Yamaha MM600G Service Manual - How To Use This Manual

Other manuals for MM600G: Owner's Manual

Summary of MM600G

  • Page 1

    Vx600erg sx600g mm600g vt600g service manual lit-12618-02-20 8ea-28197-10 981059.

  • Page 2: How To Use This Manual

    How to use this manual particularly important information is distinguished in this manual by the following notations: the safety alert symbol means attention! Be alert! Your safety is involved! Warning failure to follow warning instructions could result in severe injury or death to the snowmobile op...

  • Page 3: Chas

    Illustrated symbols (refer to the illustration) illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 general information 2 periodic inspection and adjustment 3 chassis 4 power train 5 engine 6 cooling system 7 carburetion 8 electrical 9 specifications...

  • Page 4: General Information

    – + general information periodic inspection and adjustment chassis power train engine cooling system carburetion electrical specifications index gen info chas eng powr tr carb elec spec cool 1 insp adj 2 3 4 5 6 7 8 9.

  • Page 5

    Chapter 1. General information machine identification ............................ 1-1 frame serial number ......................... 1-1 engine serial number ....................... 1-1 important information .......................... 1-2 preparation for removal and disassembly ........................

  • Page 6

    Ski .................................................................... 3-8 vx600er/vt600 ........................................ 3-8 sx600/mm600 ............................................ 3-9 inspection ............................................ 3-10 installation (vx600er/vt600) ................

  • Page 7

    Chapter 6. Cooling system heat exchanger ........................................ 6-1 vx600er/sx600/vt600 ............................ 6-1 mm600 ........................................................ 6-2 inspection .............................................. 6-3 installation ......................

  • 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 ..............

  • Page 9: Gen

    1-1 gen info machine identification general information machine identification frame serial number the frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). Engine serial number the engine serial number 1 is located on the right-hand side of the cra...

  • Page 10: Gen

    1-2 gen info important information important information preparation for removal and disassembly 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. While cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc...

  • Page 11: Gen

    1-3 gen info important information 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...

  • Page 12: Gen

    1-4 gen info special tools 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 whe...

  • Page 13: Gen

    1-5 gen 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. • 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. • cooling sy...

  • Page 14: Gen

    1-6 gen info special tools • yxr clutch bushing jig kit p/n: ys-39752 this tool is used for removal and installation of primary clutch weight and roller bushings. • clutch bushing press p/n: ys-42424 this tool is used for removing and installing the post bushings (primary sheave cap bush, sliding sh...

  • Page 15: Insp

    2-1 insp adj spark plugs engine oil fuel fuel filter fuel line oil line engine coolant carburetors recoil starter engine stop switch throttle override system (t.O.R.S.) throttle lever exhaust system decarbonization drive guard v-belt drive track and idler wheels slide runners brake and parking brake...

  • Page 16: Insp

    2-2 insp adj periodic maintenance table check oil level. Replace. Check deflection. Adjust if necessary. Check for wear and damage. Replace if necessary. Check operation. Adjust toe-out if necessary. Check for damage. Replace if necessary. Check operation. Replace bulbs if necessary. Check fluid lev...

  • Page 17: Insp

    2-3 insp adj 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 3. Measure: • spark plug gap a out of specification → regap. Use a wire thickness gauge. Spark plug gap: 0.7 ~ 0.8 mm (0.028 ~ 0...

  • Page 18: Insp

    2-4 insp adj 1 1 1 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. • the oil tank has been run empty. • as part of the pre-delivery servic...

  • Page 19: Insp

    2-5 insp adj 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. Install: • carburetors refer to “carburetors” in chapter 7. Cable adjustment ...

  • Page 20: Insp

    2-6 insp adj 1 2 2 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: • intake silencer refer to “fuel pump” in chapter 7. Cooling system coola...

  • Page 21: Insp

    2-7 insp adj 1 1 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

    2-8 insp adj 1 1 1 1 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. Warning coolant is poisonous. It is harmful or fatal if swallowed. • if coolant is swallowed, induce vomiting imme- diate...

  • Page 23: Insp

    2-9 insp adj cooling system t r . . Sea2130 t r . . 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) 20. Install: • exhaust joint • exhaust pipe refer to “exhaust assembly” in chap- ter 5. Bo...

  • Page 24: Insp

    2-10 insp adj 1 2 1 1 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 • apply 100 kpa (1.0 kg/c...

  • Page 25: Insp

    2-11 insp adj 1 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. • tighten the bleed bolt 1 . Bleed bolt: vx600er/sx600/vt6...

  • Page 26: Insp

    2-12 insp adj 3 • 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” level mark. 3. Install: • bleed bolt cap (mm600) •...

  • Page 27: Insp

    2-13 insp adj 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. Turning in → idle speed is increased. Turning out → idle speed is decreased...

  • Page 28: Insp

    2-14 insp adj 1 2 3 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 → free play is increased. Turning out → free play is decreased. • tighten the locknut. Note: after adjusting...

  • Page 29: Insp

    2-15 insp adj starter (choke) cable free play adjustment/ 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) 2. Adjust: • starter cable free play adjustment...

  • Page 30: Insp

    2-16 insp adj 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...

  • Page 31: Insp

    2-17 insp adj t r . . 2 a 1 2 3 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. • tighten the mounting bolts (front) 1 and mount- ing bolt...

  • Page 32: Insp

    2-18 insp adj 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

    2-19 insp adj 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 more than 1.5 mm (0.06 in) above the edge from 1.5 mm (0.06 in) above the edge to –0.5 mm (–0.02 in) below the edge more than –0.5 mm (–0.02 in) below the edge ...

  • Page 34: Insp

    2-20 insp adj 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. • check the engine speed when the machine starts moving forward. Out of specification → ad...

  • Page 35: Insp

    2-21 insp adj parking brake adjustment 1. Measure: • clearance a out of specification → adjust. Clearance: 1.2 ~ 1.3 mm (0.047 ~ 0.051 in) 2. Adjust: • clearance a adjustment steps: • loosen the locknuts 1 . • turn the cable adjuster 2 in or out to until the specified clearance between the brake pad...

  • Page 36: Insp

    2-22 insp adj brake fluid level inspection/ 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 note: for a correct reading of the b...

  • Page 37: Insp

    2-23 insp adj 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: • the sy...

  • Page 38: Insp

    2-24 insp adj 1 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. • tighten the bleed screws. Bleed screw: 6 nm (0.6 m · kg, 4.3 ft · lb) note: if bleeding is diffic...

  • Page 39: Insp

    2-25 insp adj 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 hou...

  • Page 40: Insp

    2-26 insp adj 1 1 2 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. • install the oil drain bolt 1 . Oil drain bolt: 16 nm (1.6 m · kg, 11 ft · lb) recommen...

  • Page 41: Insp

    2-27 insp adj 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. • make sure that the batte...

  • Page 42: Insp

    2-28 insp adj 4 5 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 . A. Start the engine and rotate the track on...

  • Page 43: Insp

    2-29 insp adj 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: 10 mm (0.39 in) sea2590

  • Page 44: Insp

    2-30 insp adj maximizing drive track life recommendations track tension during initial break-in, the new drive track will tend to stretch quickly as the track settles. Be sure to correct the track tension and alignment frequently. (see pages 2-27 ~ 2-28 for adjustment procedures.) a loose track can ...

  • Page 45: Insp

    2-31 insp adj a chassis ski/ski runner 1. Inspect: • ski • ski runner damage/wear → replace. 2. Measure: • ski runner wear limit a • plastic ski wear limit b out of specification → replace. Ski runner wear limit: 8 mm (0.31 in) plastic ski wear limit: vx600er/vt600: 13 mm (0.51 in) sx600/mm600: 8 mm...

  • Page 46: Insp

    2-32 insp adj 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- stalled securely in posi...

  • Page 47: Insp

    2-33 insp adj steering system/lubrication a t r . . B 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 . Locknut (tie rod): 25 nm (2.5 m · kg, 18 ft · lb) loctit...

  • Page 48: Insp

    2-34 insp adj lubrication b c front and rear suspension 1. Use a grease gun to inject grease into the nipples 1 . Lubricate the ball joints 2 , 3 . Recommended lubricant: esso beacon 325 grease or aeroshell grease #7a Å front ı rear (vx600er/sx600/vt600) Ç rear (mm600) sea2650 sea2660 sea2665 sea264...

  • Page 49: Insp

    2-35 insp adj 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 center of the headlight and place ...

  • Page 50: Insp

    2-36 insp adj 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 ...

  • Page 51: Insp

    2-37 insp adj 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 ex...

  • Page 52: Insp

    2-38 insp adj 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: Insp

    2-39 insp adj 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. • make sure that the battery breather hose is properly connected and is not ...

  • Page 54: Insp

    2-40 insp adj 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. • if the fuse immediately blows again, check the electrical circuit. Item 1 main fu...

  • Page 55: Insp

    2-41 insp adj 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. Special car...

  • Page 56: Insp

    2-42 insp adj carburetor tuning mid-range and high speed tuning adjustments are normally not required, but may some- times be necessary, depending on temperatures, altitude or both. Mid-range speed and high speed tuning (from 1/4 to full-throttle) can be done by adjusting the main jet. Caution: neve...

  • Page 57: Insp

    2-43 insp adj carburetor tuning guide for carburetion sea2720

  • Page 58: Insp

    2-44 insp adj carburetor tuning a standard main jet b main jet whose diameter is 10% smaller than standard c main jet whose diameter is 10% larger than standard a no. 2 position b no. 1 position c no. 3 position caution: if the intake silencer is removed from the carbure- tors, the change in pressur...

  • Page 59: Insp

    2-45 insp adj 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. 1. Tighten ...

  • Page 60: Insp

    2-46 insp adj remedy replace the main jet with the next smaller size. Replace the main jet with the next larger size. Replace the piston and spark plug. Tune the carburetors again. Begin with low- speed tuning. Check the piston for holes or seizure. Check the cooling system, gasoline octane rating a...

  • Page 61: Insp

    2-47 insp adj trouble poor performance at mid-range speeds: • momentary slow re- sponse to the throttle • poor acceleration poor performance at normal speeds: • excessive fuel con- sumption • poor acceleration poor performance at high speeds: • power loss • poor acceleration abnormal combustion: • b...

  • Page 62: Insp

    2-48 insp adj clutch specifications model: vx600er clutch high altitude Å elevation ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) ı engine idle speed 1,600 ± 100 r/min ← ← ← Ç engagement r/min 4,000 ± 200 r/min 4,100 ± ...

  • Page 63: Insp

    2-49 insp adj clutch specifications model: sx600 Å elevation ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) ı engine idle speed 1,600 ± 100 r/min ← ← ← Ç engagement r/min 4,200 ± 200 r/min ← 4,100 ± 200 r/min 4,200 ± 200...

  • Page 64: Insp

    2-50 insp adj clutch specifications model: mm600 Å elevation ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) ı engine idle speed 1,600 ± 100 r/min ← ← ← Ç engagement r/min 4,400 ± 200 r/min 4,500 ± 200 r/min 4,600 ± 200 r...

  • Page 65: Insp

    2-51 insp adj clutch specifications model: vt600 Å elevation ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) ı engine idle speed 1,600 ± 100 r/min ← ← ← 4,000 ± 200 r/min 4,100 ± 200 r/min Ç engagement r/min 3,900 ± 200 r...

  • Page 66: Insp

    2-52 insp adj clutch Å elevation ~ 1,000 m 900 ~ 1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m (~ 3,500 ft) (3,000 ~ 5,000 ft) (4,500 ~ 7,000 ft) (6,500 ~ 10,000 ft) ß roller outer dia. 14.5 mm (0.57 in) ← ← ← Ê roller bushing duralon ← ← ← Ë pri. Clutch shim none ← ← ← 90508-536a9 √ secondary sheave spri...

  • Page 67: Insp

    2-53 insp adj 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 ...

  • Page 68: Insp

    2-54 insp adj Ó outside diameter mm (in) 69.5 (2.736) 69.5 (2.736) 69.5 (2.736) 69.5 (2.736) Ì free length mm (in) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) Ï no. Of coils 5.19 5.53 5.53 4.86 ‰ wire gauge mm (in) 5.0 (0.196) 5.3 (0.209) 5.5 (0.217) 5.5 (0.217) Î color brown red green silver Ç spring r...

  • Page 69: Insp

    2-55 insp adj 5 torque cam (secondary sheave spring seat) Ç part no. 8bv-17604-71 8bv-17604-51 8bv-17604-31 8bv-17604-11 8bv-17604-91 gear selection Ï standard Î cam angle 47° 45° 43° 41° 39° ı effects ‰ identification mark 8bv71 8bv51 8bv31 8bv11 8bv91 sea2750 vx600er/sx600 mm600/vt600

  • Page 70: Insp

    2-56 insp adj 19.6 (2.00) 19.6 (2.00) 19.6 (2.00) 24.5 (2.50) 27.0 (2.75) 24.5 (2.50) 27.0 (2.75) 22.1 (2.25) 24.5 (2.50) 19.6 (2.00) 22.1 (2.25) 22.1 (2.25) 22.1 (2.25) 29.4 (3.00) 31.9 (3.25) 29.4 (3.00) 27.0 (2.75) 29.4 (3.00) 24.5 (2.50) 27.0 (2.75) 31.9 (3.25) blue-pink-blue blue-silver-blue bl...

  • Page 71: Insp

    2-57 insp adj gear selection 7 clutch weights 8ch-17605-10 35.32 g Å standard 8cr-17605-10 38.09 g 8dg-17605-00 34.30 g 8dj-17605-00 37.77 g 8dn-17605-20 42.09 g vx600er/ sx600/ mm600/ vt600 sea2760 sea2765 sea2770 sea2775 sea2780 8ek-17605-00 39.00 g sea2785.

  • Page 72: Insp

    2-58 insp adj duralon 90380-09245 9 mm (0.4 in) 90387-0514u duralon 90380-09245 9 mm (0.4 in) 90387-0514u duralon 90380-09245 9 mm (0.4 in) 90387-0514u duralon 90380-09245 9 mm (0.4 in) 90387-0514u gear selection 8 rollers Å roller with bushing part number ı outside diameter Ç bushing type (p/n) col...

  • Page 73: Insp

    2-59 insp adj high altitude tuning adjust the size of the main jet re-test try high altitude settings decide if the problem is with the pilot jet and adjust accordingly adjust the main jet size according to the chart not ok check the engagement speed and shift performance adjust the primary clutch a...

  • Page 74: Insp

    2-60 insp adj front suspension spring adjuster position preload standard 1 2 3 4 5 front suspension spring preload (vx600er/mm600/vt600) 1. Adjust: • spring preload adjustment steps: • turn the adjusting ring 1 to the proper position. Caution: be sure that the left and right spring preload is the sa...

  • Page 75: Insp

    2-61 insp adj 1 2 a 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: • loose...

  • Page 76: Insp

    2-62 insp adj spring preload (vx600er/mm600/vt600) 1. Adjust: • spring preload adjustment steps: • turn the adjusting ring 1 to the proper position. 1 2 3 4 5 softer ← → harder vx600er/mm600/vt600: 3 spring adjuster position preload Å front standard 1 2 3 4 5 6 7 softer ← → harder vx600er: 2 mm600/v...

  • Page 77: Insp

    2-63 insp adj rear suspension rear suspension-full rate 1. Adjust: • full rate adjuster adjustment steps: installation position a b c spring rate and damping soft medium hard standard b note: be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile. • loosen the nut 1...

  • Page 78: Insp

    2-64 insp adj a b a b t r . . 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) loctite ® rear suspension sea2865.

  • Page 79: Insp

    2-65 insp adj rear suspension.

  • Page 80: Chas

    3-1 chas steering chassis steering vx600er/sx600/vt600 10 nm (1.0 m · kg, 7.2 ft · lb) Å : remarks remove the parts in the order listed below. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Note: after installing all parts, refer to “cable rout- ing” in chapter 9, to check the cable, le...

  • Page 81: Chas

    3-2 chas steering mm600 10 nm (1.0 m · kg, 7.2 ft · lb) Å : remarks remove the parts in the order listed below. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Note: after installing all parts, refer to “cable rout- ing” in chapter 9, to check the cable, lead and hose routings. For insta...

  • Page 82: Chas

    3-3 chas steering Å : 25 nm (2.5 m · kg, 18 ft · lb) ı : Ç : Î : ‰ : remarks remove the parts in the order listed below. Refer to “engine assembly” in chapter 5. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 job name/part name steering column and tie rod ...

  • Page 83: Chas

    3-4 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. This may dangerously weaken the column. 2. Inspect: • bearings (steering column) 1 • collars 2 wea...

  • Page 84: Chas

    3-5 chas 1 2 a a a b 3 2 1 2 3 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) 2. Install: • tie rod 1 • locknut 2 • joints 3 3. Install: • tie rods 1 note: • make sure that the indentation a on the tie ...

  • Page 85: Chas

    3-6 chas l t lt steering t r . . 5. Adjust: • skis adjustment steps: • temporarily install the handlebar. • hold the handlebar straight and check that the skis are at right angles to the handlebar. • loosen the locknuts (relay rod) 1 . • position the skis parallel in the riding direction. • with the...

  • Page 86: Chas

    3-7 chas 8ch-10 8ed-10 t r . . 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. • center the match mark c on the handlebar 1 between the lower handl...

  • Page 87: Chas

    3-8 chas ski ski vx600er/vt600 q’ty 1 1 1 6 1 1 2 2 1 4 1 remarks remove the parts in the order listed below. Color : black color : gold for installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 10 11 job name/part name ski removal cotter pin ski stopper collar washer ski column lower...

  • Page 88: Chas

    3-9 chas ski sx600/mm600 q’ty 1 1 1 6 1 1 1 6 1 remarks remove the parts in the order listed below. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 job name/part name ski removal cotter pin ski stopper collar washer ski column lower bracket ski runner ski washer ski handle 1...

  • Page 89: Chas

    3-10 chas fwd a 1 2 5 3 7 4 1 6 8 9 9 9 ski 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 → replace. Å vx600er/vt600 ı sx600/mm600 sea3210 installa...

  • Page 90: Chas

    3-11 chas front suspension front suspension 23 nm (2.3 m · kg, 17 ft · lb) Å : q’ty 1 1 1 1 1 2 1 2 2 4 1 2 1 remarks remove the parts in the order listed below. Refer to “ski”. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 10 11 12 13 job name/part name front suspension r...

  • Page 91: Chas

    3-12 chas front suspension inspection 1. Inspect: • shock absorber 1 oil (gas) leaks/bends/damage → replace. 2. Inspect: • ski column 1 • steering arm 2 cracks/bends/damage → replace. • bushing 3 wear/scratches/damage → replace. 3. Inspect: • control rod 1 cracks/bends/damage → replace. • bushing 2 ...

  • Page 92: Chas

    3-13 chas 4. Inspect: • connecting rod 1 • stabilizer 2 cracks/bends/damage → replace. • collar 3 wear/scratches/damage → replace. 5. Inspect: • front arm 1 cracks/bends/damage → replace. Sea3280 sea3290 front suspension.

  • Page 93: Chas

    3-14 chas front suspension installation 1. Install: • control rod 1 • nut 2 • joint 3 sea3300 Å left hand ı set length a 93 ± 1° 93 ± 1° 475.5 ± 0.5 mm (18.7204 ± 0.0197 in) 472.6 ± 0.5 mm (18.6062 ± 0.0197 in) ‰ upper (vx600er/sx600/ vt600) Ç set angle b Ì color c blue Î right hand ı set length a 8...

  • Page 94: Chas

    3-15 chas c c t r . . 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) Å vx600er/vt600 ı sx600/mm600 front suspension sea3310 sea3320 sea3...

  • Page 95: Chas

    3-16 chas front suspension ski spindle camber: –0.5° to +0.5° angle finder: ys-42422 Å use an angle finder to check that the unit is level. Sea3340 sea3350 sea3360 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 fi...

  • Page 96: Chas

    3-17 chas front suspension Å ski toe out: 0 ~ 15 mm (0 ~ 0.59 in) a – b = toe out sea3380 sea3370 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. Caution: when tightening ...

  • Page 97: Chas

    3-18 chas a b c r a b c d vx600er/vt600 sx600 mm600 Å part number front suspension front arm part number ı caster a Ç control rod bracket angle b Î shock absorber bracket angle c ‰ id mark d 25.5° 25.5° 25.5° m r s 3° 3° 3° 10° 10° 7° 8dm-2382e-10 (l/h) 8dm-2382f-10 (r/h) 8cr-2382e-20 (l/h) 8cr-2382...

  • Page 98: Chas

    3-19 chas a b front suspension control rod part number vx600er/sx600/ vt600 mm600 Ç part number Å upper ı lower Å upper ı lower Î length a ‰ angle b 8cr-2384e-20 8cr-2384f-20 8cs-2384e-20 8cs-2384f-20 439.5 ± 1 mm (17.3031 ± 0.0394 in) 431.6 ± 1 mm (16.9921 ± 0.0394 in) 393.7 ± 1 mm (15.5000 ± 0.039...

  • Page 99: Powr

    Powr tr 4-1 primary sheave and drive v-belt power train primary sheave and drive v-belt q’ty 1 1 1 remarks remove the parts in the order listed below. For installation, reverse the removal procedure. Order 1 2 3 job name/part name primary sheave removal v-belt blind cap primary sheave assembly Å : 1...

  • Page 100: Powr

    Powr tr 4-2 primary sheave and drive v-belt 4 nm (0.4 m · kg, 2.9 ft · lb) Å : 14 nm (1.4 m · kg, 10 ft · lb) Ç : 6 nm (0.6 m · kg, 4.3 ft · lb) ı : 20 nm (2.0 m · kg, 14 ft · lb) Î : sea4020 q’ty 1 1 3 3 6 3 3 6 1 1 1 1 1 1 6 remarks remove the parts in the order listed below. (vx600er/vt600) for a...

  • Page 101: Powr

    Powr tr 4-3 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: 90890-01701, ys-01880 primary sheave puller: ys-01881-1, ys-01859-1 sea4030

  • Page 102: Powr

    Powr tr 4-4 sea4040 sea4050 sea4060 sea4070 disassembly 1. Remove: • fixed sheave 1 • stopper 2 • sliding sheave 3 • bushing 4 • spider 5 removal steps: • immerse the primary sheave assembly in 80 ° c ~ 100 ° c (176 ° f ~ 212 ° f) water for several minutes. • attach the lower piece of the clutch spi...

  • Page 103: Powr

    Powr tr 4-5 primary sheave and drive v-belt inspection 1. Inspect: • spider 1 • sliding sheave 2 • fixed sheave 3 • primary sheave cap 4 cracks/damage → replace. 2. Inspect: • primary sheave spring 1 cracks/damage → replace. 3. Measure: • primary sheave spring free length a out of specification → re...

  • Page 104: Powr

    Powr tr 4-6 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 out of specification → replace the slider. Slider inside clearance = a 1 + a 2 slider inside clearance: min. 0 mm (0 in) ...

  • Page 105: Powr

    Powr tr 4-7 b a lt lt 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 assembly 1. Install: • sliding sheave (onto the spider) note: be sure the sliding sheave match m...

  • Page 106: Powr

    Powr tr 4-8 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: • finger-tighten the spider until it is stopped by the fixed sheave stopper. • hold the fixed sheave with the clutch spider...

  • Page 107: Powr

    Powr tr 4-9 t r . . 1 3 5 2 4 6 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 must be installed with their threaded portions pointing in a counterclockwise direction, as illustrated...

  • Page 108: Powr

    Powr tr 4-10 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. 2. Apply: • yamalube 2-cycle oil or an equivalent grease (to threa...

  • Page 109: Powr

    Powr tr 4-11 secondary sheave secondary sheave q’ty 1 1 – 1 1 remarks remove the parts in the order listed below. Refer to “sheave distance and offset adjustment” in chapter 2. For installation, reverse the removal procedure. Order 1 2 3 4 5 job name/part name secondary sheave removal v-belt washer ...

  • Page 110: Powr

    Powr tr 4-12 secondary sheave q’ty 1 1 1 1 1 1 1 remarks remove the parts in the order listed below. (sx600) (sx600) for assembly, reverse the disassembly proce- dure. Order 1 2 3 4 5 6 7 job name/part name secondary sheave disassembly spring seat secondary sheave spring secondary sheave plate 1 fix...

  • Page 111: Powr

    Powr tr 4-13 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). • do not attem...

  • Page 112: Powr

    Powr tr 4-14 secondary sheave 5. Measure: • ramp shoe thickness a out of specification → replace the ramp shoe. Wear limit: 1.0 mm (0.04 in) assembly 1. Install: • stopper • sliding sheave screw (stopper): 6.5 nm (0.65 m · kg, 4.6 ft · lb) 2. Install: • fixed sheave 1 • bolts 2 (along with the shims...

  • Page 113: Powr

    Powr tr 4-15 a t r . . 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 number) × 10 twist angle: 80 ° ...

  • Page 114: Powr

    Powr tr 4-16 adjustment steps: • disassemble the secondary sheave. • remove the bolts and original shims 1 . • install new shims of the proper thickness and reassemble the secondary sheave. • measure the secondary sheave clearance again. Repeat these steps until the clearance is within specification...

  • Page 115: Powr

    Powr tr 4-17 job name/part name drive chain housing removal coolant hose bracket frame cross member bolt (m10 × 65) brake caliper parking brake chain tension adjuster bolt drive chain housing cover chain tensioner roller drive sprocket collar drive chain driven sprocket collar drive chain housing dr...

  • Page 116: Powr

    Powr tr 4-18 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. • bearing (chain tensioner) 4 pitting...

  • Page 117: Powr

    Powr tr 4-19 1 2 3 4 5 6 7 8 9 0 a b c d e a b drive chain housing sea4440 sea4450 3. Measure: • 14 link section a of the drive chain using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b . Out of specification → replace the drive chain. Maximum 14 link drive chain section leng...

  • Page 118: Powr

    Powr tr 4-20 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. C 1 c 2 be sure to inst...

  • Page 119: Powr

    Powr tr 4-21 job name/part name drive chain housing removal battery battery bracket coolant hose bracket frame cross member bolt (m10 × 65) brake caliper parking brake chain tension adjuster joint shift rod shift lever assembly lever bolt drive chain housing cover joint lever rod washer reverse driv...

  • Page 120: Powr

    Powr tr 4-22 remarks for installation, reverse the removal procedure. Drive chain housing q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 order 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 job name/part name spring chain tensioner roller collar spring journal reverse driven gear washer forward dri...

  • Page 121: Powr

    Powr tr 4-23 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. • bearings (drive chain housing and cover) 4 pitting/damage → replace. 2. Inspect:...

  • Page 122: Powr

    Powr tr 4-24 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. C 1 c 2 be sure to inst...

  • Page 123: Powr

    Powr tr 4-25 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 0 mm (in direction where a can be shortened appropriately) and then turn back the sh...

  • Page 124: Powr

    Powr tr 4-26 jackshaft jackshaft q’ty 1 1 1 1 1 1 2 1 remarks remove the parts in the order listed below. Refer to “secondary sheave”. Refer to “fuel pump” in chapter 7. Refer to “drive chain housing”. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 job name/part name jackshaf...

  • Page 125: Powr

    Powr tr 4-27 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. 2. Inspect: • bearing holder 1 cracks/damage → replace. • bearing 2 pitting/...

  • Page 126: Powr

    Powr tr 4-28 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) • temporarily tighten the nuts 3 . • tighte...

  • Page 127: Powr

    Powr tr 4-29 brake q’ty 1 1 1 2 2 2 remarks remove the parts in the order listed below. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 job name/part name brake pad removal cap bolt retaining pin pad spring brake pad shim 1 shim 2 6 nm (0.6 m · kg, 4.3 ft · lb) Å : 48 nm (4.8 m · ...

  • Page 128: Powr

    Powr tr 4-30 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. Use only clean brake fluid. • do not allo...

  • Page 129: Powr

    Powr tr 4-31 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 pistons into the caliper with your finger. • tighten th...

  • Page 130: Powr

    Powr tr 4-32 brake 30 nm (3.0 m · kg, 22 ft · lb) Å : 48 nm (4.8 m · kg, 35 ft · lb) ı : q’ty 1 1 2 1 1 1 2 2 2 remarks remove the parts in the order listed below. Drain. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 job name/part name brake caliper and parking brake re- m...

  • Page 131: Powr

    Powr tr 4-33 brake q’ty 1 1 1 2 2 2 2 4 2 remarks remove the parts in the order listed below. For assembly, reverse the disassembly proce- dure. Order 1 2 3 4 5 6 7 8 9 job name/part name brake caliper disassembly cap bolt retaining pin pad spring brake pad shim 1 shim 2 bleed screw piston seal pist...

  • Page 132: Powr

    Powr tr 4-34 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 • piston seals 1 removal steps: • using a wood of piece 2 , lock the right piston. • blo...

  • Page 133: Powr

    Powr tr 4-35 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. • oil delivery passage (caliper body) blow out with compressed air. Warning replace th...

  • Page 134: Powr

    Powr tr 4-36 brake 14 nm (1.4 m · kg, 10 ft · lb) Å : 30 nm (3.0 m · kg, 22 ft · lb) ı : sea4690 1 1 1 1 remove the parts in the order listed below. For assembly, reverse the disassembly proce- dure. 1 2 3 4 brake master cylinder disassembly boot circlip master cylinder kit master cylinder body q’ty...

  • Page 135: Powr

    Powr tr 4-37 30˚ a 30˚ 30˚ 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. 2. Inspect: • master cylinder kit 1 scrat...

  • Page 136: Powr

    Powr tr 4-38 slide rail suspension slide rail suspension vx600er/sx600 q’ty 2 2 1 2 remarks remove the parts in the order listed below. Loosen. Loosen. For installation, reverse the removal procedure. Order 1 2 3 4 job name/part name slide rail suspension removal rear axle nut tension adjuster blind...

  • Page 137: Powr

    Powr tr 4-39 slide rail suspension vt600 q’ty 2 2 1 remarks remove the parts in the order listed below. Loosen. Loosen. For installation, reverse the removal procedure. Order 1 2 3 job name/part name slide rail suspension removal rear axle nut tension adjuster blind cap suspension rear plate slide r...

  • Page 138: Powr

    Powr tr 4-40 q’ty 2 2 4 2 1 2 2 2 1 2 1 2 1 4 2 2 2 1 remarks remove the parts in the order listed below. (vt600) (vx600er/sx600) (vx600er/sx600) order 1 2 3 4 5 6 7 8 9 0 a b c d e f g h 4 nm (0.4 m · kg, 2.9 ft · lb) Å : 16 nm (1.6 m · kg, 11 ft · lb) ı : Ç : 49 nm (4.9 m · kg, 35 ft · lb) ‰ : 72 ...

  • Page 139: Powr

    Powr tr 4-41 slide rail suspension q’ty 2 2 2 2 2 2 2 1 1 2 2 1 remarks (vx600er/vt600) order i j k l m n o p q r s t job name/part name suspension wheel collar wheel bracket circlip suspension wheel spacer bushing collar rear suspension bracket spacer bushing collar 24 nm (2.4 m · kg, 17 ft · lb) Å...

  • Page 140: Powr

    Powr tr 4-42 slide rail suspension q’ty 1 2 1 2 4 4 2 2 2 2 2 2 remarks (vx600er/vt600) (vx600er/vt600) (vt600) (vt600) order u v w x y z [ \ ] ^ a b job name/part name rear shock absorber bushing collar pull rod collar bushing rear bracket collar suspension wheel control rod bushing bushing 49 nm (...

  • Page 141: Powr

    Powr tr 4-43 q’ty 1 2 1 1 1 1 2 2 1 1 3 (4) 2 2 1 (2) 1 2 remarks for assembly, reverse the disassembly proce- dure. Order c d e f g h i j k l m n o p q r job name/part name rear pivot arm bushing collar collar rear pivot arm bracket collar circlip suspension wheel wheel bracket shaft rear axle guid...

  • Page 142: Powr

    Powr tr 4-44 slide rail suspension mm600 q’ty 2 1 2 remarks remove the parts in the order listed below. Loosen. Loosen. For installation, reverse the removal procedure. Order 1 2 3 job name/part name slide rail suspension removal rear axle nut tension adjuster suspension rear plate slide rail suspen...

  • Page 143: Powr

    Powr tr 4-45 q’ty 2 2 2 1 1 4 2 1 1 2 1 4 2 1 2 2 2 remarks remove the parts in the order listed below. Order 1 2 3 4 5 6 7 8 9 0 a b c d e f g 4 nm (0.4 m · kg, 2.9 ft · lb) Å : 16 nm (1.6 m · kg, 11 ft · lb) ı : Ç : 49 nm (4.9 m · kg, 35 ft · lb) ‰ : 72 nm (7.2 m · kg, 52 ft · lb) Ï : job name/par...

  • Page 144: Powr

    Powr tr 4-46 slide rail suspension q’ty 2 2 2 2 2 2 2 2 1 1 2 2 1 remarks order h i j k l m n o p q r s t job name/part name suspension wheel collar wheel bracket front pivot arm bracket circlip suspension wheel collar bushing collar rear suspension bracket spacer bushing collar 24 nm (2.4 m · kg, 1...

  • Page 145: Powr

    Powr tr 4-47 slide rail suspension q’ty 1 2 1 2 4 4 2 2 2 2 1 remarks order u v w x y z [ \ ] ^ a job name/part name rear shock absorber bushing collar pull rod collar bushing suspension wheel control rod bushing bushing shaft 49 nm (4.9 m · kg, 35 ft · lb) Å : 72 nm (7.2 m · kg, 52 ft · lb) ı : sea...

  • Page 146: Powr

    Powr tr 4-48 q’ty 1 2 1 1 1 1 2 2 1 1 4 2 2 2 1 2 remarks for assembly, reverse the disassembly proce- dure. Order b c d e f g h i j k l m n o p q job name/part name rear pivot arm bushing collar collar rear pivot arm bracket collar circlip suspension wheel wheel bracket shaft rear axle guide wheel ...

  • Page 147: Powr

    Powr tr 4-49 slide rail suspension inspection 1. Inspect: • suspension wheel • guide wheel cracks/damage → replace. • wheel bearing wheel turns roughly → replace. 2. Inspect: • stopper band 1 frayed/damage → replace. • pull rod 2 bends/damage → replace. • shock absorber 3 oil leaks/damage → replace....

  • Page 148: Powr

    Powr tr 4-50 a b 1 3 2 2 1 3 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): 72 nm (7.2 m · kg, 52 ft · lb) loctite ® 2. Install: • stopper band 1 note: • for vx600er/sx600/vt600: in...

  • Page 149: Powr

    Powr tr 4-51 b a sea4890 control rod parts number 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 washer plate parts number Ó washer plate thickness È upper Ô lower ...

  • Page 150: Powr

    Powr tr 4-52 front axle and track remarks remove the parts in the order listed below. Refer to “drive chain housing”. Refer to “slide rail suspension”. Refer to “secondary sheave”. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 job name/part name front axle and track removal driv...

  • Page 151: Powr

    Powr tr 4-53 104 mm (4.09 in) 132.6 mm (5.22 in) 164.1 mm (6.46 in) 123 mm (4.84 in) 104 mm (4.09 in) 41 mm (1.61 in) 41 mm (1.61 in) 43.1 mm (1.70 in) 60 mm (2.36 in) 111.9 mm (4.41 in) 201.4 mm (7.93 in) 27 mm (1.06 in) sea4950 a front axle and track inspection 1. Inspect: • track 1 • slide metal ...

  • Page 152: Powr

    Powr tr 4-54 a a a a 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 sx600 Ç mm600 Î vt600 for europe sea4960 sea4970 front axle and track a b...

  • Page 153: Eng

    5-1 eng exhaust assembly engine exhaust assembly order 1 2 3 4 5 6 7 8 9 10 11 remarks remove the parts in the order listed below. Open. For installation, reverse the removal procedure. Q’ty 2 2 1 1 1 1 1 1 2 1 1 job name/part name exhaust assembly removal shroud shroud’s stopper wire spring 1 sprin...

  • Page 154: Eng

    5-2 eng 5 3 2 4 1 2 1 4 1 5 3 2 6 a 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. Bolt (exhaust joint): 1st: 18 nm (1.8 m · kg, 13 ft · lb) 2nd...

  • Page 155: Eng

    5-3 eng engine assembly engine assembly order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 remarks remove the parts in the order listed below. Refer to “exhaust assembly”. Refer to “carburetors” in chapter 7. Refer to “recoil starter”. Refer to “ac magneto”. Refer to “primary sheave and drive v- belt” in cha...

  • Page 156: Eng

    5-4 eng 1 engine assembly inspection 1. Inspect: • rear bracket (right) 1 cracks/damage → replace. Installation note: after installing all parts, refer to “cable routing” in chapter 9, to check the cable, lead and hose routings. 1. Fasten: • plastic band 1 note: • fasten the carburetor heating hose ...

  • Page 157: Eng

    5-5 eng 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 ± 1 mm (0.906 ± 0.039 in) engine assembly sea5080

  • Page 158: Eng

    5-6 eng cylinder head and cylinder cylinder head and cylinder q’ty 3 1 1 1 3 1 2 1 1 1 order 1 2 3 4 5 6 7 8 9 10 job name/part name cylinder head and cylinder removal spark plug cap clamp sub-wire harness 2 bracket plastic band ignition coil #3 spacer 1 ignition coil #2 spacer 2 ignition coil #1 re...

  • Page 159: Eng

    5-7 eng cylinder head and cylinder q’ty 3 1 1 3 3 1 1 3 3 3 6 6 3 6 3 3 3 order 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 job name/part name spark plug water temperature sensor cylinder head gasket cylinder gasket clamp intake manifold spacer reed valve seat reed valve stopper reed valve ga...

  • Page 160: Eng

    5-8 eng 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 crankcase with a clean rag so that you will not accidentally drop the clip into the crankcase. • before removing the piston pin, de...

  • Page 161: Eng

    5-9 eng 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. 2. Inspect: • cylinder head water jacket crust of minerals/rust → clean. 3. Measur...

  • Page 162: Eng

    5-10 eng cylinder head and cylinder sea5170 sea5180 sea5190 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. 8. Measure: • piston-to-cylinder clearance measurement steps: 1st step:...

  • Page 163: Eng

    5-11 eng 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) • if out of specification, replace the piston and piston rings as a set. 3rd step: • calculate the pi...

  • Page 164: Eng

    5-12 eng 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 angles...

  • Page 165: Eng

    5-13 eng cylinder head and cylinder 14. Inspect: • reed valves 1 bends/cracks/damage → replace. 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) 16. Measure: • reed valve bending limit a out of specificati...

  • Page 166: Eng

    5-14 eng 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. 2. Tighten: • screws 1 s...

  • Page 167: Eng

    5-15 eng a b 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. 5. Install: • gasket...

  • Page 168: Eng

    5-16 eng 1 2 3 gy o b w b/w b b/w b b/w b o b gy b b w b t r . . T r . . 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: • retighten...

  • Page 169: Eng

    5-17 eng oil pump, crankcase and crankshaft oil pump, crankcase and crankshaft q’ty 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1 order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 job name/part name oil pump, crankcase and crankshaft removal oil pump oil hose 1 rear bracket (left) front lower bracket damper clamp front upp...

  • Page 170: Eng

    5-18 eng 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 maximum runout: c 1 : 0.03 mm (0.0012 in) c 2 ~ c 5 : 0.04 mm (0.0016 in) c 6 : 0.03 mm (0.0012 in...

  • Page 171: Eng

    5-19 eng 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. Caution: lubricate the bearings immediately after examin- ing them in order ...

  • Page 172: Eng

    5-20 eng oil pump, crankcase and crankshaft installation 1. Install: • stopper ring 1 [onto the crankshaft bearing 2 (primary sheave side) as shown] 3 knock pin 2. Install: • crankshaft assembly (onto the upper crankcase Å ) note: turn the bearings and labyrinth seal to set the knock pins 1 on the b...

  • Page 173: Eng

    5-21 eng 6 2 4 5 1 3 d e b 9 a 0 7 2 4 6 f c 5 1 3 8 oil pump, crankcase and crankshaft 3. Fill: • gear room 1 recommended oil: yamalube 2-cycle gear room capacity: 25 cm 3 (0.81 imp oz, 0.77 us oz) caution: before installing and torquing the crankcase bolts, be sure to check that the crankshaft tur...

  • Page 174: Eng

    5-22 eng a 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

  • Page 175: Eng

    5-23 eng ac magneto ac magneto q’ty 1 2 1 1 1 1 1 1 1 1 remarks remove the parts in the order listed below. Refer to “recoil starter”. Disconnect. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 10 job name/part name ac magneto removal recoil starter frame cross member ac ma...

  • Page 176: Eng

    5-24 eng ac magneto removal 1. Remove: • bolts 1 • starter pulley 2 • nut 3 note: attach the primary sheave holder to hold the primary sheave. Primary sheave holder: 90890-01701, ys-01880 2. Remove: • magneto rotor 1 note: • remove the magneto rotor using the rotor puller 2 . • fully tighten the too...

  • Page 177: Eng

    5-25 eng 1 2 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. 2. Install: • woodruff key 1 caution: be...

  • Page 178: Eng

    5-26 eng 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) note: attach the primary sheave holder to hold the primary sheave. Primary sheave holder: 90890-01701, ys-01880 t r . . Sea5610

  • Page 179: Eng

    5-27 eng recoil starter recoil starter q’ty 1 1 1 1 1 1 1 1 1 1 1 remarks remove the parts in the order listed below. Refer to “exhaust assembly”. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 10 11 12 nm (1.2 m · kg, 8.7 ft · lb) Å : 18 nm (1.8 m · kg, 13 ft · lb) ı : job...

  • Page 180: Eng

    5-28 eng 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 . Inspection 1. Inspect: • drive plate 1 cracks/bends/damage → repla...

  • Page 181: Eng

    5-29 eng 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 d...

  • Page 182: Cool

    6-1 cool heat exchanger cooling system heat exchanger vx600er/sx600/vt600 q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 remarks remove the parts in the order listed below. Drain. Refer to “cooling system” in chap- ter 2. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 10 11 1...

  • Page 183: Cool

    6-2 cool heat exchanger mm600 q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 remarks remove the parts in the order listed below. Drain. Refer to “cooling system” in chap- ter 2. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 job name/part name...

  • Page 184: Cool

    6-3 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 a b.

  • Page 185: Cool

    6-4 cool 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 2 , 14 ~ 18 psi) measurement steps: • attach the cooling system tester 1 to the coolant filler cap 2 . Cooling system tester: 908...

  • Page 186: Cool

    6-5 cool water pump water pump q’ty 1 1 1 1 1 1 1 1 1 1 1 remarks remove the parts in the order listed below. Refer to “exhaust assembly” in chapter 5. Drain. Refer to “cooling system” in chap- ter 2. (vx600er/vt600) for installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 10 11 job ...

  • Page 187: Cool

    6-6 cool water pump removal 1. Remove: • impeller 1 note: attach the primary sheave holder to hold the primary sheave. Primary sheave holder: 90890-01701, ys-01880 inspection 1. Inspect: • impeller 1 • water pump cover 2 • thermostatic cover 3 cracks/damage → replace. Installation 1. Install: • impe...

  • Page 188: Carb

    7-1 carb carburetors q’ty 1 2 1 1 1 2 3 3 3 remarks remove the parts in the order listed below. Refer to “fuel pump”. Before removing the carburetors, make sure that the carburetor heating lever is turned to “off”. Unfasten. Loosen. Disconnect. For installation, reverse the removal procedure. Order ...

  • Page 189: Carb

    7-2 carb carburetors q’ty 2 1 1 1 3 1 1 3 6 3 3 3 1 1 1 remarks remove the parts in the order listed below. Loosen. For assembly, reverse the separation proce- dure. Order 1 2 3 4 5 6 7 8 9 0 a b c d e job name/part name carburetor separation carburetor heating hose starter cable holder collar sprin...

  • Page 190: Carb

    7-3 carb carburetors q’ty 1 1 1 1 1 1 1 1 1 1 1 1 remarks remove the parts in the order listed below. Turn clockwise. Order 1 2 3 4 5 6 7 8 9 0 a b job name/part name carburetor disassembly throttle stop screw carburetor switch (t.O.R.S.) throttle cable holder throttle valve assembly inner throttle ...

  • Page 191: Carb

    7-4 carb q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 remarks for assembly, reverse the disassembly proce- dure. Order c d e f g h i j k l m n o job name/part name gasket main jet main jet ring main nozzle pilot jet pilot jet sleeve float pin float needle valve screw (valve seat) valve seat assembly o-ring pilot ...

  • Page 192: Carb

    7-5 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 air. 2. Inspect: • rubber seals 1 • bearing 2 wear/damage → replace. 3. Inspect: • float 1 damage →...

  • Page 193: Carb

    7-6 carb carburetors 5. Inspect: • throttle valve 1 wear/damage → replace. 6. Check: • throttle valve movement sticks → replace carburetor body assembly. Assembly note: • before reassembling, wash all parts in clean gaso- line. • always use new gaskets and o-rings. 1. Tighten: • inner parts pilot ai...

  • Page 194: Carb

    7-7 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. • if the float height is not within specificatio...

  • Page 195: Carb

    7-8 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. • attach the fuel level gauge 1 to the float chamber nozzle. F...

  • Page 196: Carb

    7-9 carb 1 2 a 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 . 2. Bleed: • cooling sy...

  • Page 197: Carb

    7-10 carb fuel pump vx600er/vt600 fuel pump q’ty 1 1 3 3 1 1 1 1 1 3 1 1 1 remarks remove the parts in the order listed below. Loosen. Note: • first, remove the throttle and oil pump cables from the cable guide on the steering column. • when removing the intake silencer, lift up the throttle and oil...

  • Page 198: Carb

    7-11 carb sx600/mm600 fuel pump q’ty 1 1 3 3 1 1 1 3 1 1 1 remarks remove the parts in the order listed below. Loosen. Disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure. Order 1 2 3 4 5 6 7 8 9 10 11 job name/part name fuel pump removal carburetor heatin...

  • Page 199: Carb

    7-12 carb fuel pump inspection 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 • place a container 3 under t...

  • Page 200: Elec

    8-1 – + elec on off r br/l l/y l/b r br/l l/y l/b 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 te...

  • Page 201: Elec

    8-2 – + elec e wire harness sub-wire harness 2 b w og y bw o gy (black) (black) b wire harness headlight sub-wire harness y /b l yg y /b l /w y g a wire harness headlight sub-wire harness r /b g /r g /bb r /bg /r g /b b (black) (black) c wire harness sub-wire harness 1 b o /bl /r g /y l /r b o /b g ...

  • Page 202: Elec

    8-3 – + elec ignition system ignition system circuit diagram 1 ac magneto 2 rectifier/regulator 3 condenser ∗ 1 4 main fuse ∗ 2 6 battery ∗ 2 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 s brake light ...

  • Page 203: Elec

    8-4 – + elec troubleshooting no spark or weak spark. For vx600er/vt600: check the main fuse and “ignition” fuse. Refer to “fuse inspection” in chapter 2. Ok faulty replace the main fuse and/or “ignition” fuse. For vx600er/vt600: check the battery. Refer to “battery inspection” in chapter 2. Ok out o...

  • Page 204: Elec

    8-5 – + elec for sx600/mm600: check the lighting, signal and meter system. Refer to “lighting system” and “signal system”. Ok 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/m...

  • Page 205: Elec

    8-6 – + elec – + Ω× 1 w w w b ignition system condenser (sx600/mm600) 1. Disconnect: • condenser 1 2. Connect: • condenser (to the lcr meter) 3. Measure: • condenser capacity out of specification → replace. Condenser capacity: 6,800 µ f at 20 ° c (68 ° f) sea8040 sea8050 sea8060 ac magneto 1. Discon...

  • Page 206: Elec

    8-7 – + elec ignition system spark plug 1. Remove: • spark plugs 2. Measure: • spark plug gap standard spark plug: br9es (ngk) spark plug gap: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) spark plug cap 1. Remove: • spark plug cap 2. Connect: • pocket tester (to the spark plug cap) 3. Measure: • spark plug cap r...

  • Page 207: Elec

    8-8 – + elec b/y b/w b + – Ω × 1 a c ignition system b c 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 revoluti...

  • Page 208: Elec

    8-9 – + elec b/y b + – Ω × 1 b/y b/w b + – Ω × 1 sea8160 sea8170 4. Check: • throttle switch continuity faulty → replace the handlebar switch (right). Throttle switch position continuity throttle lever is operated. Yes throttle lever is not operated. No carburetor switch 1. Disconnect: • carburetor ...

  • Page 209: Elec

    8-10 – + elec 4 3 2 1 r l br br/w ignition system sea8210 sea8200 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...

  • Page 210: Elec

    8-11 – + elec 1 w /g w /r w /r w /g w /g w /r w w w w w w w w w w w w b r 2 w br w w r r 3 b r r r r b b r b r b 3 4 5 b r b r b r r b b f l /w g l /w r /y l r g Å Å r /w r b (black) 6 r /w r /w f Å f r 7 b off on start 8 r /y r /w br b /w b br b /w r /w r /y r /w r b br b /w b /w b /y ch b /y b /w ...

  • Page 211: Elec

    8-12 – + elec electrical starting system troubleshooting (vx600er/vt600) starter motor does not operate. Warning before starter motor operation, push the engine stop switch to “off”. Ok no warning a wire for the jumper lead 1 must have the equivalent capacity as that of the battery lead or more, oth...

  • Page 212: Elec

    8-13 – + elec check the main fuse and “ignition” fuse. Refer to “fuse inspection” in chapter 2. Ok correct the connection. Faulty replace the main fuse and/or “ignition” fuse. Electrical starting system * check the main switch. Faulty replace the main switch. Main switch 1. Disconnect: • main switch...

  • Page 213: Elec

    8-14 – + elec Å : 7 nm (0.7 m · kg, 5.1 ft · lb) q’ty 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 remarks remove the parts in the order listed below. Refer to “engine removal” in chapter 5. For assembly, reverse the disassembly proce- dure. Order 1 2 3 4 5 6 7 8 9 0 a b c d e f job name/part name starter motor ...

  • Page 214: Elec

    8-15 – + elec 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. 2. Measure: • commutator diameter a measure the diameter a of the commutator at...

  • Page 215: Elec

    8-16 – + elec 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. Armature coil resistance: continuity chec...

  • Page 216: Elec

    8-17 – + elec 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. 3...

  • Page 217: Elec

    8-18 – + elec 1 w /g w /r w /r w /g w /g w /r w w w w w w w w w w w w b r 2 w br w w r r 3 b r r r r b b r b r b 3 4 5 b r b r b r r b b f l /w g l /w r /y l r g Å Å r /w r b (black) 6 r /w r /w f Å f r 7 b off on start 8 r /y r /w br b /w b br b /w r /w r /y r /w r b br b /w b /w b /y ch b /y b /w ...

  • Page 218: Elec

    8-19 – + elec troubleshooting (vx600er/vt600) battery is not charged. 1. Connect: • pocket tester (to the battery terminals) 2. Measure: • battery voltage • fluid gravity battery voltage: more than 12 v at 20 ° c (68 ° f) ok out of specification • check the main fuse. Refer to “fuse inspection” in c...

  • Page 219: Elec

    8-20 – + elec – + Ω× 1 w w w 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. 1. R...

  • Page 220: Elec

    8-21 – + elec charging system.

  • Page 221: Elec

    8-22 – + elec e wire harness sub-wire harness 2 b w og y bw o gy (black) (black) b wire harness headlight sub-wire harness y /b l yg y /b l /w y g a wire harness headlight sub-wire harness r /b g /r g /bb r /bg /r g /b b (black) (black) c wire harness sub-wire harness 1 b o /bl /r g /y l /r b o /b g...

  • Page 222: Elec

    8-23 – + elec lighting system lighting system circuit diagram 1 ac magneto 2 rectifier/regulator 3 condenser ∗ 1 4 main fuse ∗ 2 6 battery ∗ 2 8 main switch e cdi unit k frame ground t tail/brake light z high beam indicator light [ speedometer light \ tachometer light a headlight b headlight beam sw...

  • Page 223: Elec

    8-24 – + elec lighting system troubleshooting headlight and/or meter light do not come on. Check the bulb(s). Ok 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. Ok faulty replace the main fuse, “igni...

  • Page 224: Elec

    8-25 – + elec lighting system tail light does not come on. Check the bulb(s). Ok 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. Ok faulty replace the main fuse, “ignition” fuse and/or “tail” fuse. F...

  • Page 225: Elec

    8-26 – + elec bulb(s) 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. 3. Check...

  • Page 226: Elec

    8-27 – + elec 6 5 4 3 l/w y lg b g 1 2 l/w y lg b g lighting system headlight relay 1. Inspect: • headlight relay (with the black coupler) 1 inspection steps: • disconnect the headlight relay from the coupler. • connect the pocket tester ( Ω × 1) to the head- light relay terminals as shown. Positive...

  • Page 227: Elec

    8-28 – + elec e wire harness sub-wire harness 2 b w og y bw o gy (black) (black) b wire harness headlight sub-wire harness y /b l yg y /b l /w y g a wire harness headlight sub-wire harness r /b g /r g /bb r /bg /r g /b b (black) (black) c wire harness sub-wire harness 1 b o /bl /r g /y l /r b o /b g...

  • Page 228: Elec

    8-29 – + elec signal system signal system circuit diagram 1 ac magneto 2 rectifier/regulator 3 condenser ∗ 1 4 main fuse ∗ 2 6 battery ∗ 2 8 main switch d water temperature sensor e cdi unit k frame ground q dc back buzzer ∗ 2 r gear position switch ∗ 2 s brake light switch t tail/brake light u fuel...

  • Page 229: Elec

    8-30 – + elec signal system troubleshooting brake light does not come on. Check the tail/brake light bulb. Refer to “lighting system”. Ok no continuity replace the bulb. For vx600er/vt600: check the main fuse, “ignition” fuse and “tail” fuse. Refer to “fuse inspection” in chapter 2. Ok faulty replac...

  • Page 230: Elec

    8-31 – + elec water temperature and/or oil level indicator lights do not come on. Signal system check the water temperature and/or oil level indicator light bulb(s). Refer to “lighting system”. Ok no continuity replace the bulb(s). For vx600er/vt600: check the main fuse, “ignition” fuse and “head” f...

  • Page 231: Elec

    8-32 – + 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. Ok faulty replace the main fuse, “ignition” fuse and/or “head” fuse. For vx600er/vt600: check the battery. Refer to “battery insp...

  • Page 232: Elec

    8-33 – + 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. Ok faulty replace the main fuse, “ignition” fuse and/or “tail” fuse. Check the battery. Refer to “battery inspection” in chapter 2. O...

  • Page 233: Elec

    8-34 – + elec g/y l brake light switch 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 yes brake lever does not operate no signal ...

  • Page 234: Elec

    8-35 – + 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. If it is dropped, it must be r...

  • Page 235: Elec

    8-36 – + elec g b a b + – Ω × 1 signal system sea8520 sea8530 sea8540 sea8550 oil level switch 1. Remove: • intake silencer refer to “fuel pump” in chapter 7. • oil level switch 1 2. Connect: • pocket tester (to the oil level switch coupler) 3. Check: • oil level switch continuity faulty → replace. ...

  • Page 236: Elec

    8-37 – + elec signal system.

  • Page 237: Elec

    8-38 – + elec e wire harness sub-wire harness 2 b w og y bw o gy (black) (black) b wire harness headlight sub-wire harness y /b l yg y /b l /w y g a wire harness headlight sub-wire harness r /b g /r g /bb r /bg /r g /b b (black) (black) c wire harness sub-wire harness 1 b o /bl /r g /y l /r b o /b g...

  • Page 238: Elec

    8-39 – + elec grip warmer system grip warmer system circuit diagram 1 ac magneto 2 rectifier/regulator 3 condenser ∗ 1 4 main fuse ∗ 2 6 battery ∗ 2 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 l passenger g...

  • Page 239: Elec

    8-40 – + 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. Ok faulty replace the main fuse and/or “ignition” fuse. For vx600er/vt600: check the battery. Refer to “b...

  • Page 240: Elec

    8-41 – + 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. Ok faulty replace the main fuse, “ignition” fuse and/or “tail” fuse. Check the battery. Refer to “battery inspection” in cha...

  • Page 241: Elec

    8-42 – + elec y/w b/r + – Ω × 1 – + Ω × 1 b w (l) (r) 2 1 grip warmer system sea8580 sea8590 sea8600 grip and thumb warmer coil 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: • grip wa...

  • Page 242: Elec

    8-43 – + elec + – Ω × 1 l b y/w b/r + – Ω × 1 sea8610 sea8620 variable resistor (grip warmer) 1. Disconnect: • variable resistor coupler 1 2. Connect: • pocket tester (to the variable resistor coupler) 3. Check: • variable resistor resistance when pulley is turned once. Out of specification → replac...

  • Page 243: Elec

    8-44 – + elec b b + – Ω × 1 y/l y/r o/b + – Ω × 1 y/l y/r o/b + – Ω × 1 passenger grip warmer switch (vt600) 1. Disconnect: • passenger grip warmer switch coupler 1 2. Connect: • pocket tester (to the passenger grip warmer switch coupler) 3. Check: • passenger grip warmer switch continuity faulty → ...

  • Page 244: Elec

    8-45 – + elec 4 3 2 1 l/r o/b l/r y sea8710 sea8700 passenger grip warmer relay (vt600) 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 re...

  • Page 245: Elec

    8-46 – + elec 0.75 s repeats 2.5 s 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 th...

  • Page 246: Elec

    8-47 – + elec 0.75 s 0.25 s 6.5 s repeats 0.75 s 0.25 s 5.5 s repeats 0.75 s 0.25 s 4.5 s repeats 0.75 s 0.25 s repeats 3.5 s fault location table no. Patterns condition reference refer to “grip warmer system”. Refer to “vari- able resis- tor (thumb warmer)”. Refer to “grip warmer system”. Refer to ...

  • Page 247: Spec

    Spec 9-1 vx600er/sx600/mm600/vt600 8dg4 (vx600er) 8ea4 (sx600) 8ej3 (mm600) 8eb4 (vt600) 2,780 mm (109.4 in) (vx600er) 2,760 mm (108.7 in) (sx600) 2,990 mm (117.7 in) (mm600/vt600) 1,200 mm (47.2 in) (vx600er/sx600/vt600) 1,115 mm (43.9 in) (mm600) 1,230 mm (48.4 in) (vx600er/sx600) 1,215 mm (47.8 i...

  • Page 248: Spec

    9-2 spec general specifications model fuel: type tank capacity carburetor: type/quantity manufacturer spark plug: type manufacturer gap transmission: primary reduction system primary reduction ratio clutch type secondary reduction system secondary reduction ratio reverse system chassis: frame type c...

  • Page 249: Spec

    Spec 9-3 model bulb wattage × quantity: headlight tail/brake light tachometer light speedometer light high beam indicator light water temperature indicator light oil level indicator light vx600er/sx600/mm600/vt600 12 v, 60 w/55 w × 2 12 v, 8 w/23 w × 1 12 v, 1.7 w × 1 12 v, 1.7 w × 1 12 v, 1.7 w × 1...

  • Page 250: Spec

    9-4 spec maintenance specifications engine maintenance specifications vx600er/sx600/mm600/vt600 18.7 ~ 19.3 cm 3 (1.14 ~ 1.18 cu.In) ∗ lines indicate straight edge measurement. Aluminum alloy with dispersion coating 65.000 ~ 65.014 mm (2.5591 ~ 2.5596 in) 64.932 ~ 64.935 mm (2.5564 ~ 2.5565 in) 10 m...

  • Page 251: Spec

    Spec 9-5 maintenance specifications crankshaft: crank width “a” crank width “b” maximum runout “c” : c 1 c 2 ~ c 5 c 6 measuring points: 1 2 connecting rod big end side clearance “d” connecting rod big end radial clear- ance “e” connecting rod small end free play “f” big end bearing: type small end ...

  • Page 252: Spec

    9-6 spec maintenance specifications carburetor: type/quantity manufacturer i.D. Mark main jet (m.J) pilot jet (p.J) jet needle (j.N) needle jet (n.J) pilot air jet (p.A.J) pilot outlet (p.O) bypass (b.P.1) pilot screw (p.S) throttle valve (th.V) valve seat size (v.S) starter jet (g.S) float height (...

  • Page 253: Spec

    Spec 9-7 maintenance specifications power train transmission: type range of ratio engagement speed r/min shift r/min sheave distance “a” sheave offset “b” v-belt: part number/manufacturer circumference width “a” primary sheave spring: part number color code diameter wire diameter preload spring rate...

  • Page 254: Spec

    9-8 spec vx600er/sx600/mm600/vt600 8dg-17605-00 34.30 g (1.211 oz) 90261-06028 (vx600er/mm600) 90261-06015 (sx600) 90261-06034 (vt600) aluminum (vx600er/mm600) steel (sx600/vt600) 10.3 mm (0.41 in) (vx600er/sx600/mm600) 13.9 mm (0.55 in) (vt600) 3 3 90261-06034 (vx600er/sx600) 90261-06015 (mm600) 90...

  • Page 255: Spec

    Spec 9-9 vx600er/sx600/mm600/vt600 rexnord s37tnb13 68 l 8dy-47110-00 (vx600er) 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) 3,072 mm (120.9 in) (vx600er/sx600) 3,584 mm (141.1 in) (mm600) 3,456 mm (136.1 in) (vt600...

  • Page 256: Spec

    9-10 spec maintenance specifications model suspension setting position: hook setting length ∗ full rate adjusting position ∗∗ shock absorber: damping force front extension compression rear extension compression slide runner: thickness track sprocket wheel: material number of teeth rear guide wheel: ...

  • Page 257: Spec

    Spec 9-11 maintenance specifications chassis model frame: frame material seat height luggage box location steering: lock-to-lock angle (left) (right) (left) (right) ski alignment toe-out size caster angle ski: ski material length width ski suspension (front suspension): type travel (front suspension...

  • Page 258: Spec

    9-12 spec maintenance specifications electrical model voltage ignition system: ignition timing (b.T.D.C.) advanced type ignition coil: model/manufacturer minimum spark gap primary coil resistance secondary coil resistance spark plug cap: type model/manufacturer resistance charging system: type nomin...

  • Page 259: Spec

    Spec 9-13 model starter motor (vx600er/vt600): model/manufacturer output armature coil resistance continuity check insulation check brush overall length spring pressure commutator diameter mica undercut starter relay (vx600er/vt600): model/manufacturer amperage rating coil resistance oil level switc...

  • Page 260: Spec

    9-14 spec clip 0.4 mm shim note: • jet needle (jn) position. Refer to the following information for the jet needle shims installation. Jn:3 jn:2.5 jn:1 jn:0.5 • oxygenated fuels use one size larger main jet than specified. Mj #1 #140 mj #2#3 #137.5 pj #42.5 jn 3 ps 2 mj #1 #138.8 mj #2#3 #136.3 pj #...

  • Page 261: Spec

    Spec 9-15 maintenance specifications tightening torque nm m · kg ft · lb parts to be tightened remarks 13 27 15 90 40 33 33 33 57 18 27 13 11 23 28 20 23 10 10 8 15 10 23 18 12 14 14 1 0.7 1 1.8 0.7 2.5 7 10 5 13 7 13 4 110 23 7 1.3 2.7 1.5 9.0 4.0 3.3 3.3 3.3 5.7 1.8 2.7 1.3 1.1 2.3 2.8 2.0 2.3 1.0...

  • Page 262: Spec

    9-16 spec tightening torque nm m · kg ft · lb parts to be tightened remarks 120 60 200 14 6 4 20 64 4 6.5 23 10 60 24 48 48 16 24 10 13 10 48 6 30 14 30 8.5 23 4 16 24 30 72 30 72 72 72 72 72 75 72 24 12.0 6.0 20.0 1.4 0.6 0.4 2.0 6.4 0.4 0.65 2.3 1.0 6.0 2.4 4.8 4.8 1.6 2.4 1.0 1.3 1.0 4.8 0.6 3.0 ...

  • Page 263: Spec

    Spec 9-17 apply loctite ® apply loctite ® apply loctite ® apply loctite ® (vt600) apply loctite ® apply loctite ® apply loctite ® 24 49 49 49 49 72 49 49 72 72 72 8.5 20 2.4 4.9 4.9 4.9 4.9 7.2 4.9 4.9 7.2 7.2 7.2 0.85 2.0 17 35 35 35 35 52 35 35 52 52 52 6.1 14 tightening torque nm m · kg ft · lb p...

  • Page 264: Spec

    9-18 spec apply loctite ® apply loctite ® (vx600er/vt600) (vx600er/vt600) (sx600/mm600) apply loctite ® apply loctite ® apply loctite ® apply loctite ® apply loctite ® apply loctite ® (mm600) 17 17 17 25 25 25 31 58 18 35 15 8.0 8.0 12 8.0 35 35 40 36 36 40 40 53 56 17 17 35 7.2 4.3 2.2 6.5 2.2 2.3 ...

  • Page 265: Spec

    Spec 9-19 general torque specifications this chart specifies torque for standard fasteners with standard i.S.O. Pitch threads. Torque specifica- tions for special components or assemblies are in- cluded in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a...

  • Page 266: Spec

    9-20 spec general torque specifications/definition of units.

  • Page 267: Spec

    Spec 9-21 cable routing sea9010

  • Page 268: Spec

    9-22 spec 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. 3 ignition coil coupler 4 ...

  • Page 269: Spec

    Spec 9-23 cable routing sea9010

  • Page 270: Spec

    9-24 spec 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 i...

  • Page 271: Spec

    Spec 9-25 cable routing sea9020

  • Page 272: Spec

    9-26 spec cable routing 1 brake hose 2 oil pump cable 3 throttle cable 4 wire harness 5 starter cable.

  • Page 273: Spec

    Spec 9-27 cable routing sea9030

  • Page 274: Spec

    9-28 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. 6 route the oil tank breather hose over the main switch wir...

  • Page 275: Spec

    Spec 9-29 cable routing sea9030

  • Page 276: Spec

    9-30 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

    Spec 9-31 cable routing sea9040

  • Page 278: Spec

    9-32 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

    Spec 9-33 cable routing sea9050

  • Page 280: Spec

    9-34 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 swi...

  • Page 281: Spec

    Spec 9-35 cable routing sea9050

  • Page 282: Spec

    9-36 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. V oil hose w coolant reservoir ...

  • Page 283: Spec

    Spec 9-37 cable routing sea9060

  • Page 284: Spec

    9-38 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 ...

  • Page 285

    Wiring dia gram vx600er/sx600/mm600/vt600 e wire harness sub-wire harness 2 b w og y bw o gy (black) (black) b wire harness headlight sub-wire harness y /b l yg y /b l /w y g a wire harness headlight sub-wire harness r /b g /r g /bb r /bg /r g /b b (black) (black) c wire harness sub-wire harness 1 b...

  • Page 286

    Color code b ..................... Black br ................... Brown ch .................. Chocolate g .................... Green gy .................. Gray l ..................... Blue lg ................... Light green o .................... Orange p ..................... Pink r ....................

  • Page 287

    Printed in usa (e) cr printed on recycled paper.