• Yamaha Vmax 700 Parts
• 1997 Yamaha Vmax 700 Sx Specs
• Yamaha Vmax 700 Recoil Rope Style

This is the Highly Detailed factory service repair manual for the1997 1998 1999 YAMAHA VMAX 500/600/700, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. They are specifically written for the do-it-yourself-er as well as the experienced mechanic.1997 1998 1999 YAMAHA VMAX 500/600/700 Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine.

Yamaha VMAX Service Repair Manual VMX12 V-MAX 2001 2002 2003 2004. YAMAHA SERVICE REPAIR MANUAL VMAX V MAX 600 700 3 CYL 1997. EBooks Manuals For Yamaha Vmax 700 Snowmobile are currently available in. Wolfgang kaschuba melanie krebs,453 detroit diesel engine service manual.

It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable.

Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: General Information Periodic Inspection and Adjustment Chassis Power Train Engine Overhaul Cooling System Carburetion Electrical Specifications Optional Kit File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have1997 1998 1999 YAMAHA VMAX 500/600/700 Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: Thanks for visiting! 1997 1998 1999 Yamaha VMAX 500/600/700 Service Repair Manual. 1. ® @ ICHAsld' - ® ISPECI er I IOPT I0 I @@ @ ® 1 m 1 B 1.

A@ B. OE031 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to @ are designed as thumb tabs to indicate the chapter's number and content. CD General information Optional kit 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 dia- gram indicate grade of lubricant and location of lubrication point. @) Apply locking agent (LOCTITE®) @) Apply engine oil @ Apply gear oil @ Apply molybdenum disulfide oil @ Apply wheel bearing grease @ Apply low-temperature lithium-soap base grease @ Apply molybdenum disulfide grease @ Apply Yamabond No.5®. INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE OVERHAUL COOLING SYSTEM CARBURETION ELECTRICAL SPECIFICATIONS OPTIONAL KIT CHAS 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 DIS- ASSEMBLY. 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 IIl-:AsI 1-1 lEOOl 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.

VX600U.8CA0001 01. NOTE: Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION 11.1 1-2 lEOll IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DIS- ASSEMBLY 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. Use proper tools and cleaning equipment. Refer to SPECIAL TOOLS. When disassemblingthe 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.

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 rein- stalled correctly. Keep away from fire. Be sure to keep to tightening torque specifi- cations. 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. IMPORTANT INFORMATION 11.1LI 300-000 300-002 300-003 '-3 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 re- placed when an engine is overhauled. All gasket surfaces, oil seal lips, and a-rings must be cleaned. 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 prop- erly tightened. BEARINGS AND OIL SEALS 1.lnstall the bearing(s) CD and oil seal(s) ® 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. Do not use compressed air to spin the bearings dry. This causes damage to the surface of the bearings.

IMPORTANT INFORMATION/SPECIAL TOOLS III 300001 1-4 CIRCLlPS 1. All circlips should be inspected carefully be- fore reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing acirclip D, make sure that the sharp edged corner ® is positioned opposite to the thrust ID it receives. See the sectional view. @ 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 ofimpropertools 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. 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 7, YU-03097 This gauge is used for run out measurement. 1-5 SPECIAL TOOLS IIIlE051. Fuel Level Gauge PIN 2, 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 synchroniza- tion. 1E071 FOR ENGINE SERVICE. Piston Pin Puller PIN 4, YU-01304 This tool is used to remove the piston pin.

LE081. Rotor Puller PIN 2, YU-33270 This tool is used to remove the magneto rotor. LE091. Cooling System Tester PIN 5, YS-22460-01 This tester is used for checking cooling system.

'-6 SPECIAL TOOLS IIIIlEl0l FOR POWER TRAIN SERVICE. Primary Sheave Holder PIN 1, 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 1, YS-28890-8 This tools are used when disassembling and as- sembling the primary sheave. LE131.

Clutch Separator Adapter PIN 0, YS-34480 This tool is used when disassembling and assem- bling the primary sheave. LE171. Clutch busing jig kit PIN YS-39752 Thistool is used when removing and installing the primary sheave busing. 1-7 SPECIAL TOOLS IIISsI 1E141.

Track Clip Installer PIN 1. YS-91045-A This tool is used for installing the track clip. 1E151 FOR ELECTRICAL SERVICE. Pocket Tester PIN 2.

YU-03112 This instrument is necessary for checking the electrical components. 1E161. Electra Tester PIN 1. YU-33260-A This instrument is invaluable for checking the electrical system. 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 I':gII2EOO5 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 First Every Pre- Month Season Item Remarks operation or or check first 800 km 3,200 km (Daily) (500 Mi) (2,000 Mi) (40 hr) (160 hr) Spark Plug: Check condition adjust the gap and clean.Replace if necessary. Check oil level.Engine Oil:.Air bleed the oil pump if necessary.Oil Filter: Check condition.Replace if necessary. Fuel: Check fuel level.Check condition.Fuel Filter: 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. Check coolant level.Engine Coolant.Air bleed the cooling system if necessary.Check throttle lever operation.Carburetor Whenever operating condition.Adjust the jets. (elevation!temperature) is changed.

Check wear and damage. Replace if necessary.Water Pump Belt Adjust water pump belt if necessary. Manual Starter: Check operation and rope damage.Replace if necessary. Engine Stop Switch: Check operation.Repair if necessary. Throttle 9verride System: Check operation.Repair if necessary. Check operation. Throttle Lever:.Repair if necessary.Exhaust System: Check for leakage.Retighten or replace gasket if necessary.Decarbonization: More frequently if necessary.

Drive V-belt Guard: Check cracks, bends or damage.Replace if necessary. Drive V-belt: Check wear and damage. Replace if necessary.

Drive Track/Idler Wheels: Check deflection, wear and damage.Adjust/replace if necessary. Slide Runner 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. IIANDSJPllo)lPERIODIC MAINTENANCE TABLE First Every Pre- Month Season Item Remarks operation or or check first 800 km 3,200 km (Daily) (500 Mi) (2,000 Mi) (40 hr) (160 hr) Check operation.Brake/.Adjust free play and/or replace pads if neces- Parking Brake sary.Check oil level.Drive Chain Oil Replace.Drive Chain: Check deflection.Adjust if necessary. Ski/ Check wear and damage.Ski Runner.Replace if necessary. Steering System Check operation.Adjust toe-out if necessary.

Lights: Check operation.Replace bulbs if necessary. Check fluid level.Battery.Check specific gravity and breather pipe opera- tion.Charge/Correct if necessary. Check engagement and shift speed.Adjust if necessary.

Wheneveroperatingelevation ischanged.Primary Sheave Check wear and damage.Replace if necessary. Lubricate with specified grease.Lubricate with specified grease.Secondary Sheave Adjust if necessary. Whenever operating elevation ischanged.Steering Column Bearing: Lubricate with specified grease.Ski and Front Suspension: Lubricate with specified grease.Suspension Component: Lubricate with specified grease.Brake Cable End and Lubricate with specified grease.Lever End/ Throttle Check cable damage. Cable End 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.

SMRKPLUG p:gSI1 ®.=::::::::;I/) 377-000 (J1-)CD.' Fi.-41 2-3 2EOll ENGINE SPARK PLUG 1.

Remove:. Spark plug 2. Inspect:. Electrode CD Wear/DamageReplace.

Insulator color ® 3. Measure:. Plug gap@ Out of specificationRegap.

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. Tighten:. Spark plug Spark plug: 28 Nm (2.8 m. kg, 20 ft. Ib) NOTE: Finger-tighten CD the spark plug before torquing ® to specification.

OILPUMP II:gltill 2-4 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. 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 ®. Place a rag under the oil pump assembly to catch oil.

Disconnect:. Oil hose ill 6. Keep the oil running out until air bubbles disappear from the oil hose ill. 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 com- plete air bleeding. Connect:. Oil delivery hoses ill. OILPUMP II:g!I1 2-5 11. Remove:.

Bleed screw D. Gasket (bleed screw) 12. Keep the oil running out until air bubbles disappear from bleed hole. Inspect:. Gasket (bleed screw) Wear/Damage Replace.

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 speci- fied distance is obtained. Distance®: VX500(E)fSTfOX: 25 - 27 mm (0.98 - 1.06 in) VX600(ElfSTfOX: 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. 800-001 801002 8OHl03 OIL FILTER INSPECTION II:gItAI 2-6 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.

Inspect:. Oil filter CD Contamination Replace. Recommended replacement interval: Every season 3. Reverse the removal procedure. 2E041 FUEL LINE INSPECTION 1. Inspect: 2E051.

Fuel hoses. Fuel delivery hoses Crack/Da mageReplace.

FUEL FILTER INSPECTION 1. Remove:. Seat 2. Disconnect:. Tail/brake light coupler 3.

Remove:. Spring bands CD. Cap®. Fuel filter @ 4. Inspect:.

Fuel filter CD Contamination Replace. Recommended replacement interval: Every season 5. Reverse the removal procedure. COOLING SYSTEM - IlANOSJP Ito) I 2-7 2E061 COOLING SYSTEM Coolant Replacement NOTE: The coolant should be changed at least seasonally. Place the machine on a level surface. Remove:.

Side cowling (right). Seat. Muffler CD.

Exhaust pipe ® 3. Remove:. Coolant filler cap CD A 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 atowel 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.

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. o 2-8 COOLING SYSTEM 1':gS14rl1 7.

Disconnect:. Coolant hoses CD (rear) 8. Drain the coolant. NOTE: Liftupthe front ofthe machineto drainthe coolant completely.

A WARNING Coolant is poisonous. It is harmful or fatal if swallowed. Ifcoolantisswallowed, induce vomiting imme- diately. 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. Remove the reservoir tank CD and drain the coolant. Install:. Reservoir tank 11.

Inspect:. Gaskets (drain bolt) DamageReplace. Install:. Gaskets. Drain bolts. Exhaust pipe/gaskets.

Muffler 13. Fill: Drain bolt: 23 Nm (2.3 m kg, 17 ft Ib) Bolts (exhaust pipe): 23 Nm (2.3 m.

kg, 17 ft Ib). 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). IIANDSJPI.

ICOOLING SYSTEM 2-9. Hard water or salt water is harmful to the engine parts; use boiled or distilled water. Do not use water containing impurities or oil.

Bleed air from the cooling system. Inspect:. Cooling system Decrease of pressure (leaks)Repair as re- quired. (see page 6-4) Inspection steps:.

Attach the Cooling System Tester D (90890- 01325, 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 ex- changer. Keep the coolant running out until air bub- bles 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 bub- bles disappear. Tighten the bleed bolt.

Bleed bolt: 6 Nm (0.6 m. kg, 4.3 ft.

Ib). 1lANDSJP 1 ICOOLING SYSTEM. 210. 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 min- utes). The rear heat exchanger will be warm to the touch.

A WARNING To avoid severe injury or death:. Makesurethe machineissecurely supported with a suitable stand. Do not exceed 3000 rpm. The machine could unexpectedly move forward if the clutch engages, ordrive 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 HFULLHlevel mark.

2E081 Water Pump Belt Deflection Adjustment 1. Remove:. Muffler 2. Check:.

Drive belt deflection Out of specificationAdjust. Drive belt deflection 8 mm (0.31 in)/ 8 kg (17.6Ib) (NEW BELT) 8 mm (0.31 in)/ 13. Adjust:.

Drive belt deflection Adjustment steps:. Remove the recoil starter CD. Attach the Primary Sheave Holder (90890- 01701, YS-01880)to hold the primarysheave. 2-11 COOLING SYSTEM IIg!Itll. 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 deflec- tion. 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). liANOSJPlfO) ICARBURETOR SYNCHRONIZATION. 2-12 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 ob- tained. I 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 eccen- tric 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. ENGINE IDLE SPEED ADJUSTMENT/ IINSPI(0) ITHROTTLE CABLE ADJUSTMENT ADJ L.' :'::;';:.' ;;;:'=.I 2-13 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.

Cl 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. Measure:. Throttle cable free play ® Out of specificationAdjust. 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 speci- fied free play is obtained. Turning in Free play is increased. Turning out Free play is decreased. Tighten the locknut.

THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECKI IINSPI(0) ISTARTER (CHOKE) CABLE ADJUSTMENT ADJ a.;.::;.;::;-=.=.I ® 214 2El22 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK A 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 upto clutch engagement rpm. The machine could start moving forward unexpectedly. Which could cause and accident. Start the engine.

NOTE: Refer to STARTING THE ENGINE. Hold the pivot point ofthe throttle lever away from the throttle switch CD. 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.

A WARNING Ifthe 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. Measure:.

Starter cable free play ® Out of specification -7 Adjust. Freeplay@: 0.5. 1.5 mm (0.02. Adjust:. Starter cable free play Adjustment steps:. Loosen the locknut CD.

Turn the adjuster CV in or out until the speci- fied 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. DRIVEV-BElT p:gSI1 2E141 POWER TRAIN DRIVE V-BELT A WARNING. Be sure there are shims (2 pes) CD between secondary fixed and sliding sheaves when installing the NEW belt.

805030. Ifthere is no gap, the clutch engagement speed L-.;;;;. Will be reduced. The machine may move 805-029 805-020 2-15 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. V-belt width CD Number of spacers 31.6 mm (1.24 in) or more 2 spacers 00.l 30.6 mm (1.20 in) 1 spacer 9 29.6 mm (1.17 in) No spacer 28 mm (1.1 in) or less Replace the V-belt 1. Remove:. Drive V-belt guard CD. DRIVEV-BEl.

P:g!I1 805-009 2-16 2. Remove:.

Drive V-belt CD Removal steps:. Rotate the secondary sliding sheave clock- wise ® 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. Inspect:. Drive V-belt CrackJWear/Damage Replace. Oil orgrease adhering tothe V-belt Check the primary and secondary sheaves. 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 secon- dary sheaves.

Measure:. Drive V-belt length ® Out of specification Replace. Drive V-belt length: 1,130 - 1,118 mm (44.5 - 44.0 in). ENGAGEMENT SPEED CHECK I':gsII 2-17 2E201 ENGAGEMENT SPEED CHECK 1. Place the machine on a level area of hard packed snow.

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) C) Engagement speed: VX500(E)fSTfDX Approx. 3,700 rfmin VX600(E)fSTfDX Approx.

3,600 rfmin. ® I I I I I I I I I J BRAKE PAD INSPECTION/DRIVE CHAIN IIgjII 2-18 2E161 BRAKE ADJUSTMENT BRAKE PAD INSPECTION 1. Apply the brake lever. Measure:. Brake pad thickness ® Out of specification Replace brake pads as a set. (see page 4-27) I Wear limit: v 5.2 mm (0.2 in) NOTE: Adjust brake every 40 hours of operation, or whenever the brake lever becomes loose during operation. Measure:.

Distance L Out of specification -) Adjust. Distance ULU 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 speci- fied distance is obtained. Turning in Distance uLu is increased.

Turning out DistanceuLU is decreased. Tighten the locknut CD. 2E171 DRIVE CHAIN Oil Level Inspection 1. Place the machine on a level surface. Remove:.

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

DRIVECHAIN p:gjII 2-19 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. 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 sure to remove any oil from the heat protec- tor. 2E182 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) 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.

CD.® TRACK TENSION ADJUSTMENT I':gsII 820003 820-004 2-20 2E151 TRACK TENSION ADJUSTMENT A 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 ofthe 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. Place the machine with the right side facing down. 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. 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.

TRACK TENSION ADJUSTMENT! IINSPIto) ISLIDE RUNNER INSPECTION ADJ L.,':'=;'.L-=.=.I 820-008 820-005 @+ 820009.J 820-001 a.

Starttheengine and rotate the track one or two turns. Stop the engine. Check the track alignment with the slide runner CID. If the alignment is incorrect. Turn the left and right adjusters to adjust. Track alignment @ Shifted (j) Shifted to right to left @ Left adjuster Turn out Turn in CID Right adjuster Turn in Turn out ® Slide runner ® Track @ Track metal ® Gap @ Forward c. Adjust track deflection to the specified amount.

Track deflection More than Less than specified specified @ Left adjuster Turn in Turn out CID Right adjuster Turn in Turn out The adjusters should be turned an equal amount. Recheck alignment and deflection. If neces- sary, repeat steps a to c until proper adjust- ment is achieved.

Tighten the rear axle nut. Rear axle nut: 75 Nm (7.5 m. kg, 54 ft Ib) SLIDE RUNNER INSPECTION 1. Inspect:. Slide runner CD Cracks/DamageMlearReplace. Measure:. Slide runner thickness CV Out of specificationReplace.

(see page 4-33) W!::03::,n)-J. IlANDSJP Ito) ISKI/SKI RUNNER/STEERING SYSTEM - 222 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). IlANDSJP. I(0) ISTEERING SYSTEM/HEADLIGHT BEAM ADJUSTMENT - 2-23 2E232 Toe-Out Adjustment 1.

Place the machine on a level surface. Check:. Ski toe-out Direct the skis straight forward. Out of specificationAdjust.

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). Locknut (rod end): X 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. Inspect:. Headlight beam direction L H The high beam should be directed down- wards at an angle of 1/20 to the horizontal. If not, adjust the direction. 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.

LUBRICATION - IlANOSJP Ito) I A 2-24 2E251 LUBRICATION Brake Lever, Brake Cable End and Throttle Lever 1. Lubricate the brake lever pivot. Brake cable end and throttle lever. IIESSO Beacon 325 Grease A 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. Esso Beacon 325 Grease or Aeroshell Grease #7A. G Front ID Rear. IlANDSJP I ICARBURETOR TUNIG - 225 2E271 TUNING CARBURETOR TUNING The carburetor is set at the factory to run at temperatures of O°C.4°F) at sea level. If the machine has to be operated underconditions otherthanthosespecified 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, afterthe 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 VX5OO(E)/ST/DX VX600(EIIST/DX Type TM36-B2S TM3S-B103 Manufacturer MIKUNI 1.0. Mark SAB-OO aeA-OO Main jet (M.J.) #151.3 #156.3 Pilot jet (P.J.) #45 #52.5 Pilot air jet 02.5 (P.A.J.) Pilot screw 1-1/S (P.S.) turns out Float height 20.3.

24.3 mm (0.799.0.957 in) Idle speed 1,450.1,60rIm +-.- CARBURETOR TUNING II:gsII 2-26 2E281 Middle-Range and High Speed Tuning No adjustment is normally required, but adjust- ments 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. Start the engine and operate the machine under normal conditions to make sure the engine operates smoothly. Then stop the en- gine. Remove:. Spark plugs 3.

Check:. Spark plug insulator CD color A medium to light tan color indicates nor- mal conditions. Distinctly different color Replace main jet. 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. IlANDSJP Ito) ICARBURETOR TUNING - 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) 1,800 - 2,400 m (6,000 - 8,000 ft) 2,400 - 3,000 m (8,000 - 10,000 ft) -30oe (-22°F) I MJ #156.3 MJ #153.8 MJ #151.3 -20oe (-4°F) I.

2E291 2. High altitude tuning Use the following guide to select main jets according to variations in elevation and tem- perature.10oe ooe 100 e 200 e (14°F) (32°F) (50°F) (68°F) I I I I MJ #153.8. MJ #151.3.MJ #151.3 (STO)-. MJ #148.8 IN:2.- MJ #148.8 IN:2 -. 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. F-MJ #146.3 IN:2-'.-MJ #140 IN:2-. PJ #50 AS:3/4 r-MJ #143.8 IN:2-. 2-27 MJ #140 IN:2 MJ #137.5 IN:2 PJ #50 AS:3/4 9 #: Main jet number Q IN: Jet needle clip position WAS: Air screw turns out £ PJ: Pilot jet number.

FOR VX600 (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) 1,800 - 2,400 m (6,000 - 8,000 ft) 2,400 - 3,000 m (8,000 - 10,000 ft) CARBURETOR TUNING I':gj1.1 -30°C -20°C -10°C O°C 10°C 20°C (-22°F) (-4°F) (14°F) (32°F) (50°F) (68°F) 1 I. MJ #160.MJ #162.5. MJ #157.5.-MJ #156.3 (STD)-.

MJ #153.8 IN:2.- MJ #153.8 IN:2-' MJ #156.3. MJ #151.3 IN:2.- MJ #151.3 IN:2-.MJ #153.8 IN:2-. MJ #148.8 IN:2.- MJ #148.8 IN:2-. MJ #151.3 IN:2-'.- -MJ #147.5 IN:2-' MJ #145 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':gII2E302 Guide for carburetion (A Throttle valve opening ID Mid-range speed tuning ® ® CD EJ Low speed tuning CID ® @ CID 1.:E. El Closed 1/8 1/4 1/2 3/4 QJ Full open (A Throttle valve opening 2-29. 1lANOSJP 1.1CARBURETOR TUNING 1/8 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 © Full open ID Throttle opning A: No 3 position B: No. 2 position C: No. 4 position irClip El Jet needle 1/2 3/4 ©Full open ID Throttle opening 2-30 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. IlANOSJP I(0) ICARBURETOR TUNING - 231 2E391 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. Tighten the air screw lightly, and back it out from its lightly seated position.

Yamaha Vmax 700 Parts

Standard tuning out: 1-1/8 2. Start the engine, and allow it to warm up for a few minutes.

1997 Yamaha Vmax 700 Sx Specs

The warm-up is complete when the engine responds normally to the throttle opening. A 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. 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. CARBURETOR TUNING II:g!I1 2-32 5.

Finally, setthe engine idle speed bytuning 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 condi- tions, the standard pilot jets may need to be replaced to obtain proper pilot air/fuel mix- ture. 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)fSTfOX: #45 VX600(E)fSTfOX: #52.5 7. By repeating steps 1to 5above, adjustthe idle speed.

IlANDSJP I' ICARBURETOR TUNING -2E311 Main jet selection chart Spark plug color Check up Remedy Light tan or gray. Carburetor is tuned properly. Dry black or fluffy Mixture is too rich. Replace main jet with the next smaller size.deposits. 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 Due to too lean a mixture, the Replace the piston and spark plug.

Yamaha Vmax 700 Recoil Rope Style

Brown spots and Tune the carburetor again, starting with low- electrodes having a piston is damaged or seized. Speed tuning. Bluish-burnt appearance. Melted electrodes and Check the piston for holes or seizure. Possibly blistered Check the cooling system, gasoline octane rating insulator. Due to too lean a mixture, the and ignition timing.

After replacing the spark plug Metallic deposits on spark plug melts. With a colder type, tune the carburetor again insulator. Starting with low-speed tuning. 2-33. IIANOSJPIollCARBURETOR TUNING.