2000 2001 2002 2003 yamaha vmax 600 service repair manual by 1636527

OE031

ILLUSTRATED SYMBOLS

(Refer to the illustration)

ICHAsld' -------

Illustrated symbols CD to @> are designed as thumb tabs to indicate the chapter's number and content.

CD <ID

General information Periodic inspection and adjustment @ Chassis @ Power train <ID Engine overhaul ® Cooling system Carburetion ® Electrical ® Specifications @> Optional kit

ISPECI er I IOPT I0

@~@~ @~

Illustrated symbols ® to ® are used to identify the specifications which appear.

Filling fluid

@ Lubricant @ Tightening

Wear limit, clearance

@ Engine speed @) Special tool ®n,V,A

®~ Illustrated symbols @) to @ in the exploded diagram indicate grade of lubricant and location of lubrication point. @) Apply locking agent (LOCTITE®) @) Apply engine oil

a 1

@ Apply gear oil @ Apply molybdenum disulfide oil

@ Apply wheel bearing grease

__ B*\

@ Apply low-temperature lithium-soap base grease

@ Apply molybdenum disulfide grease @ Apply Yamabond No.5®

INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS

CHAS

POWER TRAIN ENGINE OVERHAUL COOLING SYSTEM CARBURETION ELECTRICAL SPECIFICATIONS OPTIONAL KIT

SPEC

OPT

______________________________ ~~~IJieI 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 .................................................. 1-2 ALL REPLACEMENT PARTS ....................... 1-3 GASKETS, OIL SEALS, AND O-RINGS ...... 1-3 LOCK WASHERS/PLATES AND COTTER PINS ............................................................. 1-3 BEARINGS AND OIL SEALS ....................... 1-3 CIRCLlPS ...................................................... 1-4 SPECIAL TOOLS ................................................ 1-4 FOR TUNE UP ............................................. 1-4 FOR ENGINE SERVICE ................................ 1-5 FOR POWER TRAIN SERVICE .................... 1-6 FOR ELECTRICAL SERVICE ........................ 1-7

MACHINE IDENTIFICATION

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GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number CD is located on the· right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number CD is located on the right-hand side of the crankcase. NOTE: _______________________ The first three digits of these numbers are for model identification; the remaining digits are the unit production number.

Starting Serial Number: VX500U ......•. SAB-0001 01 .. VX500EU ..•... SBp·000101 .. VX500STU .... SBN·000101 .. VX500DXU ... SBB·000101 .. VX600U ........ 8CA·0001 01 .. VX600EU ...... SCF·000101 .. VX600STU .... SCC·000101 .. VX600DXU ... SCB·000101 ..

NOTE: _________________________ Designs and specifications are subject to change without notice.

1-1

~~~ 1...... 1

IMPORTANT INFORMATION 1 lEOll

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., from high pressure water splashes. 2. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS" .

3. When disassembling the machine, keep mated parts together. This includes gears, cylinders, pistons, and other parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.

4. During disassembly ofthe machine, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help ensure that all parts are reinstalled correctly. 5. Keep away from fire.

6. Be sure to keep to tightening torque specifications. When tightening bolts, nuts, and screws, start with larger-diameter pieces, and proceed from an inner-positioned one to an outer-positioned one in a criss-cross pattern.

1-2

IMPORTANT INFORMATION

1~~~ 1.1LI

ALL REPLACEMENT PARTS 1. We recommend use ofYamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

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

LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates CD and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. 300-000

BEARINGS AND OIL SEALS 1.lnstall the bearing(s) CD and oil seal(s) ÂŽ with their manufacturer's marks or numbers facing outwards. (In other words, the stamped letters must be on the side exposed to view.) When installing oil.seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

300-002

Do not use compressed air to spin the bearings dry. This causes damage to the surface of the bearings.

300-003

'-3

IMPORTANT INFORMATION/SPECIAL TOOLS

I~~~ I~ I

CIRCLlPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing a circlip <D, make sure that the sharp edged corner ® is positioned opposite to the thrust <ID it receives. See the sectional view. 300·001

@ Shaft lE021

SPECIAL TOOLS Some special tools are necessary for completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques.

NOTE: _______________________ Be sure to use the correct part number when ordering the tool, since the part number differs according to the area as shown below. The first part number is for Europe, and the second part is for the U.S.A. and Canada. e.g. 90890 - *****, YU- *****

FORTUNE UP • Sheave Gauge PIN YS-91047-3 <D, YS-39506-5 ® This gauge is used to measure sheave distance and for offset adjustment.

lE041

• Dial Gauge PIN 90890-03097, YU-03097 This gauge is used for run out measurement.

1-4

SPECIAL TOOLS

I~~~ I~ I

lE051

• Fuel Level Gauge PIN 90890-01312, YM-01312-A This gauge is used to measure the fuel level in the float chamber.

lE061

• Vacuum Gauge PIN -, YS-33275 This gauge is used for carburetor synchronization.

1E071

FOR ENGINE SERVICE • Piston Pin Puller PIN 90890-01304, YU-01304 This tool is used to remove the piston pin.

lE081

• Rotor Puller PIN 90890-01362, YU-33270 This tool is used to remove the magneto rotor.

lE091

• Cooling System Tester PIN 90890-01325, YS-22460-01 This tester is used for checking cooling system.

1-5

SPECIAL TOOLS

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FOR POWER TRAIN SERVICE • Primary Sheave Holder PIN 90890-01701, YS-01880 This tool is used to hold the primary sheave.

lElll

• Primary Sheave Puller (18 mm) PIN YS-01881-1 CD, YS-38517 CV Thistool is used for removing the primary sheave.

lE121

• Clutch Spider Separator PIN 90890-01711, YS-28890-8 This tools are used when disassembling and assembling the primary sheave.

lE131

• Clutch Separator Adapter PIN 90890-01740, YS-34480 This tool is used when disassembling and assembling the primary sheave.

lE171

• Clutch busing jig kit PIN YS-39752 Thistool is used when removing and installing the primary sheave busing.

'-6

SPECIAL TOOLS

II~~~

ISs I

1E141

• Track Clip Installer PIN 90890-01721. YS-91045-A This tool is used for installing the track clip.

1E151

FOR ELECTRICAL SERVICE • Pocket Tester PIN 90890-03112. YU-03112 This instrument is necessary for checking the electrical components.

1E161

• Electra Tester PIN 90890-03021. YU-33260-A This instrument is invaluable for checking the electrical system.

1-7

__________ I':g!I-.1 CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ................................................ 2-1 PERIODIC MAINTENANCE TABLE ................... 2-1 ENGINE .....................................................•........ 2-3 SPARK PLUG ............................................... 2-3 OIL PUMP .................................................... 2-4 OIL FILTER INSPECTION ..........................•. 2-6 FUEL LINE INSPECTION ............................. 2-6 FUEL FILTER INSPECTION ..............•.......... 2-6 COOLING SYSTEM ............................•.....•.• 2-7 CARBURETOR SYNCHRONIZATION •••.... 2-12 ENGINE IDLE SPEED ADJUSTMENT •..... 2-13 THROTTLE CABLE ADJUSTMENT .......••• 2-13 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK ............................................•.•...... 2-14 STARTER (CHOKE) CABLE ADJUSTMENT ........................................ 2-14 POWER TRAIN ................................................. 2-15 DRIVE V-BELT ............................................ 2-15 ENGAGEMENT SPEED CHECK ................ 2-17 BRAKE ADJUSTMENT .................................... 2-18 BRAKE PAD INSPECTION ........................ 2-18 DRIVE CHAIN ............................................. 2-18 TRACK TENSION ADJUSTMENT ............ 2-20 SLIDE RUNNER INSPECTION .................. 2-21 CHASSIS .......................................................... 2-22 SKI/SKI RUNNER ....................................... 2-22 STEERING SYSTEM .................................. 2-22 HEADLIGHT BEAM ADJUSTMENT ......... 2-23 LUBRICATION ........................................... 2-24 TUNING ............................................................ 2-25 CARBURETOR TUNING ............................ 2-25 CLUTCH TUNING ...................................... 2-36 GEARING SELECTION .............................. 2-38 HIGH ALTITUDE TUNING ............................... 2-41

INTRODUCTION/PERIODIC MAINTENANCE TABLE

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2EOO5

PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, iffollowed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE TABLE

Spark Plug:

Preoperation check (Daily)

Remarks

Item

Check oil level.

* Air bleed the oil pump if necessary.

* Oil Filter:

Check condition. Replace if necessary.

Fuel:

Check fuel level.

* Fuel Filter:

Check condition. Replace if necessary.

* Fuel Line:

Check fuel hose for cracks or damage. Replace if necessary.

* Oil Line:

Check oil hose for cracks or damage. Replace if necessary.

Engine Coolant

* Air bleed the cooling system if necessary.

•

Check coolant level.

Whenever operating condition (elevation!temperature) is changed.

* Adjust the jets.

•

Check wear and damage. Replace if necessary.

•

Adjust water pump belt if necessary.

Manual Starter:

•

Engine Stop Switch:

Check operation Repair if necessary.

• • •

Check operation. Repair if necessary.

Throttle 9verride System:

Th rottl e Lever:

Check operation. Repair if necessary.

* Exhaust System: * Decarbonization:

Check for leakage. Retighten or replace gasket if necessary.

•

More frequently if necessary. Check cracks, bends or damage. Replace if necessary.

Drive V-belt Guard:

Drive V-belt:

Check wear and damage. Replace if necessary.

Drive Track/Idler Wheels:

* Adjust/replace if necessary.

• • • •

• •

Check operation and rope damage. Replace if necessary.

Slide Runner

• • •

•

Check throttle lever operation.

*Water Pump Belt

Every Season or 3,200 km (2,000 Mi) (160 hr)

Check condition adjust the gap and clean. Replace if necessary.

Engine Oil:

Carburetor

First Month or first 800 km (500 Mi) (40 hr)

Check deflection, wear and damage. Check wear and damage.

* Replace if necessary.

• • • •

It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic. 2-1

•

_ _ _ _ _PERIODIC ~_ _ _TABLE _ IIANDSJPllo)l MAINTENANCE _ _~ _ Item

Preoperation check (Daily)

Remarks

Check operation. Brake/ Parking Brake

* Drive Chain Oil

* Adjust free

play and/or replace pads if neces-

•

sary.

•

Check oil level. Replace.

* Drive Chain:

Check deflection. Adjust if necessary.

Ski/ Ski Runner

Check wear and damage.

Steering System

First Month or first 800 km (500 Mi) (40 hr)

* Replace if necessary. Check operation.

* Adjust toe-out if necessary. Check operation. Replace bulbs if necessary.

Battery

* Check specific gravity and breather pipe opera-

Check fluid level.

• • • •

tion. Charge/Correct if necessary. Check engagement and shift speed. Check wear and damage. Replace if necessary. Lubricate with specified grease.

* Steering Column Bearing: * Ski and Front Suspension: * Suspension Component: * Brake Cable End and Lever End/ Throttle Cable End

• • • • • • • • • • • •

Wheneveroperatingelevation is changed.

Adjust if necessary.

* Secondary Sheave

• •

**.

Lights:

* Primary Sheave

Every Season or 3,200 km (2,000 Mi) (160 hr)

Lubricate with specified grease.

Whenever operating elevation is changed.

Adjust if necessary. Lubricate with specified grease. Lubricate with specified grease. Lubricate with specified grease. Lubricate with specified grease. Check cable damage. Replace if necessary.

Shroud Latches:

Make sure the shroud latches are hooked.

Fittings/Fasteners:

Check tightness. * Repair if necessary.

Service Tools/Spare Parts:

Check proper placement.

• • •

*: It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic. **: Perform after 1 Month or 80 km (50 Mi) and every 1 Month or 800 km (500 Mi).

2-2

_________________________S_M_R_K_PL_U__ G

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2EOll

ENGINE SPARK PLUG 1. Remove: • Spark plug 2. Inspect: • Electrode CD

®*=::::::::;~I/)

Wear/Damage~Replace.

• Insulator color ®

377-000

3. Measure: • Plug gap@ Out of specification~Regap. Use wire thickness gauge. Spark plug gap: 0.7 - 0.8 mm (0.028 - 0.032 in)

Clean the plug with a spark plug cleaner if necessary. Standard spark plug: BR9ES (NGK)

Before installing a spark plug, clean the gasket surface and plug surface.

4. Tighten: • Spark plug Spark plug: 28 Nm (2.8 m • kg, 20 ft • Ib)

(·~_J1-)CD

NOTE: ________________________ Finger-tighten CD the spark plug ® to specification.

.. ' fi>\ ... ----~

"41

2-3

before torquing

_________________________O_I_LP_U_M_P

II:g~ltill

2E021

OIL PUMP Air Bleeding

The oil pump and delivery line must be bled on the following occasions: • When any portion of the oil system has been disconnected. • When the machine has been turned on its side. • Whenever the oil tank has been run empty. • During pre-delivery. 1. Remove: • Reservoir tank ill

2. Fill: • Oil tank ill Oil tank capacity: 2.9 L (2.6 Imp qt, 3.1 US qt) Recommended oil: Vamalube 2-cycle oil 3. Loosen the oil tank bolt ®. 4. Place a rag under the oil pump assembly to catch oil. 5. Disconnect: • Oil hose ill 6. Keep the oil running out until air bubbles disappear from the oil hose ill. 7. Connect: • Oil hose ill

8. Disconnect: • Oil delivery hoses ill 9. Feed the uYamalube 2-cycle oil" into the oil delivery hoses ill using an oil can ® for complete air bleeding. 10. Connect: • Oil delivery hoses ill

2-4

_________________________O_I_LP_U_M_P

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11. Remove: • Bleed screw <D • Gasket (bleed screw) 12. Keep the oil running out until air bubbles disappear from bleed hole.

13. Inspect: • Gasket (bleed screw) Wear/Damage ~ Replace. 14. Install: • Gasket (bleed screw) • Bleed screw

Cable Adjustment

NOTE: _________________________ Before adjusting the oil pump cable, the throttle cable distcmce should be adjusted.

Adjustment steps: • Loosen the locknut <D. • Turn the adjuster® in or out until the specified distance is obtained.

Distance® : VX500(E)fST fOX: 25 - 27 mm (0.98 - 1.06 in) VX600(ElfST fOX: 27 - 29 mm (1.06 -1.14 in)

Turning in

Distance ® is increased.

Turning out

Distance ® is decreased.

• Tighten the locknut and push in the adjuster cover.

2-5

OIL FILTER INSPECTION

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2E031

OIL FILTER INSPECTION 1. Remove: • Oil filter CD NOTE: _______________________ Plug the oil hoses so that the oil will not run outof the oil tank and oil pump. 800-001

2. Inspect: • Oil filter CD Contamination

Replace.

Recommended replacement interval: Every season 3. Reverse the removal procedure.

2E041

FUEL LINE INSPECTION 1. Inspect: • Fuel hoses • Fuel delivery hoses Crack/Da mage~Replace.

2E051

FUEL FILTER INSPECTION 1. Remove: • Seat 2. Disconnect: • Tail/brake light coupler 3. Remove: • Spring bands CD • Cap® • Fuel filter @

801·002

4. Inspect: • Fuel filter CD Contamination

Replace.

Recommended replacement interval: Every season 5. Reverse the removal procedure. 8OHl03

2-6

Ito) I I -----------------------------------------------------COOLING SYSTEM

lA NOSJP

2E061

COOLING SYSTEM Coolant Replacement NOTE: _______________________ The coolant should be changed at least seasonally. 1. Place the machine on a level surface. 2. Remove: • Side cowling (right) • Seat • Muffler CD • Exhaust pipe ®

3. Remove: • Coolant filler cap

WARNING

Do not remove the coolant filler cap CD when the engine is hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place thick rag like a towel overthe radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.

4. Place an open container under the drain bolts

CD· S.Remove: • Drain bolts 6. Drain the coolant.

NOTE: _________________________ Lift up the tail ofthe machine to drain the coolant.

2-7

COOLING SYSTEM

1':gS 14rl1

7. Disconnect: • Coolant hoses CD (rear) 8. Drain the coolant.

NOTE: _ _ _ _ _ _ _ _ _ _ __ Lift up the front ofthe machineto drainthe coolant completely.

WARNING

Coolant is poisonous. It is harmful or fatal if swallowed. • If coolant is swallowed, induce vomiting immediately. Get immediate medical attention. • If coolant splashes in eyes, flush with water. Call a physician. • If coolant splashes on skin or clothes, wash immediately with soap and water. 9. Remove the reservoir tank coolant. 10. Install: • Reservoir tank 11. Inspect: • Gaskets (drain bolt)

CD and drain the

Damage~Replace.

12. Install: • • • •

Gaskets Drain bolts Exhaust pipe/gaskets Muffler Drain bolt: 23 Nm (2.3 m· kg, 17 ft· Ib) Bolts (exhaust pipe): 23 Nm (2.3 m • kg, 17 ft· Ib)

13. Fill: • Cooling system Recommended Coolant: High quality ethylene glycol anti-freeze containing corrosion inhibitor Coolant and water mixed ratio: SO%: 400/0 Total amount: VX500(E)/VXSOO(E)/VX500DX/ VXSOODX 4.2 L (3.70 Imp qt, 4.44 US qt) VX500ST/VXSOOST 4.S L (4.05 Imp qt, 4.8S US qt) Reservoir tank capacity: 0.2 L (0.18 Imp qt, 0.21 US qt) 2-8

_ _ _ _ _ _ _COOLING __ _ IIANDSJPI ~ I_ SYSTEM _ _ .. ~ • Hard water or salt water is harmful to the engine parts; use boiled or distilled water. • Do not use water containing impurities or oil. 14. Bleed air from the cooling system.

15. Inspect: • Cooling system Decrease of pressure (leaks)~Repair as required. (see page 6-4)

Inspection steps: • Attach the Cooling System Tester <D (9089001325, YU-22460-01) to the coolant fi lIer ®. • Apply 100 kPa (1.0 kg/cm2, 14 psi). • Measure the pressure with gauge. 2E071

Air bleeding 1. Bleed air from the cooling system. Air bleeding steps: • Lift up the tail of the machine. • Connect plastic tubes <D tightly to the bleed screws ® on the heat exchanger. • Loosen the bleed screws ® of Heat exchanger. • Keep the coolant running out until air bubbles disappear, while adding coolant slowly to the radiator. • Tighten the bleed screws.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • Ib)

• Add coolant to fill the specified level ®. • Loosen the bleed bolt @ on the water pump housing. • Keep the coolant running out until air bubbles disappear. • Tighten the bleed bolt. Bleed bolt: 6 Nm (0.6 m • kg, 4.3 ft • Ib)

2-9

_ _______ __ _ 1. lANDSJP 1. ~ I. COOLING SYSTEM • Install the radiator cap. Apply and lock the parking brake. Start the engine and run it at approximately 2500 ... 3000 rpm until the thermostat opens and the coolant circulates (approximately 3 ... 5 minutes). The rear heat exchanger will be warm to the touch.

WARNING

To avoid severe injury or death: • Make surethe machine is securely supported with a suitable stand. • Do not exceed 3000 rpm. The machine could unexpectedly move forward if the clutch engages, or drive line damage and excessive V-belt wear could occur. • Operate the engine only in a well-ventilated area. • Remove the radiator cap and bleed air on the cooling system again, as shown in the steps above. No air bubbles ~ OK. • Add coolant up to the specified level. • Pour coolant into the reservoir tank CD until the coolant level reaches HFULL Hlevel mark.

2E081

Water Pump Belt Deflection Adjustment 1. Remove: • Muffler 2. Check: • Drive belt deflection Out of specification~Adjust. Drive belt deflection 8 mm (0.31 in)/ 8 kg (17.6Ib) (NEW BELT) 8 mm (0.31 in)/ 13 ... 20 kg (28.7 ... 44.1 Ib) 3. Adjust: • Drive belt deflection Adjustment steps: • Remove the recoil starter CD. • Attach the Primary Sheave Holder (9089001701, YS-01880)to hold the primarysheave. 2·10

COOLING SYSTEM

tll

II~g! I

• Remove the starter pulley 0. • Remove the screws @ of the starter pulley. • Adjust the drive belt deflection by adding or removing a shim G). Add shim

Tension becomes lower.

Remove shim

Tension becomes higher. Shim size

Part number

Thickness

8CA-15721-00

0.5 mm (0.02 in)

8CA-15722-00

1.0 mm (0.04 in)

• Install the starter pulley and drive belt. • Recheck the drive belt deflection. If out of specification, readjust the drive belt deflection.

4. Tighten: Starter pulley bolt: 23 Nm (2.3 m· kg, 17 ft· Ib) Recoil starter bolt: 10 Nm (1.0 m • kg, 7.2 ft· Ib)

2-11

_ ____ __ _ _ _ liANOSJPlfO) CARBURETOR SYNCHRONIZATION . . ~ 2E094

CARBURETOR SYNCHRONIZATION 1. Remove: • Carburetor assembly (see page 7-2) 2. Adjust: • Carburetor synchronization Adjustment steps: • First adjustthe throttle valve height@ at the No.2 carburetor by turning the throttle stop screw CD until the specified height is obtained.

Throttle valve height: VX500 (E)/ST/DX: 1.5 mm (0.059 in) VX600 (E)/ST/DX: 1.6 mm (0.063 in)

• Second adjust the throttle valve height@on the No.1® carburetor with adjusting eccentric nut@. • Move the throttle lever 2 - 3 times. • Make sure all the carburetor throttle valves are on the same height. • Install the carburetor. • Remove the air chamber and then plug the hole in the carburetor joint with plug and connect the Vacuum Gauge (YS-33275) to the fitting. • Start the engine and let it warm up. • If vacuum reading are not same, turn the adjusting eccentric nut@inoroutsothatthe vacuum reading are the same. NOTE: ______________________ When read the vacuum gauge, make sure carburetor covers G) are installed.

2-12

I .

ENGINE IDLE SPEED ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT

IINSP I(0) I ADJ ~

L...:."':'::;"';:;.....&._"';;;:'=..I

2El0l

ENGINE IDLE SPEED ADJUSTMENT 1.Adjust: • Engine idle speed Adjustment steps: • Start the engine and let it warm up . • Turn the throttle stop screws CD in or out to adjust the engine idle speed. Turning in

Idle speed becomes higher.

Turning out

Idle speed becomes lower.

Engine idle speed: 1,450 - 1,650 r/min

NOTE: After adjusting the engine idle speed, the throttle cable free play should be adjusted.

2E131

THROTTLE CABLE ADJUSTMENT NOTE: _______________________ Before adjusting the throttle cable free play, the engine idle speed should be adjusted. 1. Measure: • Throttle cable free play ® Out of specification~Adjust. Throttle cable free play: 1.0 - 2.0 mm (0.04 - 0.08 in) 2. Adjust: • Throttle cable free play Adjustment steps: • Loosen the locknut CD . • Turn the adjuster ® 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.

2-13

THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECKI STARTER (CHOKE) CABLE ADJUSTMENT

IINSP I (0) I ADJ ~

a...:....;;.::;;..;::;~_-=-.=..I

2El22

THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK

WARNING

When checking T.O.R.S.: • Be sure the parking brake is applied. • Be sure the throttle lever moves smoothly. • Do not run the engine up to clutch engagement rpm. Otherwise. the machine could start moving forward unexpectedly. which could cause and accident. 1. Start the engine. NOTE: _______________________ Refer to STARTING THE ENGINE.

2. Hold the pivot point ofthe throttle lever away from the throttle switch CD. 3. Press CV the throttle lever gradually. The T.O.R.S warning light should turn on and off and the engine should run between 2800 and 3000 rpm.

WARNING

If the engine does not run between 2800 and 3000 rpm. stop the engine by turning the main switch to "OFF" position and consult a Yamaha dealer. 2E131

STARTER (CHOKE) CABLE ADJUSTMENT 1. Pull the outer tube of starter cable CD upward. 2. Measure: • Starter cable free play ® Out of specification -7 Adjust. Freeplay@: 0.5 .. 1.5 mm (0.02 .. 0.06 in)

3. Adjust: • Starter cable free play Adjustment steps: • Loosen the locknut CD . • Turn the adjuster CV 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 and push in the adjuster cover. 2·14

________________________D_R_IV_E_V_-B_El__ T

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2E141

POWER TRAIN DRIVE V-BELT

WARNING

• Be sure there are shims (2 pes) CD between secondary fixed and sliding sheaves when· installing the NEW belt. • Ifthere is no gap, the clutch engagement speed will be reduced. The machine may move

805030

L -_ _ _ _ _ _....;;;~;;..-._ _ _ _ _ _.....

unexpectedly when the engine is started . • The spacer of the secondary sheave should be adjusted.

To ensure proper clutch performance, the spacers in the secondary clutch must be repositioned as the V-belt wears.

"\ ~

00.l [9

V-belt width

31.6 mm (1.24 in) or more 30.6 mm (1.20 in) 29.6 mm (1.17 in) 28 mm (1.1 in) or less

805-029

1. Remove: • Drive V-belt guard

805-020

2-15

Number of spacers

2 spacers 1 spacer No spacer Replace the V-belt

________________________D_R_IV_E_V_-B_El___ •

P:g!I~1

2. Remove: • Drive V-belt CD Removal steps: • Rotate the secondary sliding sheave clockwise ® and push it @ so that it separates from the fixed sheave. • Pull @ the belt up over the secondary fixed sheave. • Remove the belt from the secondary sheave and primary sheave.

3. Inspect: • Drive V-belt CrackJWear/Damage ~ Replace. Oil orgrease adhering tothe V-belt ~ Check the primary and secondary sheaves.

4. Inspect: • Primary sheave • Secondary sheave Oil or grease adhering to the primary and secondary sheaves ~ Remove the oil or grease using a rag soaked in lacquerthinner or solvent. Check the primary and seconda ry sheaves. 805-009

5. Measure: • Drive V-belt length ® Out of specification ~ Replace. Drive V-belt length: 1,130 - 1,118 mm (44.5 - 44.0 in)

2-16

ENGAGEMENT SPEED CHECK

I':gs I_I

2E201

ENGAGEMENT SPEED CHECK 1. Place the machine on a level area 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 ~ Adjust the primary sheave. (see page 2-36)

2-17

Engagement speed: VX500(E)fST fDX Approx. 3,700 rfmin VX600(E)fSTfDX Approx. 3,600 rfmin

BRAKE PAD INSPECTION/DRIVE CHAIN

II~gj

I_I

2E161

BRAKE ADJUSTMENT

BRAKE PAD INSPECTION 1. Apply the brake lever. 2. Measure: • Brake pad thickness ® Out of specification ~ Replace brake pads as a set. (see page 4-27)

~ I

I I

I I I I

Wear limit: I~ ~ 5.2 mm (0.2 in) v

NOTE: _________________________ Adjust brake every 40 hours of operation, or whenever the brake lever becomes loose during operation.

3. Measure: • Distance "L" Out of specification --) Adjust. Distance UL U

69.0

71.0 mm (2.72

2.8 in)

4. Adjust: • Distance "L" Adjustment steps: • Loosen the locknut CD. • Turn the adjuster CV in or out until the specified distance is obtained. Turning in

Distance uL u is increased.

Turning out

DistanceuL is decreased. U

• Tighten the locknut CD.

2E171

DRIVE CHAIN Oil Level Inspection 1. Place the machine on a level surface. 2. Remove:

2-18

• Muffler 3. Place a rag under the checking hole level). 4. Remove: • Checking bolt CV • Gasket (checking bolt)

(oil

_____________ D_RI_VE_C_H_A_IN

p:gj I_I

5. Inspect: • Oil level (drive chain housing) Oil flows out ~ Oil level is correct. Oil does not flow out ~ Oil level is low. Add oil until oil flows out. Recommended oil: Gear oil API GL-3 SAE #75 or #80

6. Inspect: • Gasket (checking bolt) Damage ~ Replace. 7. Tighten: Checking bolt: 10 Nm (1.0 m· kg, 7.2 ft· Ib)

Oil Replacement Oil replacement step: • Warm up the engine for several minutes. • Remove the Muffler. • Place some rags under the chain housing and place a small gutter to channel the oil into the hole. • Lift up the front of the machine. • Remove the drain plug CD.

Be su re to remove any oil from the heat protector.

Recommended oil: Gear oil API GL-3 SAE #75 or #80 Oil capacity: VX500 (E)/500ST /600(E)/600ST: 250 cm3 (8.8 Imp OZ, 8.5 US OZ) VX500DX/600DX: 300 cm3 (10.6 Imp OZ, 10.1 US OZ) 2E182

Chain Slack Adjustment 1. Adjust: • Drive chain slack Adjustment steps: • Loosen the locknut CD and unthread sealing washer CV slightly. • Turn the adjuster @ in until it is finger tight. • Tighten the locknut. 2-19

TRACK TENSION ADJUSTMENT

I':gs I_I

2E151

TRACK TENSION ADJUSTMENT

WARNING

A broken track, track fittings, or debris thrown by the track could be dangerous to an operator or bystanders. Observe the following precautions. • Do not allow anyone to stand behind the machine when the engine is running. • When the rear of the machine is raised to allow the track to spin, a suitable stand must be used to support the rear of the machine. Never allow anyone to hold the rear of the machine off the ground to allow the track to spin. Never allow anyone near a rotating track. • Inspect track condition frequently. Replace the track if it is damaged to the depth where fabric reinforcement material is visible. • Never install studs (cleats) closer than three inches to the edge of the track.

1. Place the machine with the right side facing down. 2. Measure: • Track deflection CD Pull at the track center window exerting a force of 10 kg (22 Ib) using a spring scale 0. Out of specification ~ Adjust.

Track deflection: 25 .. 30 mm (0.98 .. 1.18 in)

...® 820003

3. Adjust: • Track deflection Adjustment steps: • Lift the rear of the machine onto a suitable stand to raise the track off the ground. • Loosen the rear axle nut CD.

NOTE: _ _ _ _ _ _ _ _ _ _ __ It is not necessary to remove the cotter pin 0.

820-004

2-20

IINSP I to) I ADJ

TRACK TENSION ADJUSTMENT! SLIDE RUNNER INSPECTION

L...:.,':'=;':"".L--=.=...I

a. Starttheengine and rotate the track one or two turns. Stop the engine. b. Check the track alignment with the slide runner CID. If the alignment is incorrect. turn the left and right adjusters to adjust.

820-008

Track alignment @ Left adjuster

CID Right adjuster

® Slide runner @ Track metal

@ Shifted

(j) Shifted

to right

to left

Turn out

Turn in

Turn out

® Track ® Gap

@ Forward

c. Adjust track deflection to the specified amount.

820-005

More than

Less than

specified

@ Left adjuster

Turn in

Turn out

CID Right adjuster

Turn in

Turn out

Track deflection

The adjusters should be turned an equal amount .

820009

• Recheck alignment and deflection. If necessary, repeat steps a to c until proper adjustment is achieved. • Tighten the rear axle nut. Rear axle nut: 75 Nm (7.5 m • kg, 54 ft· Ib)

~ ..... _ _ _ _ _ _ _ .J

820-001

SLIDE RUNNER INSPECTION 1. Inspect: • Slide runner CD Cracks/DamageMlear~Replace.

2. Measure: • Slide runner thickness CV Out of specification~Replace. (see page 4-33)

~ W~~!:~:03::,_n_)______

--J

lANDSJP Ito) I I -----------------------------------------------------SKI/SKI RUNNER/STEERING SYSTEM

2E212

CHASSIS SKI/SKI RUNNER 1. Check: • Ski • Ski runner • Ski cover Wear/Damage

Replace.

Ski runner wear limit G): 8 mm (0.31 in)

Do not operate the machine without the ski cover to prevent ski wear and damage.

2E221

STEERING SYSTEM Free Play check 1. Check: • Steering system free play Push the handlebar up and down and back and forth. Turn the handlebar slightly to the right and left. Excessive free play ~ check to be sure the handlebar, tie rod ends and relay rod ends are installed securely in position.lffree play still exists, check the steering bearing front suspension links and ski mounting area for wear, and replace if necessary. (see page 3-9)

2·22

I(0) I I -----------------------------------------------------STEERING SYSTEM/HEADLIGHT BEAM ADJUSTMENT

lANDSJP.

2E232

Toe-Out Adjustment 1. Place the machine on a level surface. 2. Check: • Ski toe-out Direct the skis straight forward. Out of specification~Adjust. Ski toe - out (@ - @): 0.0 .. 15.0 mm (0.0 .. 0.6 in) Ski stance (6) (center to center): 1,010 mm (39.8 in) 3. Adjust: • Ski toe-out Adjustment steps: • Loosen the locknuts CD (tie-rod) . • Turn the relay rod ® in or out until the specified toe-out is obtained . • Tighten the locknuts CD (tie-rod).

X ~

Locknut (rod end): 25 Nm (2.5 m· kg, 18 ft· Ib) LOCTITE®

Left side

[§] Right side

2E241

HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Inspect: • Headlight beam direction The high beam should be directed downwards at an angle of 1/2 to the horizontal. If not, adjust the direction. 0

3.0 m (10 ft)

7.6 m (25 ft)

26 mm (1.0 in)

66 mm (2.6 in)

3. Adjust: • Headlight beam direction Adjust the headlight beam by tightening or loosening the adjusters CD.

2-23

lA NOSJP Ito) I I -----------------------------------------------------LUBRICATION

2E251

LUBRICATION Brake Lever, Brake Cable End and Throttle Lever

1. Lubricate the brake lever pivot. brake cable end and throttle lever.

I_I A

ESSO Beacon 325 Grease

WARNING

Apply a dab of grease to the cable end only. Do not grease the brake/throttle cables themselves because they could become frozen, which could cause loss of control.

2E261

Front and Rear ~uspension

1.lnjectgreasethrough nipplesG) using agrease gun. --..

g] Front [ID Rear

2-24

Esso Beacon 325 Grease or Aeroshell Grease #7 A.

I ~I I ----------------------------------------------CARBURETOR TUNI~G

lANDSJP

2E271

TUNING CARBURETOR TUNING The carburetor is set at the factory to run at temperatures of O°C .. -20°C (32°F .. -4°F) at sea level. If the machine has to be operated under conditions otherthan those specified above, . the carburetor must be reset as required. Special care should be taken in carburetor setting so that the piston will not be damaged or seized.

In this model, the engine oil is mixed with the fuel just before the fuel enters the carburetors. During initial fuel flow to the carburetor it is not always possible to supply the optimum fuel/oil mixture depending on the throttle opening. Therefore, after the carburetors have been tuned or maintained, or after the float chamber is removed for cleaning or jet replacement, be sure to idle the engine for about three minutes in order to avoid engine trouble.

Before performing the carburetor tuning, make sure that the following items are set to specification. • Engine idle speed adjustment • Throttle cable free play adjustment • Carburetor synchronization • Starter cable adjustment • Oil pump cable free play adjustment Carburetor Tuning Data 1. Standard specifications MODEL Type

VX5OO(E)/ST/DX VX600(EIIST/DX TM36-B2S

TM3S-B103

Manufacturer MIKUNI 1.0. Mark

SAB-OO

Main jet (M.J.) #151.3 Pilot jet (P.J.) #45 Pilot air jet (P.A.J.) Pilot screw (P.S.)

2·25

02.5

aeA-OO #156.3 #52.5 ~

Float height

1-1/S turns out 20.3 .. 24.3 mm (0.799 .. 0.957 in)

Idle speed

1,450 .. 1,6&0 rIm +-

CARBURETOR TUNING

II:gs I_I

2E281

Middle-Range and High Speed Tuning No adjustment is normally required, but adjustments may sometimes be necessary, depending on temperatures and/or altitude. Middle-range speed and high speed tuning (from 1/4 to full-throttle) can be done by adjusting the main jet.

The engine should never be run without the air intake silencer and air chamber installed; severe engine damage may result.

1. Start the engine and operate the machine under normal conditions to make sure the engine operates smoothly. Then stop the engine. 2. Remove: â&#x20AC;˘ Spark plugs

3. Check: â&#x20AC;˘ Spark plug insulator CD color A medium to light tan color indicates normal conditions . Distinctly different color ~ Replace main jet. 4. The main jet should be adjusted on the basis of the following HMain jet selection chart".

NOTE: ________________________ By checking the condition of the spark plugs currently being used, itiseasyto get some idea of the engine condition and catch potential problems before they are too far advanced.

2-26

lANDSJP Ito) I I ----------------------------------------------~

CARBURETOR TUNING 2E291

2. High altitude tuning Use the following guide to select main jets according to variations in elevation and temperature. FOR VX500 (E)/ST/DX

~ [ID

Altitude

0- 100 m (0 - 300 ft)

100 - 600 m (300 - 2,000 ft)

600 - 1,200 m (2,000 - 4,000 ft)

1,200 - 1,800 m (4,000 - 6,000 ft)

-30 oe (-22°F)

-20 oe (-4°F)

-10 oe (14°F)

(32°F)

10 0 e (50°F)

20 0 e (68°F)

MJ #156.3

MJ #153.8 ~

ooe

...

MJ #151.3

....-..MJ #151.3 (STO)----.. MJ #153.8

...

.. . . ..

MJ #148.8 IN:2

.....- MJ #148.8 IN:2 - - - . MJ #151.3

MJ #146.3 IN:2

....-.. MJ #146.3 IN:2 ----. r--MJ #148.8JN:2--.

MJ #143.8 IN:2

.... MJ #143.8 IN:2 ....

1,800 - 2,400 m (6,000 - 8,000 ft)

f---MJ #146.3 IN:2--'

2,400 - 3,000 m (8,000 - 10,000 ft)

...-MJ #140 IN:2----.. PJ #50 AS:3/4 r----MJ #143.8 IN:2--.

MJ #140 IN:2

MJ #137.5 IN:2 PJ #50 AS:3/4

[9 # : Main jet number [Q] IN: Jet needle clip position

W AS: Air screw turns out [£] PJ : Pilot jet number

2-27

I':gj 1-.1

CARBURETOR TUNING FOR VX600 (E)/ST/DX

~ [ID

Altitude

.. . ..

-10°C (14°F)

O°C (32°F)

MJ #160

.. ...

10°C (50°F)

20°C (68°F)

MJ #157.5

...--MJ #156.3 (STD)----. MJ #158.8

...

MJ #153.8 IN:2

...-- MJ #153.8 IN:2----'

600 - 1,200 m (2,000 - 4,000 ft)

2,400 - 3,000 m (8,000 - 10,000 ft)

MJ #162.5

100 - 600 m (300 - 2,000 ft)

1,800 - 2,400 m (6,000 - 8,000 ft)

-20°C (-4°F)

...

0- 100 m (0 - 300 ft)

1,200 - 1,800 m (4,000 - 6,000 ft)

-30°C (-22°F)

MJ #156.3

...

MJ #151.3 IN:2

...-- MJ #151.3 IN:2----.

...

- M J #153.8 IN:2---.

MJ #148.8 IN:2

...-- MJ #148.8 IN:2----. -

...

MJ #151.3 IN:2--'

...--

MJ #145 IN:2

- M J #147.5 IN:2--'

MJ #145 IN:2

----.

...

MJ #142.5 AS:7/8 IN:2

[g # : Main jet number [QJ IN: Jet needle clip position [[] AS: Air screw turns out [.EJ PJ : Pilot jet number

NOTE: ________________________ These jetting specifications are subjectto change. Consult the latest technical information from Yamaha to be sure you have the most up-to-date jetting specifications.

CD ®

Clip Jet needle @ Air screw G) Main jet 2-28

CARBURETOR TUNING

I':g~ I_I

2E302

Guide for carburetion

(A] Throttle valve opening

[ID Mid-range speed tuning

CD CID

[EJ Low speed tuning

® @

CID

1...

:E ....

[El Closed 1/8

1/4

1/2

3/4

(A] Throttle valve opening

2-29

[QJ Full open

**1

_ ______ __ _1 NOSJP 1_ ~ _ CARBURETOR TUNING _lA

A: Standard main jet B: Main jet whose diameter is 10010 smaller than standard C: Main jet whose diameter is 10010 larger than standard

1/2 3/4 [ID Throttle opning

ÂŠ Full open

A: No_ 3 position B : No. 2 position C: No. 4 position

ir]Clip

1/8

1/2

3/4

[El Jet needle

ÂŠ Full open

[ID Throttle opening

If the Air Silencer Box is removed from the carburetors, the change in pressure in the intake will create a LEAN MIXTURE that may well cause severe engine damage. The Air Silencer Box has no effect on performance characteristics and must be secured to the carburetor during carburetor tuning and adjustment. Also, it must always be in place when the engine is operated. Examine the Silencer regularly for cleanliness and freedom from obstruction.

2-30

CARBURETOR TUNING --------------------------------------~-------------2E391

I I(0) I lA NOSJP

Low Speed Tuning The carburetor is built so that low speed tuning can bedone byadjustingtheairscrewandthrottle stop screw CD.

The engine should never be run without the air intake silencer and air chamber installed; severe engine damage may result. 1. Tighten the air screw lightly, and back it out from its lightly seated position. Standard tuning out:

1-1/8

2. Start the engine, and allow it to warm up for a few minutes. The warm-up is complete when the engine responds normally to the throttle opening.

WARNING

Do not move the throttle enough to reach the following engagement speed. The snowmobile could accidentally start to move forward. Engine revolutions: 2,600 r/min

3. Adjustthethrottle stop screws evenly untilthe engine speed is at 2,000 - 2,500 r/min.

4. Slowly loosen the pilot screws evenly. As the pilot screw is loosened, the mixture will be come leaner, and engine speed will increase. Adjust the pilot screws to attain the highest possible engine speed.

2Âˇ31

CARBURETOR TUNING

II:g!.I_1

5. Finally, setthe engine idle speed by tuning the throttle stop screws in (to increase engine speed) or out (to decrease engine speed). Standard idle speed: 1,450 .. 1,650 rfmin

6. If the engine low speed performance is still poor in high elevation under extreme conditions, the standard pilot jets may need to be replaced to obtain proper pilot air/fuel mixture.

NOTE: ________________________ In this case, set the carburetor on the richer side; use a larger number pilot jet with a highes number. Standard pilot jet: VX500(E)fST fOX: #45 VX600(E)fST fOX: #52.5 7. By repeating steps 1 to 5 above, adjustthe idle speed.

2-32

CARBURETOR TUNING

------------------------------------------------------

lANDSJP I'~ ~

2E311

Main jet selection chart Spark plug color

Check up

Remedy

Light tan or gray.

Carburetor is tuned properly.

Dry black or fluffy deposits.

Mixture is too rich.

Replace main jet with the next smaller size.

White or light gray.

Mixture is too lean.

Replace main jet with the next larger size.

White or gray insulator with small black or gray brown spots and electrodes having a bluish-burnt appearance.

Due to too lean a mixture, the piston is damaged or seized.

Replace the piston and spark plug. Tune the carburetor again, starting with lowspeed tuning.

Due to too lean a mixture, the spark plug melts.

Check the piston for holes or seizure. Check the cooling system, gasoline octane rating and ignition timing. After replacing the spark plug with a colder type, tune the carburetor again starting with low-speed tuning.

Melted electrodes and possibly blistered insulator. Metallic deposits on insulator.

2-33

_ _ _ _ _ _ _ _ _ _ IIANOSJPI·oll CARBURETOR TUNING .

. ~.

2E321

Troubleshooting

Trouble Hard starting

Add gasoline Excessive use of starter Clean spark plug (Excessively opened choke) Fuel passage is clogged or frozen

Poor idling (Related troubles) • Poor performance at low speeds • Poor acceleration • Slow response to throttle • Engine tends to stall

Remedy

Check point Insufficient fuel

Clean

Correct Overflow Improper idling speed adjustment Adjust idling speed • Pilot screw

• Throttle stop screw

Adjust

Damaged pilot screw

Replace pilot screw Clean

Clogged bypass hole

Clogged or loose pilot Clean and retighten jet

Adjustment Return starter level to its seated position. Parts otherthan aircarburetor. • Clogged fuel tank air vent, clogged fuel filter, or clogged fuel passage. Carburetor • Clogged or frozen air vent, or clogged valve. • If water collects in float chamber, clean. (Also check for ice) Bottom the pilot screw lightly, and back it outto specification. Start the engine and turn pilot screw in and out 1/4 turn each time. When the engine runs faster, back out throttle stop screw so the engine idles at specified speed. Tightened too much - Engine speed is higher. Backed out too much - Engine does not idle.

Remove pilot jet, and blow it out with compressed air.

Air leaking into carbu- Retighten bend screw retor joint Defective starter valve seat Overflow Poor performance at mid-range speeds (Related troubles) • Momentary slow response to throttle • Poor acceleration Poor performance at normal speeds (Related troubles) • Excess fuel consumption • Poor acceleration

Clean or replace Correct

Clogged or loose pilot Clean and retighten jet

Remove pilot jet, and blow it out with compressed air.

Lean mixtures Clogged air vent

Overhaul carburetor Clean Remove the air vent pipe, and clean.

Clogged or loose main jet Overflow

Clean and retighten Check float and float valve and clean

2·34

Remove main jet, and blow it out with compressed air.

CARBURETOR TUNING

Trouble

Check point Poor performance at Starter valve is left open high speeds (Related troubles) Clogged air vent • Power loss Clogged or loose main • Poor acceleration jet

Adjustment Return starter lever to its home position.

Remove and clean Clean and retighten

Clogged fuel pipe

Clean or replace

Dirty fuel tank

Clean fuel tank

Air leaking into fuel line

Check joint and retighten

Low fuel pump performance

Repair pump or replace

Clogged fuel filter Clogged intake

Replace

Abnormal combus- Lean mixtures tion (Mainly backfire) Dirty carburetor

Overflow (Related troubles) • Power idling • Poor performance at low, mid-range, and high speeds fuel • Excessive consumption • Hard starting • Power loss • Poor acceleration

Remedy Fully close valve

I':gs 1_I

Remove main jet and clean with compressed air, then install.

Check for and remove ice Clean carburetor and adjust Clean carburetor

Dirty or clogged fuel pipe

Clean or replace fuel pipe

Clogged air vent

Clean

Clogged float valve

Disassemble and Clean while taking care not to scratch valve seat. clean

Scratched or unevenly Clean or replace Valve seat is press'fitted to worn float valve or float valve and valve body. valve seat The body must be replaced if seat seat is damaged. Broken float

Replace float

Incorrect float level

If not within the specified range, check the following parts and replace any defective part. Replace float assembly. • Replace float • Replace arm pin • Replace float

• Worn float tang • Worn pin • Deformed float arm

2-35

_ _______ _ _ 1_lANDSJP 1_ (0) CLUTCH TUNING ~ I_ CLUTCH TUNING High Altitude Tuning Clutch Setting Data (VX500(E)fST fOX) @ltem

rnJ Idle speed:

900 - 1,500 m 3,000 - 5,000 ft (MA)

1,400 - 2,100 m 4,500 - 7,000 ft (MA)

2,000 mS,500 ft(HA)

20139

++++-

+++19139

+++18/39

W-P-W 78.7mm 30.0kg-2.25 kg/mm 05.5mm 0S0mm

+++++-

+++-

0-1,000 m 3,500 ft (STD) Approx. 1,550rpm

[g Clutch engagement: Approx. 3,700rpm [Q] Shift speed: Approx. 7,S50rpm ~ Geering: [f] Primary spring: [Q] Color

[BJ Length 0] Pre-Ioad rate Q] Wiredia. 00 Outside dia.

[jJ Weight:

IMI Weight rivet: [ID Weight bush: IQ] Roller bush: (f] Pri. clutch shim: IQ] Secondary spring:

[Q] Color [BJ Length 0] Pre-Ioad rate Q] Wiredia. 00 Outer dia. [B] Sec. torque cam: [ยง] Sec. clutch shim:

8AV-17605-10 Steel 13.3mm Duralon

+Aluminum 10.3mm

None

+++Aluminum 10.3mm

Duralon None

++-

P 85mm 60 0 (B-2)

+++++++-

++-

05.0mm 0S5mm 39 0 None

500 (A-2) ++360

W ............... White P ................... Pink

2-36

CLUTCH TUNING

II:g~

I_I

Clutch Setting Data (VX600(E)/DX) ~Item

lID Idle speed:

o ~ 1,000 m 3,500 ft (STD)

900 ~ 1,500 m 3,000 ~ 5,000 ft (MA)

1,400 ~ 2,100 m 4,500 ~ 7,000 ft (MA)

2,000 m ~ 6,500 ft ~ (HA)

Approx. 1,550rpm

[g Clutch engagement: Approx. 3,600rpm

rnl Shift speed:

Approx. 7,650rpm 20/37

L·Y·L 78.0mm 25.0kg·2.Okgfmm 8S.5mm 860mm

~Weight: IMI Weight rivet: 1Nl Weight bush:

8AY-17605-10 Steel 17.2mm Duralon

[Q] Roller bush: If] Pri. clutch shim:

Duralon 1.0 mm x 2pcs.

[g] Geering:

20/39

19/39

!El Primary spring: IQ] Color

IBl Length ill Pre-Ioad rate III Wiredia. 00 Outside dia.

Steel 13.3mm

Aluminum 10.3mm

None

IQJ Secondary spring: IQ] Color

IBl Length ill Pre-Ioad rate III Wiredia. 00 Outer dia.

lID Sec. torque cam:

rru Sec. clutch shim:

P 85mm 500 (A-2) fl5.0mm fl65mm 390 None

900 ~ 1,500 m 3,000 ~ 5,000 ft (MA)

1,400 ~ 2,100 m 4,500 ~ 7,000 ft (MA)

2,000 m ~ 6,500 ft ~ (HA)

(VX600ST) ~Item

lID Idle speed:

o ~ 1,000 m 3,500 ft (STD) Approx. 1,550rpm

[g Clutch engagement: Approx. 3,600rpm

rnl Shift speed:

Approx. 7,650rpm 20/39

L·Y· L 78.Omm 25.0kg·2.0kglmm 8S.5mm 860mm

[g] Geering:

19/39

18/39

!El Primary spring: [g] Color

IBl Length ill Pre-Ioad rate III Wiredia. 00 Outside dia. ~Weight: IMI Weight rivet: 1Nl Weight bush:

8AY-17605-10 Steel 17 .2mm Duralon

[Q] Roller bush: If] Pri. clutch shim:

Duralon 1.0 mm x 2pcs.

Steel 13.3mm

W-Y-W 76.5 mm 25.0 kg-2.25 kg/mm

Aluminum 10.3mm

None

++-

IQJ Secondary spring: IQ] Color

IBl Length ill Pre-Ioad rate III Wiredia. 00 Outer dia.

lID Sec. torque cam:

rru Sec. clutch shim:

P 85mm 60 0 (B·2) fl5.0mm fl65mm 390 None

500 (A-2)

L ..•.•... Blue

Y .•..•• Yellow 2-37

CLUTCH TUNING/GEARING SELECTION

II:gs I_I

2E331

The clutch may require tuning depending upon the area of operation and desired handling characteristics. The clutch can be tuned by changing engagement and shifting speed. Clutch engagement speed is defined as the engine speed where the machine first begins to move from a complete stop. Shifting speed is the engine speed when the machine passes a point 200 - 300 m (650 - 1,000 ft) from the starting position afterthe machine has been started at full-throttle from a dead stop. Normally, when a machine reaches shift speed, the vehicle speed increases but the engine speed remains nearly constant. Under unfavorable conditions (wet snow, icy snow, hills, or rough terrain), however, engine speed may decrease after the shift speed has been reached.

[A] Engine speed

[ID Good condition

~ Bad condition

[QJ Clutch

[QJClutch shifting speed

shifting speed

[El Clutch

engagement speed

[ill Travelled distance.

[ill -

[[) Starting position 200 - 300 mm (650 - 1.000 ft)

[[) Starting position 200 - 300 mm (650 - 1,000 ft)

GEARING SELECTION The reduction ratio of driven gear to drive gear must be set according to the snow condition. If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be made larger. If there are few rough surfaces or better snow condition; the ratio should be made smaller.

Travelled distance

Gear Ratio Chart

The following drive and driven gears and chains are available as options. The figures in upper lines represent the driven and drive gear ratios, while those in lower lines represent the number of chain links. (see page 2-39)

NOTE: _______________________ Do not set the gearing to any of the indicated (x) settings.

2-38

GEARING SELECTION

I'~gj

I_I

CD Chain and sprocket parts No. ~ Parts name

[Q] Drive sprocket

VX500(E)/ST

VX500DX/600DX

VX600(E)/ST

17T

89J-17682-70

8BB-17682-70

8AY-17682-70

18T

89J-17682-80

8BB-17682-80

8AY-17682-80

19T

89J-17682-90

8BB-17682-90

8AY-17682-90

20T(STD)

89J-17682-00

8BB-17682-00

8AY-17682-00

21T

89J-17682-10

8BB-17682-10

8AY-17682-10

33T

89J-47587-30

8BB-47587-30

89A-47587-30

35T

89J -47587 -50

8BB-47587-50

89A-47587-50

(f) Driven sprocket

[f] Chain (links)

[g Parts No.

[ID Teeth&Links

37T*2

89J-47587-70

8BB-47587-70

89A-47587-70

39T*1

89J-47587-90

8BB-47587-90

89A-47587-90

68l

94860-02068

94880-03068

70l 72l(STD)

94860-02070

94880-03070

94860-02072

94880-03072

*1: VX500(E)/ST/DXNX600ST/STD *2: VX600(E)/DX/STD

Â® Gear ratio

17T

18T

19T

20T

21T

33T

1.941 68l

1.833 68l

1.737 68l

1.650 70l

1.571 70l

35T

2.059 68l

1.944 70l

1.842 70l

1.750 70l

1.667 70l

37T

2.176 70l

2.056 70l

1.947 70l

1.850 72l*2

1.762 72l

39T

2.294 70l

2.167 72l

2.053 72l

1.950 72l*l

1.857 72l

[BJ Driven gear

@ Socondary spring

rn Parts No.

QJ Spring rate (kgmm/rad)

[KJ No. of coils

[IJ Color

!Ml Wire gauge [ffi Free length (mm)

(mm)

90508-50793

571

6.0

G-Y

5.0

90508-50654

641

5.3

Sb-Y

5.0

90508-50571 (STD)

721

4.7

5.0

90508-50746

721

4.7

5.0

93.5

G) Torque cam (secondary spring seat)

IQ] Parts No.

II] Cam angle

8AB-17684-70

370

8AB-18784-00 (STD)

390 42 0

8AB-17684-20

2-39

G .................. Green Y .................. Yellow Sb ................ Sky blue P .................. Pink W ................. White

lANDSJP Ito) I I ---------------------------------------------------~

GEARING SELECTION

ill Secondary spring twist angle 90508-50571 (P)/90508-50746 ~at 1 2 mlSheav8 20· 50· *2 A 30· 60· *1 B 10· 40· C

(W) 3 80· 90· 70·

90508-50793 (G-Y) ~at

4 110· 120· lOO·

ml Sheave

A B C

~at

A B C

1 45· 55· 35·

2 75· 85· 65·

3 105· 115· 95·

2 80· 90· 70·

4 20· 30· 10·

3 110· 120· lOO·

*1: VX500(E)/ST/DXNX600ST *2: VX600(E)/DX

90508-50793 (Sb-Y) IIID Sheave

1 50· 60· 40·

4 15· 25· 5·

S .............. Silver L .............. Blue Go ........... Gold Y .............. Yellow P .............. Pink

R .............. Red W ............ White G ............. Green Sb ............ Sky blue *3: VX600(E)/ST/DX *4: VX500(E)/ST/DX

<ID Primary spring [Q) Spring

[g Parts No.

rate

90501-481J 1 90501-487G 8 90501-507G 2 90501-524G 5 90501-501G 7 90501-521J 6 90501-507G 7 90501-527G 1 90501-524G 4 90501-526G 4 90501-556G 6 90501-553G 0 90501-557G 6 90501-556G 5 90501-553G 6 90501-550J 8 90501-557G 5 9050 1-556G 7 90501-584G 2 90501-555G 8 90501-581J 7 90501-582J 1 90501-607G 4 90501-607G 0 90501-584G 1 90501-605G 7 90501-607G 3 90501-606G 9 90501-604G 0 90501-602J 0

(kg/mm) 1.0 1.5 1.5 1.5 1.5 1.5 1.75 1.75 1.75 2.0 2.0 2.0 2.25 2.25 2.25 2.25 2.5 2.5 2.5 2.46 2.5 2.5 2.75 2.75 2.75 2.75 3.0 3.0 3.0 3.0

III Preload (kg) 20.0 15.0 20.0 25.0 25.0 30.0 15.0 20.0 25.0 15.0 20.0 25.0 15.0 20.0 25.0 30.0 15.0 20.0 24.0 24.0 25.0 30.0 15.0 20.0 24.0 25.0 15.0 20.0 24.0 30.0

[EJ Calor

[ill Wire [8J Outside gauge diameter (mm) (mm)

SoloS Go Go-L-Go Go-Y-Go Go-Y-Go Go-P-Go R-Go-R R-L-R R-Y-R L-Go-L L L-Y-L W-Go-W W-L-W W-Y-W W-P-W Y-Go-Y Y-L-Y Y Y Y Y-P-Y G-Go-G G-L-G G-Y-G G-Y-G P-Go-P P-L-P P-Y-P P 2-40

4.8 4.8 5.0 5.2 5.0 5.2 5.0 5.2 5.2 5.2 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.8 5.8 5.8 5.8 6.0 6.0 5.8 6.0 6.0 6.0 6.0 6.0

60.0 60.0 60.0 60.0 59.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0

DJ No. of coils 5.16 4.19 4.61 5.08 4.65 5.09 4.24 4.65 4.64 4.32 4.95 5.10 4.62 4.62 4.61 4.62 4.36 4.36 4.95 4.43 4.96 4.96 5.12 5.12 4.70 5.00 4.86 4.86 4.80 4.74

QJ Free length

(mm) 85.4 75.4 78.7 82.1 81.7 85.4 74.0 76.8 79.7 72.9 75.4 78.0 72.1 74.3 76.5 78.7 71.4 73.4 75.0 75.2 75.4 75.4 70.9 72.7 74.1 74.1 70.4 72.1 73.3 75.4

00 Remarks

HIGH ALl11lJDE TUNING

II:g~ 14fl1

2E341

HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below. Confirm STD settings â&#x20AC;˘ Carburetor (page 2-25) â&#x20AC;˘ Spark plug (page 2-3)

l Adjust main jet size according to the chart (page 2-27)

Test main jet size (performance & plug color) I OK

f-Not OK--

Adjust main jet size

I+-

Not OK

OK Not OK

! Decide if problem is pilot jet and adjust accordingly Check engagement speed and shift performance High altitude tuning OK Adjust primary clutch as re-

quired (page 2-36)

Not OK

Adjust secondary clutch as required (page 2-36)

2-41

lANDSJP Ito) I I ----------------------------------------------~

HIGH ALTITUDE TUNING 2E361

Rear Suspension Stopper band setting 1. Adjust: • Stopper band length

NOTE: _________________________ This adjustment affects the characteristics of the machine.

handling

Adjustment steps: • Remove the stopper band securing bolt and washers. • Adjust the length of the stopper band CD.

VX500(E)NX600(E)

Front [Ki

No. 1

No.2

Rear [ID

No.1

VXSOOST/VX600ST/ VXSOODX/VX6OODX

• Tighten the bolt (stopper band)

Nut (stopper band): 4 Nm (0.4 m • kg, 2.9 ft • Ib)

Choosing other settings:

NOTE: The standard settings work well under most general riding conditions. The suspension can be adjusted to work better in one set of conditions, but only at the expense of performance in another. Keep this in mind when you adjust the suspension. Front [Ki; No. 5 hole (Shortest) More weight on skis: • Heavy steering/ oversteer • More maneuverability Favors: hard pack snow, ice, smooth trails, tight turns

No. 1 hole (Longest) Less weight on skis: • Light steering/ understeer • Better acceleration and speed Favors: deep snow, straight line acceleration, top speed

Rear [ID;

2-42

No.l hole (Longest)

No. 5 hole (Shortest)

Less weight on track: • More suspension travel • Greater riding comfort Favors: Rougher trails

More weight on track: • Better acceleration and speed • Firmer handling Favors: deep snow, smooth surfaces

_ __ _ liANOSJPI _ ______ HIGH ALTITUDE TUNING . . U* ~ I . 2E371

Spring Preload 1.Adjust: • Spring preload Adjustment steps: • Turn the spring seat CD in or out.

Standard

Spring seat distance Preload VX500(EINX600(ElI

VXSOODXNX600DX/

® Length (Front) VX500STNX600ST

® Length (Front)

Cb) Length (Rear) ~ Front

Longer

Shorter

Harder

Softer

Max. 85.5 mm (3.37 in)

77.5 mm (3.05 in)

Min. 70.5 mm (2.78 in)

Max. 85.5 mm (3.37 in)

72.5 mm (2.85 in)

Min. 70.5 mm (2.78 in)

Max. 85 mm (3.35 in)

77 mm (3.03 in)

Min.

69 mm (2.72 in)

[ID Rear

WARNING

This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to open flame or high temperature, as this could cause it to explode. 2. Adjust: • Pivot arm setting A-Frontl Position

(STD)

@ B-Rear

Position

(STD) @*2

2·43

Performance of starting Maneuverability acceleration *1 Fair Better Better Less

Riding comfort Soft Hard

*1: This is due to change of we ightt ran sfer on the track. *2: When the @ positon is selected, the stopper bands should be at No.1 position in order to maintain R/R suspenssion at standard height.

~~~~~~~~~~~~~~ICHA~~ CHAPTER 3. CHASSIS

STEERING .......................................................... 3-1 REMOVAL ...........................................•........ 3-2 INSPECTION ................................................ 3-4

INSTALLATION ........................................... 3-5· SKI ............................................... ~ ...................... 3-8 REMOVAL .................................................... 3-9 INSPECTION ................................................ 3-9 INSTALLATION ........................................... 3-9

FRONT SUSPENSION ..................................... 3-11 REMOVAL .................................................. 3-12 INSPECTION .............................................. 3-14

INSTALLATION ......................................... 3-15

______________________________~S~TE~E~R~IN~G~lcHASI~ I CHASSIS STEERING

ill ®

Handlebar Steering column @ Bearing @ Bearing holder <ID Lock washer ® Relay rod (j) Tie-rod

15 Nm (1.5 m' kg, 11 ft ·Ib)

27 Nm (2.7 m • kg, 20 ft ·Ib)

A USE NEW ONE

3-1

_________________________________S_T_E_ER~I_N_G_lcHASI~ REMOVAL 1. Remove: • Handlebar cover CD

2. Disconnect: • Handlebar switch coupler (right) • Brake light switch coupler • Headlight beam switch coupler • Grip warmer leads

3. Remove: • Holder CD (throttle cable) 4. Disconnect: • Throttle cable ® • Oil pump cable ® (from throttle lever)

5. Remove: • Brake cable Removal steps: • Loosen the locknut CD . • Turn in the adjuster fully ® . • Disconnect the brake cable end ® from the brake lever.

6. Remove: • Band • Handlebar holders CD (upper) • Handlebar ®

3-2

_______________________________S_TE_E_R_IN_G_lcHASI~

7. Remove: • Seat • Center cover ill

NOTE: _______________________ Remove the holding nuts (main switch, "STARTER" lever, and disconnect the grip warmerswitch couplerwhen removing the center cover. 8. Remove: • Intake silencer (see page 7-9) • Carburetors (see page 7-2) • Engine assembly (see page 5-1)

9. Remove: • Cotter pin ill • Nut (relay rod)

NOTE: _______________________ When removing the relay rod from the steering column, the relay rod end needs to be held fixed in order to facilitate the locknut removal.

10. Straighten: • Lock washer tabs (upper and lower) • 11.Remove: • • • • •

Nuts ill Bolts® Lock washers Bearing holders <ID Bearings @ (upper)

• Collars • Steering column <ID • Bearings ® (lower)

3-3

__________________________________S_T_E_ER_I_N__ G

ICHASI~

12. Remove: • Cotter pins CD • Bolts® • Washers @ (suspension arm side)

13. Remove: • Cotter pin CD • Bolt • Relay rod ® • Tie rods@ • Cotter pin G) • Nut@ • Washer • Relay arm ® INSPECTION 1. Inspect: • Handlebar CD • Steering column ® Bends/Cracks/Damage

Replace.

WARNING

Do not attempt to straighten a bent column. This may dangerously weaken the column.

2. Inspect: • Bearings CD (steering column) • Collars ® Wear/Damage ~ Replace. • Steering column @ (bearing contact surfaces) Scratches/Wear/Damage ~ Replace.

3. Inspect: • Relay rod CD • Tie-rods ® Bends/Cracks/Damage ~ Replace.

tItS

f :

WARNING

Do not attempt to straighten a bent rod. This may dangerously weaken the rod.

3-4

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