Light
  21
- Coolant Temperature Warning Light
  22
- Engine Stop Switch
  24
- Brake Lever
  24
- Parking Brake Lever
  25
- Drive Select Lever
  25
- Headlight Beam Switch
  26
- Grip Warmer Control Knob
  26
- Thumb Warmer Control Knob
  26
- Passenger Grip Warmer Switch
  27
- Tripmeter Reset Knob
  27
- Shroud Latches
  27
- Drive Guard
  28
- V-Belt Holders
  28
- Spark Plug Holders
  28
- Carburetor Heating Lever
  28
- Backrest
  29
- Storage Compartment
  29
Pre-Operation Checks

30
- Fuel
  30
- Engine Oil
  31
- Coolant
  31
- Throttle Lever
  32
- Recoil Starter
  32
- Throttle Override System (T.O.R.S.)
  32
- Brake
  33
- Brake Fluid Leakage
  34
- V-Belt
  34
- Drive Guard
  34
- Drive Track
  35
- 51-MM (2.0-In) High-Profile Pattern Drive Track
  35
- Slide Runners
  35
- Skis and Ski Runners
  36
- Steering System
  36
- Lights
  36
- Battery
  37
- Air Filter
  37
- Fittings and Fasteners
  38
- Tool Kit and Recommended Equipment
  38
Operation

39
- Starting the Engine
  39
- Emergency Engine Starting
  40
- Break-In
  42
- Riding Your Snowmobile
  43
- Getting to Know Your Snowmobile
  43
- Learning to Ride Your Snowmobile
  43
- To Start out and Accelerate
  44
- Braking
  44
- Turning
  44
- Riding Uphill
  45
- Riding Downhill
  45
- Traversing a Slope
  46
- Ice or Icy Surface
  46
- Hard-Packed Snow
  46
- Operation on Surfaces Other than Snow or Ice
  47
- Maximizing Drive Track Life
  48
- Strap
  49
- Driving
  50
- Stopping the Engine
  51
- Transporting
  52
Periodic Maintenance

53
- Periodic Maintenance Chart
  53
- Tool Kit
  56
- Spark Plug Inspection
  56
- Engine Idle Speed Adjustment
  57
- Throttle Cable Adjustment
  58
- Oil Pump Cable Adjustment
  58
- Carburetor Adjustment
  59
- High Altitude Adjustments
  61
- Cooling System
  62
- V-Belt Replacement
  64
- Checking the Oil Level of the Drive Chain Housing
  67
- Checking the Brake Pads
  68
- Checking the Parking Brake Pads
  68
- Checking the Brake Fluid Level
  69
- Brake Fluid Replacement
  70
- Suspension
  70
- Drive Track Adjustment
  76
- Ski Alignment
  78
- Handlebar Adjustment
  79
- Lubrication
  81
- Headlight Bulb Replacement
  82
- Headlight Beam Adjustment
  82
- Battery
  83
- Fuse Replacement
  84
Troubleshooting

85
Storage

88
Specifications

90
- Dimensions
  90
- Engine
  90
- Chassis
  91
- Electric
  92

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Yamaha VT600G 2002 Motorcycle Manuals

Yamaha VT600G Service Manual (287 pages)

Table of Contents

Chapter 1. General Information

Machine Identification

Important Information

Special Tools

Chapter 2

Periodic Inspection and Adjustment

Introduction

Periodic Maintenance Table

Engine

Power Train

Chassis

Electrical

Tuning

Chapter 3

Chassis

Steering

Front Suspension

Chapter 4. Power Train

Primary Sheave and Drive V-Belt

Secondary Sheave

Drive Chain Housing

Jackshaft

Brake

Slide Rail Suspension

Front Axle and Track

Chapter 5

Engine

Exhaust Assembly

Engine Assembly

Cylinder Head and Cylinder

Oil Pump, Crankcase and Crankshaft

Ac Magneto

Recoil Starter

Chapter 6. Cooling System

Heat Exchanger

Water Pump

Chapter 7. Carburetion

Carburetors

Fuel Pump

Chapter 8. Electrical

Switch Inspection

Ignition System

Electrical Starting System (Vx600Er/Vt600)

Charging System (Vx600Er/Vt600)

Lighting System

Signal System

Grip Warmer System

Fault Location Table

Chapter 9. Specifications

General Specifications

Maintenance Specifications

General Torque Specifications

Definition of Units

Cable Routing

Yamaha VT600G Manual (282 pages)

Table of Contents

Yamaha VT600G Owner's Manual (98 pages)

Table of Contents

Yamaha Motor Corporation, U.s.a. Snowmobile Limited Warranty

Yamaha Extended Service (Y.e.s.)

Location of the Important Labels

Safety Information

Description

Control Functions

Pre-Operation Checks

Operation

Periodic Maintenance

Troubleshooting

Storage

Specifications

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