Yamaha SRX700D Service Manual
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Yamaha SRX700D Service Manual

Yamaha SRX700D Service Manual

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SERVICE MANUAL
SRX700D
SRX700SD
LIT-12618-02-09
8DN-28197-10
981035

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Summary of Contents for Yamaha SRX700D

  • Page 1 SERVICE MANUAL SRX700D SRX700SD LIT-12618-02-09 8DN-28197-10 981035...
  • Page 2 NOTICE HOW TO USE THIS MANUAL This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers Particularly important information is distinguished and their qualified mechanics. It is not possible to in this manual by the following notations: put an entire mechanic’s education into one...

  • Page 3: Periodic Inspection And

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

  • Page 5: Table Of Contents

    CHAPTER 1. YAMAHA POWER VALVE SYSTEM GENERAL INFORMATION (Y.P.V.S.) ADJUSTMENT ......2-15 YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) PRE-SEASON CHECKS ..2-16 MACHINE IDENTIFICATION ......1-1 FRAME SERIAL NUMBER ......1-1 POWER TRAIN ..........2-18 ENGINE SERIAL NUMBER ....... 1-1 SHEAVE DISTANCE AND OFFSET ADJUSTMENT ........
  • Page 6 INSPECTION ..........4-20 INSPECTION ..........5-28 JACKSHAFT AND DRIVE CHAIN INSTALLATION ........5-29 HOUSING INSTALLATION ..... 4-21 YAMAHA POWER VALVE SYSTEM BRAKE ............4-22 (Y.P.V.S.) ............5-30 BRAKE PAD REPLACEMENT ....4-23 REMOVAL ..........5-32 BRAKE CALIPER DISASSEMBLY ... 4-27 INSPECTION ..........
  • Page 7 TROUBLESHOOTING ......8-21 GRIP AND THUMB WARMER COIL ..8-22 FUEL PUMP ............ 7-12 VARIABLE RESISTOR ......8-22 INSPECTION ..........7-13 INSTALLATION ........7-13 YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) ............8-23 CIRCUIT DIAGRAM ......... 8-23 CHAPTER 8. TROUBLESHOOTING ......8-24 ELECTRICAL SERVOMOTOR ........

  • Page 8: Chapter 1. General Information

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number is located on the right-hand side of the SDN1010 frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number is located on the right-hand side of the crankcase.

  • Page 9: Important Information

    SDN1070 ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjust- ments. SDN1080...

  • Page 10: Gaskets, Oil Seals, And O-Rings

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

  • Page 11: Special Tools

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

  • Page 12: For Engine Service

    SPECIAL TOOLS INFO FOR ENGINE SERVICE • Piston pin puller P/N: YU-01304 (for U.S.A./Canada) 90890-01304 (for Europe) This tool is used to remove the piston pin. SDN1190 • Rotor holding puller P/N: YU-33270 (for U.S.A./Canada) 90890-01362 (for Europe) This tool is used to remove the magneto rotor. SDN1200 •...

  • Page 13: For Carburetion Service

    SDN1320 • Electro tester P/N: YU-33260-A (for U.S.A./Canada) 90890-03021 (for Europe) This instrument is invaluable for checking the electrical system. SDN1330 • Yamaha power valve system (Y.P.V.S.) adjustment coupler. SDN1340 P/N: YS-43092 This tool is used for adjusting the Y.P.V.S.

  • Page 14: Periodic Inspection And Adjustment

    INSP INTRODUCTION/PERIODIC MAINTENANCE TABLE PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale.
  • Page 15 INSP PERIODIC MAINTENANCE TABLE Initial Every Pre- 1 month Seasonally operation Item Remarks check first 800 km 3,200 km (daily) (500 mi) (2,000 mi) (40 hr) (160 hr) Slide runner Check for wear and damage. Replace if necessary. Brake/parking brake Check operation and fluid leakage.

  • Page 16: Engine

    INSP SPARK PLUGS ENGINE SPARK PLUGS 1. Remove: • Spark plug caps • Spark plugs 2. Inspect: • Electrodes 1 Damage/wear → Replace the spark plug. • Insulator color 2 SDN2010 3. Measure: • Spark plug gap a Out of specification → Regap. Use a wire thickness gauge.

  • Page 17: Oil Pump

    INSP OIL PUMP OIL PUMP Air bleeding CAUTION: The oil pump and oil delivery line must be bled in the following cases: • Any portion of the oil system has been disconnected. • The machine has been turned on its side. •...

  • Page 18: Fuel Line Inspection

    INSP OIL PUMP/FUEL LINE INSPECTION 13. Install: • Gasket (bleed screw) • Bleed screw 14. Install: • Carburetors Refer to “CARBURETORS” in CHAPTER 7. Cable adjustment NOTE: Before adjusting the oil pump cable, the throttle cable distance should be adjusted. Adjustment steps: •...

  • Page 19: Cooling System

    INSP COOLING SYSTEM COOLING SYSTEM Coolant replacement NOTE: The coolant should be changed at least every season. 1. Place the machine on a level surface. 2. Remove: • Exhaust pipe #1 (L), #2, #3 (R) • Exhaust pipe joint #1 (L), #2, #3 (R) Refer to “EXHAUST ASSEMBLY”...
  • Page 20 INSP COOLING SYSTEM 5. Place an open container under the coolant drain bolt 1. 6. Remove: • Coolant drain bolt • Gasket (coolant drain bolt) 7. Drain the coolant. NOTE: Lift up the tail of the machine to drain the coolant. SDN2120 8.
  • Page 21 INSP COOLING SYSTEM 14.Fill: • Cooling system Recommended coolant: High quality ethylene glycol antifreeze containing corrosion inhibitors Coolant : water mixed ratio: 3 : 2 (60% : 40%) Total amount: 5.6 L (4.9 lmp qt, 5.9 US qt) CAUTION: • Hard water or salt water is harmful to engine parts.
  • Page 22 INSP COOLING SYSTEM Air bleeding steps: • Lift up the tail of the machine. • Remove the bleed screw 1 on the heat ex- changer. • While slowly adding coolant to the coolant reservoir tank, drain the coolant until no more air bubbles appear.

  • Page 23: Carburetor Synchronization

    CARBURETOR SYNCHRONIZATION/ INSP ENGINE IDLE SPEED ADJUSTMENT CARBURETOR SYNCHRONIZATION 1. Remove: • Carburetors Refer to “CARBURETORS” in CHAPTER 7. 2. Adjust: • Carburetor synchronization Adjustment steps: • Turn the throttle stop screw 1 of carburetor #2 until the specified throttle valve height a is obtained.

  • Page 24: Throttle Cable Freeplay Adjustment

    INSP THROTTLE CABLE FREEPLAY ADJUSTMENT THROTTLE CABLE FREEPLAY ADJUSTMENT NOTE: • Before adjusting the throttle cable freeplay, the engine idle speed should be adjusted. • Adjust the throttle cable freeplay while the cable is in the cable guide. 1. Measure: •...

  • Page 25: Throttle Override System (T.o.r.s.) Check

    INSP THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK 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 the clutch engage- ment speed.

  • Page 26: Starter (Choke) Cable Freeplay Adjustment

    STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT/ INSP EXHAUST SYSTEM INSPECTION STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT 1. Measure: • Starter cable freeplay a Out of specification → Adjust. Starter cable freeplay a: 0.5 ~ 1.5 mm (0.02 ~ 0.06 in) SDN2240 2. Adjust: •...

  • Page 27: Heat Shield Clamp Replacement

    INSP HEAT SHIELD CLAMP REPLACEMENT HEAT SHIELD CLAMP REPLACEMENT Clamps on the exhaust pipe heat shields may become loose and cause a rattling noise, which is due to the deformation of the heat shields. These clamps are not adjustable and must be replaced when they become loose.

  • Page 28: Yamaha Power Valve System (Y.p.v.s.) Adjustment

    INSP YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) ADJUSTMENT YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) ADJUSTMENT WARNING When adjusting the valve clearance, do not oper- ate the engine. 1. Remove: • Y.P.V.S. valve assembly 1 SDN2250 2. Adjust: • Y.P.V.S. SDN2255 Adjustment steps: •...

  • Page 29: Yamaha Power Valve System (Y.p.v.s.) Pre-Season Checks

    INSP YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) ADJUSTMENT/ YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) PRE-SEASON CHECKS • Loosen the bolts A. Y.P.V.S. valve clearance a: 2.0 ~ 3.5 mm (0.08 ~ 0.14 in) Turning in → Clearance a is increased. Turning out → Clearance a is decreased.
  • Page 30 • If the valve is stuck, inspect it and then either remove any carbon or reassemble the valve, refer to the “YAMAHA POWER VALVE SYSTEM (Y.P.V.S.)” in CHAPTER 5. • If the valve is not stuck, but the water temperature indicator light remains lit, refer to the “FAULT LOCATION TABLE”...

  • Page 31: Power Train

    INSP SHEAVE DISTANCE AND OFFSET ADJUSTMENT POWER TRAIN SHEAVE DISTANCE AND OFFSET ADJUSTMENT 1. Open the shroud 2. Remove: • Drive V-belt guard • Drive V-belt 3. Remove: • Exhaust pipe #1 (L), #2, #3 (R) Refer to “EXHAUST ASSEMBLY” in CHAP- TER 5.
  • Page 32 INSP SHEAVE DISTANCE AND OFFSET ADJUSTMENT 7. Adjust: • Sheave distance Adjustment steps: • Loosen the engine mounting bolts. • Adjust the position of the engine so that the sheave distance is within the specification. • Tighten the engine mounting bolts. SDN2340 Mounting bolt 1: 50 Nm (5.0 m •...

  • Page 33: Drive V-Belt

    INSP DRIVE V-BELT DRIVE V-BELT WARNING When installing the new V-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to –0.5 mm (–0.020 in) below the edge a. If the V-belt is not positioned correctly, the clutch engagement speed will be changed.
  • Page 34 INSP DRIVE V-BELT 2. Adjust the position of the V-belt by removing or adding a spacer 1 on each adjusting bolt 2. V-belt position Adjustment More than 1.5 mm (0.06 in) above the Remove a spacer edge From 1.5 mm (0.06 in) above the edge to –...

  • Page 35: Engagement Speed Check

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

  • Page 36: Brake Lever Adjustment

    INSP BRAKE LEVER ADJUSTMENT BRAKE LEVER ADJUSTMENT 1. Adjust: • Brake lever position (distance from the grip to the brake lever) Adjustment steps: • Loosen the locknut 1. • While lightly pushing the brake lever in direc- tion a, turn the adjusting bolt 2 by fingers to SDN2480 set the brake lever to the desired position.

  • Page 37: Brake Fluid Level Inspection

    BRAKE FLUID LEVEL INSPECTION/ INSP BRAKE PAD INSPECTION BRAKE FLUID LEVEL INSPECTION 1. Place the machine on a level surface. 2. Check: • Fluid level Fluid level is under the “LOWER” level line a → Fill to the proper level. Recommended brake fluid: DOT 4 SDN2490...

  • Page 38: Brake Hose Inspection

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

  • Page 39: Drive Chain

    AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP DRIVE CHAIN NOTE: If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. •...
  • Page 40 INSP DRIVE CHAIN CAUTION: There is a magnet attached to the end of the dipstick. It is used to remove any metal particles that may accumulate in the drive chain housing. Be sure to: • Pull the dipstick out slowly and gently so the metal particles do not fall off the magnet back into the drive chain housing.
  • Page 41 INSP DRIVE CHAIN • Install the oil drain bolt. Oil drain bolt: 16 Nm (1.6 m • kg, 11 ft • lb) Recommended oil: Gear oil API “GL-3” SAE #75 or #80 Oil capacity: 0.25 L (8.8 Imp oz, 8.5 US oz) Chain slack adjustment 1.

  • Page 42: Track Tension Adjustment

    INSP TRACK TENSION ADJUSTMENT TRACK TENSION ADJUSTMENT WARNING A broken track or track fittings, and 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.

  • Page 43: Slide Runner Inspection

    TRACK TENSION ADJUSTMENT/ INSP SLIDE RUNNER INSPECTION a. Start the engine and rotate the track once or twice. Stop the engine. b. Check the track alignment with the slide run- ner 3. If the alignment is incorrect, turn the left and right adjusters to adjust.

  • Page 44: Chassis

    INSP SKI/SKI RUNNER/STEERING SYSTEM CHASSIS SKI/SKI RUNNER 1. Inspect: • • Ski runner Damage/wear → Replace. Ski runner wear limit a: 8 mm (0.31 in) SDN2640 Plastic ski wear limit b: 8 mm (0.31 in) CAUTION: To avoid scratching, wearing and damaging the plastic skis, be careful when loading and unload- ing the snowmobile and avoid riding in areas with little or no snow and on surfaces with sharp...
  • Page 45 INSP STEERING SYSTEM/LUBRICATION 3. Adjust: • Ski toe-out Adjustment steps: • Loosen the locknuts (tie-rod) 1. • Turn the tie rod 2 in or out until the specified toe-out is obtained. • Tighten the locknuts (tie-rod) 1. SDN2680 Locknut (rod end) 1: 25 Nm (2.5 m •...

  • Page 46: Lubrication

    INSP LUBRICATION LUBRICATION Brake lever, throttle lever and throttle cable end 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables. Recommended lubricant: ESSO Beacon 325 Grease WARNING SDN2700 Apply a dab of grease onto only the end of the cables.

  • Page 47: Electrical

    INSP HEADLIGHT BEAM ADJUSTMENT ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Place the machine in front of a wall at the recommended distance D. Refer to the table below. SDN2740 3. Measure the distance H from the floor to the center of the headlight and place a mark on the wall at that height.

  • Page 48: Tuning

    INSP CARBURETOR TUNING TUNING CARBURETOR TUNING The carburetors are set at the factory to run at temperatures of 0°C ~ –20°C (32°F ~ –4°F) at sea level. If the machine is to be operated under conditions other than those specified above, the carburetors must be properly adjusted.
  • Page 49 NOTE: These jetting specifications are subject to change. Consult the latest technical information from Yamaha to be sure you have the most up-to-date jetting specifications. Clip Jet needle Pilot mixture screw Main jet...
  • Page 50 INSP CARBURETOR TUNING Guide for carburetion SDN2780 2-37...
  • Page 51 INSP CARBURETOR TUNING Standard main jet Main jet whose diameter is 10% smaller than standard Main jet whose diameter is 10% larger than standard SDN2790 position position position SDN2800 CAUTION: If the air silencer box is removed from the carbu- retors, the change in pressure in the intake will create a lean mixture that may cause severe engine damage.
  • Page 52 INSP CARBURETOR TUNING Low-speed tuning The carburetors are built so that low speed tuning can be done by adjusting the pilot mixture screw 1 and throttle stop screw 2. CAUTION: Never run the engine without the air intake si- lencer installed. Severe engine damage may re- sult.
  • Page 53 INSP CARBURETOR TUNING Main jet selection chart Spark plug color Diagnosis Remedy Light tan or gray Carburetors are tuned properly. Dry black or fluffy Mixture is too rich. Replace the main jet with the next smaller deposits size. White or light gray Mixture is too lean.
  • Page 54 INSP CARBURETOR TUNING Trouble Diagnosis Adjustment • Remove the pilot jet, clean it with compressed air, Poor performance at Clogged or loose pilot mid-range speeds: and then install it. • Momentary slow re- • Make sure that the pilot jet is fully tightened. sponse to the throt- •...

  • Page 55: Clutch

    INSP CLUTCH CLUTCH G Green High altitude W White Yellow Specifications Model: SRX700/SRX700S Å Elevation ~ 800 m 900 ~1,500 m 1,400 ~ 2,100 m 2,000 ~ 3,000 m 2,400 m ~ (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ft ~) ←...
  • Page 56 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shift- ing speeds. Clutch engagement speed is defined as the en- gine speed at which the machine first begins to move from a complete stop.

  • Page 57: Gear Selection

    INSP GEAR SELECTION 1 Chain and sprocket part number Å Part name ı Teeth & links Ç Part no. Î Standard 20 teeth 8DW-17682-00 21 teeth 8DW-17682-10 ‰ Drive sprocket 22 teeth 8DW-17682-20 23 teeth SRX700/SRX700S 8DW-17682-30 37 teeth 8DW-47587-70 Ï...
  • Page 58 INSP GEAR SELECTION 5 Torque cam (secondary spring seat) SDN2850 ı Effects Ç Part no. Î Cam angle ‰ Identification mark Ï Standard 8BV-17604-71 8BV71 SRX700/SRX700S 47° 8BV-17604-51 45° 8BV51 8BV-17604-31 43° 8BV31 8BV-17604-11 41° 8BV11 8BV-17604-91 39° 8BV91 2-45...
  • Page 59 INSP GEAR SELECTION 6 Primary spring SDN2860 ‰ Ï Ó È Ô Î Spring rate Preload Wire Outside Free Ò Standard Ì Color No. of Parts No. N/mm N/mm gauge diameter length coils (kg/mm) (kg) mm (in) mm (in) mm (in) 90501-551L3 19.6 (2.0) 294 (30)
  • Page 60 INSP GEAR SELECTION 7 Clutch weights Å Standard 8CH-17605-10 35.32 g SDN2900 8CR-17605-10 38.09 g SDN2890 8DF-17605-10 37.84 g SDN2910 8DG-17605-00 39.26 g SDN2940 8DJ-17605-00 37.77 g SDN2930 8DN-17605-20 42.09 g SRX700 SRX700S SDN2950 2-47...
  • Page 61 INSP GEAR SELECTION 8 Rollers I.D. 9 mm (0.4 in) Å ROLLER with ı OUTSIDE Ç BUSHING Î IDENTIFICATION ‰ Standard Ï EFFECTS BUSHING PART DIAMETER TYPE (P/N) MARK (Width) NUMBER 8CR-17624-00-00 14.5 mm Duralon (0.57 in) 90380-09245-00 8CR-17624-10-00 15.0 mm Duralon (0.59 in) 90380-09245-00...

  • Page 62: High Altitude Tuning

    INSP HIGH ALTITUDE TUNING HIGH ALTITUDE TUNING To attain the best performance in high altitude conditions, carefully tune the snowmobile as outlined below. Check STD settings • Carburetors • Spark plugs Adjust the main jet size according to the chart Test the main jet Not OK Adjust the size of the main jet...

  • Page 63: Front Suspension

    INSP FRONT SUSPENSION FRONT SUSPENSION Spring preload 1. Adjust: • Spring preload Adjustment steps: • Turn the spring seat 1 in or out. Standard Spring seat SDN2A10 Shorter ← → Longer distance Harder ← → Softer Preload Min. Max. a Length 213 mm 223 mm 233 mm...
  • Page 64 INSP FRONT SUSPENSION Damping force (SRX700S) 1. Adjust: • Damping force Adjustment steps: • Turn the adjusting screw 1 in or out with the adjusting screwdriver 2. Standard 8 Clicks out* SDN2A30 1 Click out* (turns in a) Minimum (hard) 16 Clicks out* (turns out b) Maximum (soft) * From the fully turned-in position...

  • Page 65: Rear Suspension

    INSP REAR SUSPENSION REAR SUSPENSION Stopper band 1. Adjust: • Stopper band tension CAUTION: Make sure the left and right sides of the rear suspension stopper band are adjusted evenly. NOTE: This adjustment affects the handling characteris- tics of the machine. Adjustment steps: •...
  • Page 66 INSP REAR SUSPENSION Spring preload 1. Adjust: • Spring preload Adjustment steps: • Turn the spring seat 1 in or out. Spring seat Standard Shorter ← → Longer distance Harder ← → Softer Preload SDN2A50 Min. Max. Å Length a 180 mm 190 mm 200 mm...
  • Page 67 INSP REAR SUSPENSION Rear suspension-full rate 1. Adjust: • Full rate adjuster Adjustment steps: Installation position Spring rate Soft Medium Hard and damping Standard NOTE: Be sure to make this adjustment when there is no SDN2A70 load (rider or cargo) on the snowmobile. •...
  • Page 68 INSP REAR SUSPENSION This model has a “Easy adjust” system for the Full rate adjuster. The bolt has teeth on it. So when the bolt is turned, it rides up and down the bracket. NOTE: • The nut has to be loosen first, while the bolt is held in place with a wrench.

  • Page 69: Chapter 3. Chassis

    CHAS STEERING CHASSIS STEERING Å 15 Nm (1.5 m • kg, 11 ft • lb) SDN3010 Order Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Handlebar removal Handlebar cover Plastic band Oil tank breather hose Disconnect.
  • Page 70 CHAS STEERING Å 23 Nm (2.3 m • kg, 17 ft • lb) ı 25 Nm (2.5 m • kg, 18 ft • lb) Ç 35 Nm (3.5 m • kg, 25 ft • lb) Î 42 Nm (4.2 m • kg, 30 ft • lb) ‰...

  • Page 71: Inspection

    CHAS STEERING INSPECTION 1. Inspect: • Handlebar 1 • Steering column 2 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent column. This may dangerously weaken the column. SDN3030 2. Inspect: • Bearings (steering column) 1 • Collars 2 Wear/damage →...

  • Page 72: Installation

    CHAS STEERING INSTALLATION 1. Install: • Bushings 1 NOTE: Mount the bushing with clearance a to the end of the relay arm 2. a Approx. 1 mm (0.04 in) SDN3080 2. Install: • Tie rods 1 NOTE: • Make sure that the indentation a on the tie rod faces out.
  • Page 73 CHAS STEERING 4. Adjust: • Skis Adjustment steps: • Temporarily install the handlebar. • Hold the handlebar straight and check that the skis are at right angles to the handlebar. • Loosen the locknuts (relay rod) 1. • Position the skis parallel in the riding direc- tion.

  • Page 74: Ski

    CHAS Å 11 Nm (1.1 m • kg, 8.0 ft • lb) ı 21 Nm (2.1 m • kg, 15 ft • lb) ç 48 Nm (4.8 m • kg, 35 ft • lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SDN3150 Order...

  • Page 75: Inspection

    CHAS INSPECTION 1. Inspect: • Ski 1 • Ski runner 2 • Ski stopper 3 • Ski column lower bracket 4 • Ski handle 5 Wear/cracks/damage → Replace. • Mounting bolt 6 • Collar 7 • Bolts 8 Wear/damage → Replace. SDN3160...

  • Page 76: Front Suspension

    CHAS FRONT SUSPENSION FRONT SUSPENSION Å 23 Nm (2.3 m • kg, 17 ft • lb) ı 42 Nm (4.2 m • kg, 30 ft • lb) Ç 48 Nm (4.8 m • kg, 35 ft • lb) Î 50 Nm (5.0 m • kg, 36 ft • lb) ‰...

  • Page 77: Inspection

    CHAS FRONT SUSPENSION HANDLING NOTES WARNING This shock absorber contains highly compressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper han- dling.
  • Page 78 CHAS FRONT SUSPENSION 4. Inspect: • Connecting rod 1 • Stabilizer 2 Cracks/bends/damage → Replace. • Collar 3 Wear/scratches/damage → Replace. SDN3210 5. Inspect: • Front arm 1 Cracks/bends/damage → Replace. SDN3220 3-10...

  • Page 79: Installation

    CHAS FRONT SUSPENSION INSTALLATION 1. Install: • Control rod 1 • Nut 2 • Joint 3 a Set length Å Left hand Ç Ì ı Set length color SDN3230 a (mm) angle (˚) 460.2 ± 0.5 mm 94 ± 1 ‰...
  • Page 80 CHAS FRONT SUSPENSION Ski spindle camber Place the unit on a level surface and check the ski spindle camber. DO NOT elevate the front end. 1 Using an angle finder, be sure that the unit sits parallel with the floor. Place the angle finder up against the flat aluminum part of the belly pan.
  • Page 81 CHAS FRONT SUSPENSION 4 Install the radius rod onto the trailing arm and tighten the bolt. Tighten the ball joint locknut and apply grease to the ball joint. Repeat the procedure for the other side. SDN3280 CAUTION: When tightening the ball joint locknut, be sure to keep the ball joint outer housing centered with the ball to prevent binding.

  • Page 82: Chapter 4. Power Train

    POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT Å : 1st 120 Nm (12.0 m • kg, 85 ft • lb) 2nd 60 Nm (6.0 m • kg, 43 ft • lb) SDN4010 Order Job name/Part name Q’ty Remarks Primary sheave removal...
  • Page 83 POWR PRIMARY SHEAVE AND DRIVE V-BELT Å 3 Nm (0.3 m • kg, 2.2 ft • lb) ı 6 Nm (0.6 m • kg, 4.3 ft • lb) Ç 14 Nm (1.4 m • kg, 10 ft • lb) Î 200 Nm (20 m •...

  • Page 84: Removal

    POWR PRIMARY SHEAVE AND DRIVE V-BELT REMOVAL 1. Remove: • Primary sheave assembly 1 NOTE: Use the primary sheave holder 2 and primary sheave puller 3. Primary sheave holder: SDN4030 90890-01701, YS-01880 Primary sheave puller: YS-01881-1, YS-01882-1 DISASSEMBLY 1. Remove: •...

  • Page 85: Inspection

    POWR PRIMARY SHEAVE AND DRIVE V-BELT CAUTION: • The spider has a left-handed thread. • Since a high torque is required to loosen the spider, make sure that the spider, fixed sheave and special tool are well secured. Loosen the spider carefully to prevent cracks and damage to the sheaves and spider.
  • Page 86 POWR PRIMARY SHEAVE AND DRIVE V-BELT 5. Inspect: • Weight 1 • Roller 2 • Bushing 3 • Slider 4 • Rivet 5 • Collar Wear/scratches/damage → Replace. SDN4110 Slider inside clearance Min. 0 mm (0 in) Max. 0.3 mm (0.0118 in) Rivet replacement steps: •...

  • Page 87: Assembly

    POWR PRIMARY SHEAVE AND DRIVE V-BELT ASSEMBLY 1. Install: • Sliding sheave (onto the spider) NOTE: Be sure the sliding sheave match mark (X) is aligned with the spider match mark (X). SDN4150 2. Install: • Fixed sheave (onto the spider) NOTE: ®...
  • Page 88 POWR PRIMARY SHEAVE AND DRIVE V-BELT • Tighten the spider to specification using the bar wrench 3. Spider: 200 Nm (20 m • kg, 145 ft • lb) CAUTION: The spider has a left-handed thread. SDN4190 WARNING • Do not operate the primary sheave until the ®...

  • Page 89: Installation

    POWR PRIMARY SHEAVE AND DRIVE V-BELT INSTALLATION 1. Install: • Primary sheave assembly CAUTION: Be sure to remove any oil or grease from the tapered portion of the crankshaft and spider using a cloth dampened with thinner. SDN4220 2. Apply: •...

  • Page 90: Secondary Sheave

    POWR SECONDARY SHEAVE SECONDARY SHEAVE Å 64 Nm (6.4 m • kg, 46 ft • lb) SDN4250 Order Job name/Part name Q’ty Remarks Secondary sheave removal Remove the parts in the order listed below. V-belt Washer Shim – Refer to “SHEAVE DISTANCE AND OFFSET ADJUSTMENT”...
  • Page 91 POWR SECONDARY SHEAVE Å 4 Nm (0.4 m • kg, 2.9 ft • lb) ı 6.5 Nm (0.65 m • kg, 4.6 ft • lb) Ç 10 Nm (1.0 m • kg, 7.2 ft • lb) Î 23 Nm (2.3 m • kg, 17 ft • lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SDN4260...

  • Page 92: Disassembly

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

  • Page 93: Assembly

    POWR SECONDARY SHEAVE 5. Measure: • Ramp shoe thickness a Out of specification → Replace the ramp shoe. Wear limit a: 1.0 mm (0.04 in) SDN4310 ASSEMBLY 1. Install: • Stopper • Sliding sheave Screw (stopper): 6.5 Nm (0.65 m • kg, 4.6 ft • lb) 2.
  • Page 94 POWR SECONDARY SHEAVE Installation steps: • Hold the spring seat 1 and turn the fixed sheave 2 counterclockwise to the specified angle a. NOTE: The holes in the spring seat should align with the bolts on the sliding sheave. SDN4340 a = (sheave hole number + spring seat hole number) ×...

  • Page 95: Installation

    • Measure the secondary sheave clearance again. Repeat these steps until the clearance is within specification. SDN4370 NOTE: Yamaha recommends keeping the original shims. Shims: Part number Thickness 90201-061H1 0.5 mm (0.02 in) 90201-06037 1.0 mm (0.04 in) INSTALLATION 1.

  • Page 96: Drive Chain Housing

    POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING Å 16 Nm (1.6 m • kg, 11 ft • lb) ı 24 Nm (2.4 m • kg, 17 ft • lb) Ç 48 Nm (4.8 m • kg, 35 ft • lb) Î...

  • Page 97: Inspection

    POWR DRIVE CHAIN HOUSING INSPECTION 1. Inspect: • Drive chain housing 1 • Drive chain housing cover 2 Cracks/damage → Replace. • Oil seals (drive chain housing) Wear/damage → Replace. • Bearings (drive chain housing and cover) 3 Pitting/damage → Replace. SDN4390 •...
  • Page 98 POWR DRIVE CHAIN HOUSING 3. Measure: • 14 link section a of the drive chain 1 2 3 4 5 6 7 8 9 0 A B C D E Using a spring scale, pull on the drive chain with 36 kg (80 lbs) of force b. Out of specification →...

  • Page 99: Installation

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

  • Page 100: Jackshaft

    POWR JACKSHAFT JACKSHAFT Å 8.5 Nm (0.85 m • kg, 6.1 ft • lb) ı 23 Nm (2.3 m • kg, 17 ft • lb) SDN4440 Job name/Part name Order Q’ty Remarks Jackshaft removal Remove the parts in the order listed below. Secondary sheave Refer to “SECONDARY SHEAVE”.

  • Page 101: Inspection

    POWR JACKSHAFT INSPECTION 1. Inspect: • Jackshaft 1 Scratches (excessive)/damage → Replace. • Splines 2 Wear/damage → Replace the jackshaft. • Bearing contact surface 3 Scratches/wear/damage → Replace the jackshaft. SDN4450 2. Inspect: • Bearing holder 1 Cracks/damage → Replace. •...

  • Page 102: Jackshaft And Drive Chain Housing Installation

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

  • Page 103: Brake

    POWR BRAKE BRAKE Å 6 Nm (0.6 m • kg, 4.3 ft • lb) ı 48 Nm (4.8 m • kg, 35 ft • lb) SDN4490 Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring...

  • Page 104: Brake Pad Replacement

    POWR BRAKE CAUTION: Disc brake components rarely require disassem- bly. DO NOT: • Do not disassemble components unless abso- lutely necessary. • Do not use solvents on internal brake compo- nents. • Do not use contaminated brake fluid for clean- ing.
  • Page 105 POWR BRAKE 2. Install: • Brake pads • Pad spring Installation steps: • Connect a suitable hose 1 tightly to the cali- per bleed screw 2. Put the other end of this hose into an open container. • Loosen the caliper bleed screw and push the SDN4520 pistons into the caliper with your finger.
  • Page 106 POWR BRAKE Å 10 Nm (1.0 m • kg, 7.2 ft • lb) ı 23 Nm (2.3 m • kg, 17 ft • lb) Ç 48 Nm (4.8 m • kg, 35 ft • lb) SDN4540 Order Job name/Part name Q’ty Remarks Brake caliper and parking brake re-...
  • Page 107 POWR BRAKE SDN4550 Job name/Part name Order Q’ty Remarks Brake caliper disassembly Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring Brake pad Shim 1 Shim 2 Bleed screw Oil seal Piston For assembly, reverse the disassembly pro- cedure.

  • Page 108: Brake Caliper Disassembly

    POWR BRAKE BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: • Pistons SDN4560 • Piston oil seals 1 Removal steps: • Using a wood of piece 2, lock the right piston.

  • Page 109: Brake Caliper Assembly

    POWR BRAKE 1. Inspect: • Caliper piston 1 Scratches/rust/wear → Replace the caliper assembly. • Caliper cylinder 2 Wear/scratches → Replace the caliper as- sembly. • Caliper body 3 Cracks/damage → Replace. SDN4590 • Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and dust seals whenever a caliper is disassembled.
  • Page 110 POWR BRAKE Å 14 Nm (1.4 m • kg, 10 ft • lb) ı 30 Nm (3.0 m • kg, 22 ft • lb) SDN4610 Job name/Part name Order Q’ty Remarks Brake master cylinder removal Remove the parts in the order listed below. Brake fluid Drain.

  • Page 111: Inspection

    POWR BRAKE INSPECTION 1. Inspect: • Master cylinder 1 Wear/scratches → Replace the master cyl- inder assembly. • Master cylinder body 2 Cracks/damage → Replace. • Oil delivery passage (master cylinder body) Blow out with compressed air. SDN4620 2. Inspect: •...

  • Page 112: Slide Rail Suspension

    POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION Å 72 Nm (7.2 m • kg, 52 ft • lb) SDN4650 Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Tension adjuster Loosen. Blind cap Suspension rear plate Slide rail suspension...
  • Page 113 POWR SLIDE RAIL SUSPENSION Å 4 Nm (0.4 m • kg, 2.9 ft • lb) ı 16 Nm (1.6 m • kg, 11 ft • lb) Ç 24 Nm (2.4 m • kg, 17 ft • lb) Î : 30 Nm (3.0 m • kg, 22 ft • lb) ‰...
  • Page 114 POWR SLIDE RAIL SUSPENSION Å 24 Nm (2.4 m • kg, 17 ft • lb) ı 49 Nm (4.9 m • kg, 35 ft • lb) Ç 72 Nm (7.2 m • kg, 52 ft • lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SDN4670 Order...
  • Page 115 POWR SLIDE RAIL SUSPENSION Å 49 Nm (4.9 m • kg, 35 ft • lb) ı 72 Nm (7.2 m • kg, 52 ft • lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SDN4680 Job name/Part name Order Q’ty Remarks...
  • Page 116 POWR SLIDE RAIL SUSPENSION Å 24 Nm (2.4 m • kg, 17 ft • lb) ı 72 Nm (7.2 m • kg, 52 ft • lb) Ç 75 Nm (7.5 m • kg, 54 ft • lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SDN4690 Order...

  • Page 117: Inspection

    POWR SLIDE RAIL SUSPENSION INSPECTION 1. Inspect: • Suspension wheel • Guide wheel Cracks/damage → Replace. • Wheel bearing Wheel turns roughly → Replace. SDN4700 2. Inspect: • Stopper band 1 Frayed/damage → Replace. • Pull rod 2 Bends/damage → Replace. •...

  • Page 118: Front Axle And Track

    POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK Å 8 Nm (0.8 m • kg, 5.8 ft • lb) ı 20 Nm (2.0 m • kg, 14 ft • lb) SDN4730 Job name/Part name Q’ty Remarks Order Front axle and track removal Remove the parts in the order listed below.

  • Page 119: Inspection

    POWR FRONT AXLE AND TRACK INSPECTION 1. Inspect: • Track 1 • Slide metal 2 Wear/cracks/damage → Replace. SDN4740 2. Inspect: • Sprocket wheel 1 Wear/break/damage → Replace. • Front axle 2 Bends/scratches (excessive)/damage → Replace. SDN4750 INSTALLATION 102 mm 123 mm 102 mm (4.02 in)

  • Page 120: Exhaust Assembly

    EXHAUST ASSEMBLY ENGINE EXHAUST ASSEMBLY Å 13 Nm (1.3 m • kg, 9.4 ft • lb) ı 15 Nm (1.5 m • kg, 11 ft • lb) Ç 16 Nm (1.6 m • kg, 11 ft • lb) SDN5010 Order Job name/Part name Q’ty Remarks...
  • Page 121 EXHAUST ASSEMBLY Å 13 Nm (1.3 m • kg, 9.4 ft • lb) ı 15 Nm (1.5 m • kg, 11 ft • lb) Ç 16 Nm (1.6 m • kg, 11 ft • lb) SDN5020 Order Job name/Part name Q’ty Remarks Gasket 1...

  • Page 122: Removal

    EXHAUST ASSEMBLY REMOVAL 1. Remove: • Exhaust pipe joint #1 (L) • Exhaust pipe joint #2 • Exhaust pipe joint #3 (R) NOTE: Put identification marks on each exhaust pipe joint for reference during reinstallation. SDN5023 INSTALLATION 1. Install: • Exhaust pipe joint #3 (R) •...
  • Page 123 EXHAUST ASSEMBLY Å When installing springs 4, 6 and 9, the longer hook should face forward. ı When installing spring 2, the longer hook should face upward. Ç Install the spring 1 with the hook pulling from the top. SDN5030...

  • Page 124: Engine Assembly

    Remove the parts in the order listed below. Exhaust assembly Refer to “EXHAUST ASSEMBLY”. Carburetors Refer to “CARBURETORS” in CHAPTER 7. Y.P.V.S. Refer to “YAMAHA POWER VALVE SYSTEM (Y.P.V.S.)”. Recoil starter Refer to “RECOIL STARTER”. AC magneto Refer to “AC MAGNETO”.

  • Page 125: Inspection

    ENGINE ASSEMBLY INSPECTION 1. Inspect: • Rear bracket (right) 1 Cracks/damage → Replace. SDN5050 INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Be sure to fasten the oil pump cable 1 with SDN5060 the cable holder 2 on the ignition coil bracket.

  • Page 126: Cylinder Head And Cylinder

    CYLINDER HEAD AND CYLINDER CYLINDER HEAD AND CYLINDER Å : 14 Nm (1.4 m • kg, 10 ft • lb) SDN5070 Order Job name/Part name Q’ty Remarks Cylinder head and cylinder removal Remove the parts in the order listed below. Spark plug cap Cable holder Outlet water jacket joint...
  • Page 127 CYLINDER HEAD AND CYLINDER Å Ç 14 Nm (1.4 m • kg, 10 ft • lb) 33 Nm (3.3 m • kg, 24 ft • lb) ı 20 Nm (2.0 m • kg, 14 ft • lb) 13 Nm (1.3 m • kg, 9.4 ft • lb) Î...

  • Page 128: Removal

    CYLINDER HEAD AND CYLINDER REMOVAL 1. Remove: • Piston pin clip • Piston pin • Piston • Small end bearing NOTE: • Before removing the piston pin clip, cover the SDN5090 crankcase with a clean rag so that you will not accidentally drop the clip into the crankcase.

  • Page 129: Inspection

    CYLINDER HEAD AND CYLINDER INSPECTION 1. Eliminate: • Carbon deposits (from the combustion chamber) Use the rounded scraper 1. CAUTION: Do not use a sharp instrument. Avoid damaging or scratching the surface. SDN5110 2. Inspect: • Cylinder head water jacket Crust of minerals/rust →...
  • Page 130 CYLINDER HEAD AND CYLINDER 7. Eliminate: • Score marks and lacquer deposits (from the piston wall) Use 600 ~ 800 grit wet sandpaper. NOTE: Sand in a crisscross pattern. Do not sand exces- sively. SDN5150 8. Measure: • Piston-to-cylinder clearance Measurement steps: 1st step: •...
  • Page 131 CYLINDER HEAD AND CYLINDER Piston size (standard) (P): 68.944 ~ 68.947 mm (2.7143 ~ 2.7144 in) • If out of specification, replace the piston and piston rings as a set. 3rd step: • Calculate the piston-to-cylinder clearance with the following formula: Piston-to-cylinder clearance = Cylinder bore (C) –...
  • Page 132 CYLINDER HEAD AND CYLINDER 10. Install: • Piston ring (into the cylinder) Push in the ring with the piston crown. NOTE: Insert the ring into the cylinder, and push it ap- proximately 20 mm (0.8 in) into the cylinder. Push in the ring with the piston crown so that the ring SDN5200 is at right angles to the cylinder bore.
  • Page 133 CYLINDER HEAD AND CYLINDER 14. Inspect: • Reed valves 1 Bends/cracks/damage → Replace. SDN5240 15. Measure: • Valve stopper height a Out of specification → Replace the valve stopper. Valve stopper height a: 10.3 ~ 10.7 mm (0.41 ~ 0.42 in) SDN5250 16.

  • Page 134: Installation

    CYLINDER HEAD AND CYLINDER INSTALLATION 1. Install: • Reed valves • Reed valve stoppers NOTE: • Place the reed valve 1 with its concave surface facing toward the reed valve seat 2. • Fit the reed valve stopper cut a into the corre- sponding cut b on the reed valve.
  • Page 135 CYLINDER HEAD AND CYLINDER 5. Check: • Piston ring position CAUTION: • Make sure that the ring ends are properly fitted around the ring locating pins in the piston grooves. • Be sure to check that the manufacturer’s marks or numbers stamped on the rings face upward. SDN5320 6.
  • Page 136 CYLINDER HEAD AND CYLINDER 9. Connect: • Ignition coil leads Ignition coil #1 Black/White lead → Sub-wire harness Orange lead Ignition coil #2 Black/White lead → Sub-wire harness Gray lead Ignition coil #3 Black/White lead → Sub-wire harness White lead Ignition coil #1, #2, #3 Black lead →...

  • Page 137: Oil Pump, Crankcase And Crankshaft

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

  • Page 138: Inspection

    OIL PUMP, CRANKCASE AND CRANKSHAFT INSPECTION 1. Measure: • Runout Use the V-blocks and a dial gauge. Out of specification → Replace or repair the crankshaft. Dial gauge: 90890-03097, YU-03097 SDN5370 Runout limit: : 0.03 mm (0.0012 in) : 0.04 mm (0.0016 in) : 0.03 mm (0.0012 in) 89.5 mm (3.52 in) 84.5 mm (3.33 in)
  • Page 139 OIL PUMP, CRANKCASE AND CRANKSHAFT 4. Inspect: • Lower crankcase 1 • Upper crankcase 2 • Front lower brackets 3 • Front upper brackets 4 • Rear bracket 5 • Dampers 6 Cracks/damage → Replace. SDN5400 5. Inspect: SDN5410 • Impeller driven gear teeth 1 Wear/damage →...

  • Page 140: Installation

    OIL PUMP, CRANKCASE AND CRANKSHAFT INSTALLATION 1. Install: • Stopper rings 1 (onto the lower crankcase bearing 2 as shown) Knock pin SDN5430 2. Install: • Crankshaft assembly (onto the upper crankcase Å) NOTE: Turn the bearings and labyrinth seal to set the knock pins 1 on the bearings and labyrinth seal into the pin holes 2 in the upper crankcase Å.
  • Page 141 OIL PUMP, CRANKCASE AND CRANKSHAFT 3. Fill: • Gear room 1 Recommended oil: YAMALUBE 2-cycle Gear room capacity: 25 cm (0.81 Imp oz, 0.77 US oz) SDN5470 CAUTION: Before installing and torquing the crankcase bolts, be sure to check that the crankshaft turns smoothly.

  • Page 142: Ac Magneto

    AC MAGNETO AC MAGNETO Å 23 Nm (2.3 m • kg, 17 ft • lb) ı 110 Nm (11.0 m • kg, 80 ft • lb) SDN5510 Order Job name/Part name Q’ty Remarks AC magneto removal Remove the parts in the order listed below. Recoil starter Refer to “RECOIL STARTER”.

  • Page 143: Removal

    AC MAGNETO REMOVAL 1. Remove: • Bolts 1 • Starter pulley 2 • Nut 3 NOTE: Attach the primary sheave holder to hold the primary sheave. SDN5520 Primary sheave holder: 90890-01701, YS-01880 2. Remove: • Magneto rotor 1 NOTE: • Remove the magneto rotor using the rotor puller 2.

  • Page 144: Installation

    AC MAGNETO INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in CHAPTER 9, to check the cable, lead and hose routings. 1. Install: • Woodruff key 1 CAUTION: Be sure to remove any oil or grease from the tapered portion of the crankshaft using a cloth dampened with thinner.
  • Page 145 AC MAGNETO 4. Install: • Stator coil NOTE: • Pass the pickup coil lead 1 under the pickup coil 2 as shown. • Install the holder so that the side with notches a faces outward. SDN5560 5-26...

  • Page 146: Recoil Starter

    RECOIL STARTER RECOIL STARTER Å 18 Nm (1.8 m • kg, 13 ft • lb) ı 23 Nm (2.3 m • kg, 17 ft • lb) Ç 48 Nm (4.8 m • kg, 35 ft • lb) ı 9 10 Å...

  • Page 147: Removal

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

  • Page 148: Installation

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

  • Page 149: Yamaha Power Valve System (Y.p.v.s.)

    YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) Å 6.5 Nm (0.65 m • kg, 4.7 ft • lb) ı 11 Nm (1.1 m • kg, 8.0 ft • lb) SDN5650 Order Job name/Part name Q’ty Remarks YAMAHA POWER VALVE SYSTEM Remove the parts in the order listed below.
  • Page 150 YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) Å 7 Nm (0.7 m • kg, 5.1 ft • lb) ı 8 Nm (0.8 m • kg, 5.8 ft • lb) : 1 ESSO beacon 325 grease or Aeroshell grease #7A SDN5660 Order Job name/Part name Q’ty...

  • Page 151: Removal

    YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) REMOVAL 1. Remove: • Y.P.V.S. valve assembly NOTE: Put identification marks on each valve for refer- ence during reinstallation. SDN5670 INSPECTION 1. Eliminate: • Carbon deposit (from the valve) Use the rounded scraper 1. CAUTION: Do not use a sharp instrument.

  • Page 152: Installation

    YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) 3. Install: • Valve housing 1 NOTE: Align the projection a on valve housing 1 with the projection b on valve housing 2. SDN5720 4. Install: • Y.P.V.S. cables Refer to the illustrations. Cable Installation Position...
  • Page 153 YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) 2. Install: • Y.P.V.S. valve assembly NOTE: • Position each valve very carefully in its original place. • The projection a on the Y.P.V.S. valve assem- bly should face upward. • Refer to page 2-15 ~ 2-16 for proper Y.P.V.S.

  • Page 154: Heat Exchanger

    COOL HEAT EXCHANGER COOLING SYSTEM HEAT EXCHANGER SDN6010 Order Job name/Part name Q’ty Remarks Heat exchanger removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAP- TER 2. Coolant filler cap Coolant reservoir tank Coolant hose 1 Coolant hose 2 Joint pipe...

  • Page 155: Inspection

    COOL HEAT EXCHANGER INSPECTION 1. Inspect: • Coolant hoses 1 • Heat exchangers 2 • Joint pipe 3 • Coolant reservoir tank 4 • Carburetor heating hoses 5 Cracks/damage → Replace. SDN6020 2. Measure: • Filler cap opening pressure Cap opens with a pressure below the speci- fied pressure →...

  • Page 156: Water Pump

    COOL WATER PUMP WATER PUMP Å 10 Nm (1.0 m • kg, 7.2 ft • lb) ı 13 Nm (1.3 m • kg, 9.4 ft • lb) SDN6040 Order Job name/Part name Q’ty Remarks Water pump removal Remove the parts in the order listed below. Exhaust pipe Refer to “EXHAUST ASSEMBLY”...

  • Page 157: Removal

    COOL WATER PUMP REMOVAL 1. Remove: • Impeller 1 NOTE: Attach the primary sheave holder to hold the primary sheave. Primary sheave holder: SDN6050 90890-01701, YS-01880 INSPECTION 1. Inspect: • Impeller 1 • Water pump cover 2 Cracks/damage → Replace. SDN6060 INSTALLATION 1.

  • Page 158: Outlet Water Jacket Joint

    COOL OUTLET WATER JACKET JOINT OUTLET WATER JACKET JOINT Å 4 Nm (0.4 m • kg, 2.9 ft • lb) ı 10 Nm (1.0 m • kg, 7.2 ft • lb) Ç 23 Nm (2.3 m • kg, 17 ft • lb) SEJ6080 Order Job name/Part name...

  • Page 159: Inspection

    COOL OUTLET WATER JACKET JOINT INSPECTION 1. Inspect: • Carburetor heating knob 1 • Thermostat cover 2 • Outlet water jacket joint 3 Cracks/damage → Replace. SDN6090 2. Inspect: • Thermostatic valve 1 Valve does not open at 40 ~ 44°C (112 ~ 120°F) →...

  • Page 160: Installation

    COOL OUTLET WATER JACKET JOINT INSTALLATION 1. Install: • Thermostat 1 NOTE: Align the hole a in the thermostat with to notch b in the thermostat cover. SDN6130 2. Install: • Thermo sensor 1 Water temperature sensor 1: 23 Nm (2.3 m • kg, 17 ft • lb) CAUTION: Be very careful when handling the water tem- SDN6140...

  • Page 161: Chapter 7. Carburetion

    Job name/Part name Q’ty Remarks Remove the parts in the order listed below. Carburetors removal Servomotor assembly Refer to “YAMAHA POWER VALVE SYSTEM (Y.P.V.S.)” in CHAPTER 5. Intake silencer Refer to “FUEL PUMP”. Before removing the carburetors, make sure Carburetor heating knob that the carburetor heating knob is turned to “OFF”.
  • Page 162 CARB CARBURETORS Å 3.5 Nm (0.35 m • kg, 2.5 ft • lb) SEJ7020 Order Job name/Part name Q’ty Remarks Carburetor separation Remove the parts in the order listed below. Carburetor heating hose Starter cable holder Collar Spring Screw Loosen. Starter rod Spring Starter lever...
  • Page 163 CARB CARBURETORS Å 0.7 Nm (0.07 m • kg, 0.51 ft • lb) ı 1 Nm (0.1 m • kg, 0.7 ft • lb) Ç 1.8 Nm (0.18 m • kg, 1.3 ft • lb) Î 2.5 Nm (0.25 m • kg, 1.8 ft • lb) SDN7030 Order Job name/Part name...
  • Page 164 CARB CARBURETORS Å 0.7 Nm (0.07 m • kg, 0.5 ft • lb) ı 1 Nm (0.1 m • kg, 0.7 ft • lb) Ç 1.8 Nm (0.18 m • kg, 1.3 ft • lb) Î 2.5 Nm (0.25 m • kg, 1.8 ft • lb) SDN7040 Order Job name/Part name...

  • Page 165: Inspection

    CARB CARBURETORS INSPECTION 1. Inspect: • Carburetor body • Fuel passage Contamination → Clean. NOTE: • Use a petroleum based solvent for cleaning. • Blow out all passages and jets with compressed SDN7050 air. 2. Inspect: • Rubber seals 1 •...

  • Page 166: Assembly

    CARB CARBURETORS 5. Inspect: • Throttle valve 1 Wear/damage → Replace. 6. Check: • Throttle valve movement Sticks → Replace carburetor body assem- bly. SDN7090 ASSEMBLY NOTE: • Before reassembling, wash all parts in clean gasoline. • Always use new gaskets and O-rings. 1.
  • Page 167 CARB CARBURETORS Measurement and adjustment steps: • Hold the carburetor upside down. • Measure the distance between the carburetor body and top of the floats. NOTE: The float arm should resting on the needle valve without exerting pressure on it. •...

  • Page 168: Fuel Level Adjustment

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

  • Page 169: Throttle Position Sensor (Tps) Inspection And Adjustment

    CARB CARBURETORS THROTTLE POSITION SENSOR (TPS) INSPECTION AND ADJUSTMENT NOTE: Before adjusting the TPS, properly adjust the idle speed. 1.Inspect: • Gy/B G/Y R/Y Inspection steps: • Disconnect TPS coupler. • Connect the pocket taster (Ω × 1k) to the TPS –...
  • Page 170 CARB CARBURETORS 2.Adjust: • TPS position Adjustment steps: • Disconnect the TPS coupler. • Connect the test coupler to the TPS. • Connect three dry cells (1.5 V × 3 pcs.) in series to the test coupler. Dry cells (–) → 1 Dry cells (+) →...

  • Page 171: Installation

    CARB CARBURETORS INSTALLATION NOTE: After installing all parts, refer to “CABLE ROUT- ING” in chapter 9, to check the cable, lead and hose routings. 1. Adjust: • Starter cable freeplay Refer to “STARTER (CHOKE) CABLE AD- JUSTMENT” in CHAPTER 2. 2.

  • Page 172: Fuel Pump

    CARB FUEL PUMP FUEL PUMP Å 7 Nm (0.7 m • kg, 5.1 ft • lb) ı 10 Nm (1.0 m • kg, 7.2 ft • lb) SDN7190 Order Job name/Part name Q’ty Remarks Fuel pump removal Remove the parts in the order listed below. Air duct Screw Loosen.

  • Page 173: Inspection

    CARB FUEL PUMP INSPECTION 1. Inspect: • Fuel hose 1 • Fuel delivery hoses 2 • Vacuum hose 3 • Oil delivery hose 4 Clogs/damage → Replace. SDN7200 2. Check: • Fuel pump operation Checking steps: • Connect the Mity vac 1 to the pulser hose 2. Mity vac: 90890-06756, YB-35956 SDN7210...

  • Page 174: Chapter 8. Electrical

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

  • Page 175: Ignition System

    – ELEC IGNITION SYSTEM SDN8030...

  • Page 176: Troubleshooting

    – ELEC IGNITION SYSTEM TROUBLESHOOTING NO SPARK OR WEAK SPARK. Check the spark plug gap. OUT OF SPECIFICATION Repair or replace the spark plug. Check the spark plug cap resistance. OUT OF SPECIFICATION Replace the spark plug cap. Check the ignition coil resistance. OUT OF SPECIFICATION Replace the ignition coil.

  • Page 177: Spark Plug Cap

    – ELEC IGNITION SYSTEM SPARK PLUG CAP 1. Remove: • Spark plug cap 2. Connect: • Pocket tester (to the spark plug cap) 3. Measure: • Spark plug cap resistance Out of specification → Replace. SDN8040 Spark plug cap resistance: 5 kΩ...

  • Page 178: Spark Plug

    – ELEC IGNITION SYSTEM SPARK PLUG 1. Remove: • Spark plugs 2. Measure: • Spark plug gap Standard spark plug: BR9ECS (NGK) Spark plug gap: SDN8090 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should malfunc- tion during operation, T.O.R.S.

  • Page 179: Handlebar Switch (Right)

    – ELEC IGNITION SYSTEM HANDLEBAR SWITCH (RIGHT) Engine stop switch and throttle switch 1. Disconnect: • Handlebar switch (right) coupler 2. Connect: • Pocket tester SDN8130 3. Check: • Engine stop switch continuity Faulty → Replace the handlebar switch Ω × 1 (right).

  • Page 180: Main Switch

    – ELEC IGNITION SYSTEM MAIN SWITCH 1. Disconnect: • Main switch coupler 2. Connect: • Pocket tester 3. Check: • Main switch continuity Faulty → Replace. SDN8180 Switch position Continuity Color code Switch position Y/B Y/R START Continuity CONDENSER 1. Disconnect: •...

  • Page 181: Emergency Engine Starting

    – ELEC IGNITION SYSTEM EMERGENCY ENGINE STARTING If a short circuit occurred in the lighting system, the signal system, or the meter system, the en- gine can be started and the vehicle ridden in an emergency by cutting off the load control relay. 1.

  • Page 182: Lighting System

    – ELEC LIGHTING SYSTEM SDN8210...

  • Page 183: Troubleshooting

    – ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT, TAIL LIGHT AND/OR METER LIGHT DO NOT COME ON. Check the bulb(s). NO CONTINUITY Replace the bulb(s). Check the headlight relay and load control relay. FAULTY Replace the headlight relay and/or load control relay. Check for voltage on the condenser coupler.

  • Page 184: Bulb(S)

    – ELEC LIGHTING SYSTEM BULB(S) 1. Remove: • Headlight bulb a • Tail/brake light bulb b • Meter light bulb c 2. Connect: • Pocket tester (to the bulb terminals) SDN8220 WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot. Do not touch the bulb until it cools down.

  • Page 185: Headlight Relay

    – ELEC LIGHTING SYSTEM HEADLIGHT RELAY SDN8245 1. Inspect: • Headlight relay (blue) 1 Inspection steps: • Disconnect the headlight relay from the cou- pler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay terminals as shown.

  • Page 186: Signal System

    – ELEC SIGNAL SYSTEM SDN8270 8-13...

  • Page 187: Troubleshooting

    – ELEC SIGNAL SYSTEM TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. Check the tail/brake light bulb. NO CONTINUITY Replace the bulb. Check the load control relay. FAULTY Replace the load control relay. Check the brake light switch. FAULTY Replace the brake light switch. Check for voltage on the condenser coupler.
  • Page 188 – ELEC SIGNAL SYSTEM WATER TEMPERATURE AND/OR OIL LEVEL INDICATOR LIGHTS DO NOT COME ON. Check the water temperature and/or oil level indicator light bulb(s). NO CONTINUITY Replace the bulb(s). Check the load control relay. FAULTY Replace the load control relay. Check for voltage on the condenser coupler.
  • Page 189 – ELEC SIGNAL SYSTEM FUEL METER DOES NOT OPERATE. Check the load control relay. FAULTY Replace the load control relay. Check the stator coil. FAULTY Replace the AC magneto. Check the fuel sender. FAULTY Replace the fuel sender. Check for voltage on the condenser coupler. OUT OF SPECIFICATION Correct the connection and/or replace the rectifier/ regulator.

  • Page 190: Tail/Brake Light Bulb

    – ELEC SIGNAL SYSTEM TAIL/BRAKE LIGHT BULB 1. Remove: • Tail/brake light bulb Terminal Continuity 1 – 2 1 – 3 SDN8280 BRAKE LIGHT SWITCH SDN8290 1. Check: • Brake light switch continuity Faulty → Replace. Switch position Continuity Brake lever operates Brake lever does not operate...

  • Page 191: Water Temperature Sensor

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

  • Page 192: Oil Level Switch

    – ELEC SIGNAL SYSTEM OIL LEVEL SWITCH 1. Remove: • Intake silencer Refer to “FUEL PUMP” in CHAPTER 7. • Oil level gauge 1 SDN8320 2. Connect: • Pocket tester (to the oil level switch coupler) 3. Check: • Oil level switch continuity Faulty →...

  • Page 193: Grip Warmer System

    – ELEC GRIP WARMER SYSTEM SDN8360 8-20...

  • Page 194: Troubleshooting

    – ELEC GRIP WARMER SYSTEM TROUBLESHOOTING GRIP WARMER DOES NOT OPERATE. Check the main switch. NO CONTINUITY Replace the main switch. Check the grip and thumb warmer. NO CONTINUITY Replace the grip warmer and/or thumb warmer. Check the variable resistor. CORRECT INCORRECT Replace the variable resistor.

  • Page 195: Grip And Thumb Warmer Coil

    – ELEC GRIP WARMER SYSTEM GRIP AND THUMB WARMER COIL 1. Disconnect: • Grip warmer leads 1 • Thumb warmer coupler 2 2. Connect: • Pocket tester (to the grip warmer coil leads and/or thumb warmer coil leads) SDN8370 3. Check: •...

  • Page 196: Yamaha Power Valve System (Y.p.v.s.)

    – ELEC YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) SDN8410 8-23...

  • Page 197: Troubleshooting

    – ELEC YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) TROUBLESHOOTING SERVOMOTOR DOES NOT MOVE. Check the main switch. NO CONTINUITY Replace the main switch. Check the servomotor operation. DOES NOT MOVE Replace the servomotor. Check for voltage on the condenser coupler. OUT OF SPECIFICATION Correct connection and/or replace the DC regula- tor.

  • Page 198: Servomotor

    – ELEC YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) SERVOMOTOR SDN8420 1. Remove: • Cover 1 2. Disconnect the Y.P.V.S. check coupler cap 1 SDN8430 from the Y.P.V.S. check coupler 2. 3. Inspect: SDN8440 • Servomotor Inspection steps: • Connect the Y.P.V.S. adjustment coupler 1 to the Y.P.V.S.

  • Page 199: Fault Location Table

    – ELEC FAULT LOCATION TABLE FAULT LOCATION TABLE NOTE: When more than one problem is detected, the water temperature indicator light flashes in the pattern of the lowest numbered problem. After that problem is corrected, the water temperature indicator light flashes in the pattern of the next lowest numbered problem.
  • Page 200 – ELEC FAULT LOCATION TABLE Patterns Condition Reference Discontinuity or short- Refer to ing of the servomotor is “SERVOMO- detected. TOR”. SDN8490 Discontinuity of the Refer to “VARI- variable resistor is ABLE RESIS- detected. TOR”. Repeat 0.75S 2.5S SDN8500 Shorting of grip Refer to “GRIP Repeat warmer is detected.

  • Page 201: Chapter 9. Specifications

    Maximum horse power r/min 8,250 ± 250 r/min Maximum torque r/min Starting system Recoil hand starter Lubrication system: Separate lubrication (YAMAHA AUTOLUBE) Engine oil: Type YAMALUBE 2-cycle oil Tank capacity 3.3 L (2.9 Imp qt, 3.5 US qt) Drive chain housing oil: Type Gear oil API “GL-3”...
  • Page 202 SPEC GENERAL SPECIFICATIONS Model SRX700 SRX700S Carburetor: Type/quantity TM33/3 Manufacturer MIKUNI Spark plug: Type BR9ECS Manufacturer 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Transmission: Primary reduction system V-Belt Primary reduction ratio 3.8 ~ 1.0 : 1 Clutch type Automatic centrifugal engagement Secondary reduction system Chain Secondary reduction ratio...

  • Page 203: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model SRX700 SRX700S Cylinder head: Volume (with spark plug) 25.3 ~ 25.6 cm (1.54 ~ 1.56 cu.in) <0.03 mm (0.0012 in)> <Warp limit> *Lines indicate straight edge measurement. Cylinder: Material Cast iron Bore size 69.000 ~ 69.014 mm (2.7165 ~ 2.7171 in) <Taper limit>...
  • Page 204 SPEC MAINTENANCE SPECIFICATIONS SRX700 SRX700S Model Crankshaft: Crank width “A” 56.95 ~ 57.00 mm (2.242 ~ 2.244 in) Crank width “B” 292.75 ~ 293.30 mm (11.526 ~ 11.547 in) Crankshaft deflection “C” : C Below 0.03 mm (0.0012 in) Below 0.04 mm (0.0016 in) Below 0.03 mm (0.0012 in) Measuring points: 1 89.5 mm (3.52 in)
  • Page 205 SPEC MAINTENANCE SPECIFICATIONS SRX700 SRX700S Model Carburetor: Type/quantity TM33/3 Manufacturer MIKUNI I.D. mark 8DN10 Main jet (M.J) #1: 147.5 #2,3: 146.3 Pilot jet (P.J) #42.5 Jet needle (J.N) 6GM26-3 Needle jet (N.J) Pilot air jet (P.A.J) Pilot outlet (P.O) ø0.9 Bypass (B.P.1) Pilot screw...

  • Page 206: Power Train

    SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model SRX700 SRX700S Transmission: Type V-belt automatic 3.8 ~ 1.0 :1 Range of ratio 4,000 ± 200 r/min (3,800 ~ 4,200 r/min) Engagement r/min 8,500 ± 250 r/min (8,250 ~ 8,750 r/min) Shift r/min Sheave center distance “A” 267 ~ 270 mm (10.52 ~ 10.62 in) Sheave offset “B”...
  • Page 207 SPEC MAINTENANCE SPECIFICATIONS SRX700 SRX700S Model Rivet: Outer Part number 90261-06033 Material Steel Size 17.2 mm (0.68 in) Quantity 3 pcs Hole quantity 3 pcs Inner Part number 90261-06034 Material Steel Size 13.9 mm (0.55 in) Quantity 3 pcs Hole quantity 3 pcs Secondary sheave spring: Part number...
  • Page 208 SPEC MAINTENANCE SPECIFICATIONS SRX700 SRX700S Model Track: Part number 8EA-47110-00 Width 381 mm (15.0 in) Length 3,072 mm (120.9 in) Pitch 64 mm (2.52 in) Number of links Thickness “A” 6 mm (0.24 in) Height “B” 23 mm (0.91 in) Deflection 25 ~ 30 mm (0.98 ~ 1.18 in)/10 kg (22 lb) Slide rail suspension:...
  • Page 209 SPEC MAINTENANCE SPECIFICATIONS SRX700 SRX700S Model Slide runner: Thickness 17.8 mm (0.70 in) <Wear limit> <10 mm (0.39 in)> Track sprocket wheel: Material Polyethylene Number of teeth Rear guide wheel: Material High-molecular-weight polyethylene with rubber Outside diameter 178 mm (7.01 in) Brake: Pad thickness 10.2 mm (0.40 in)

  • Page 210: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model SRX700 SRX700S Frame: Frame material Aluminum Seat height 685 mm (26.8 in) Rear side of seat Luggage box location Steering: Lock-to-lock angle (left) 34.8° (L ski) 29.6° (R ski) (right) 29.6° (L ski) 34.8° (R ski) Ski alignment Toe-out Toe-out size...

  • Page 211: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model SRX700 SRX700S Voltage: 12 V Ignition system: Advanced type Electrical type AC magneto: Magneto model/manufacturer F4T36971/MITSUBISHI 189 ~ 231 Ω at 20°C (68°F) Pickup coil resistance (color code) (White/Red – White/Green) 0.36 ~ 0.44 Ω at 20°C (68°F) Charge coil resistance (color code) (White –...
  • Page 212 Coil resistance Grip warmer: 1.53 ~ 1.87 Ω at 20°C (68°F) Heater resistance Water temperature sensor: Model/manufacturer 0190/MITSUBISHI Sensor resistance 0.29 ~ 0.35 kΩ at 80°C (176°F) 0.17 ~ 0.21 kΩ at 100°C (212°F) Y.P.V.S. servo motor Model/manufacturer 8DF/YAMAHA 9-12...

  • Page 213: High Altitude Settings

    SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS SRX700/700S Tempera- –40°C –29°C –18°C –7°C 4°C 16°C ture (–40°F) (–20°F) (0°F) (20°F) (40°F) (60°F) Altitude MJ #1 #152.5 MJ #1 #151.3 MJ #1 #150 MJ #1 #148.8 MJ #1 #147.5 MJ #2#3 #150 MJ #2#3 #148.8 MJ #2#3 #147.5 MJ #2#3 #146.3...

  • Page 214: Tightening Torque

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m • kg ft • lb Crankcase (M8 × 80) (first) Tighten the bolts in two (final) stages. Crankcase (M8 × 35) Engine bracket and frame Engine rear bracket (right • center) and engine Engine rear bracket (left) and engine Engine rear bracket (left) and connecting arm Engine front bracket and damper...
  • Page 215 SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Tightening torque Parts to be tightened Remarks m • kg ft • lb Primary sheave (first) 12.0 Tighten the bolts in two (final) stages. See NOTE. Spider and sliding sheave 20.0 Left-hand thread. ® Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) Bolt...
  • Page 216 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Parts to be tightened Remarks m • kg ft • lb Wheel bracket shaft and sliding frame Set bolt (front axle) Speedometer gear assembly NOTE: Tightening steps: 1. Tighten the bolt to a torque of 120 Nm (12 m • kg, 85 ft • lb). 2.
  • Page 217 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Tightening torque Parts to be tightened Remarks m • kg ft • lb Handlebar holder Steering column Upper Lower Steering column and relay rod Relay rod and relay arm Relay arm and tie rod Tie rod and steering arm Relay arm Locknut (relay rod/tie rod) Apply LOCTITE...

  • Page 218: General Torque Specifications

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

  • Page 219: Cable Routing

    SPEC CABLE ROUTING 30° SDN9130 9-19...
  • Page 220 SPEC CABLE ROUTING CABLE ROUTING 1 Water temperature sensor coupler 2 T.O.R.S. connector 3 Ignition coil coupler 4 Throttle position sensor coupler 5 Pass the throttle cable through the duct boss. 6 Brake hose 7 Install the main switch coupler behind the instrument panel.
  • Page 221 SPEC CABLE ROUTING SDN9140 9-21...
  • Page 222 D Install the metal clip facing downward. E Insert the fuel tank breather hose until it can not be inserted further. F Condenser coupler G YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) check coupler H Fuel hose I Pulser hose J Oil hose...
  • Page 223 SPEC CABLE ROUTING SDN9145 9-23...
  • Page 224 SPEC CABLE ROUTING K Load control relay (white) L Headlight relay (blue) M Rectifier regulator N Condenser O Route the fuel tank breather hose behind the condenser. P Condenser coupler Q Fasten the condenser leads and CDI unit leads with a plastic band.
  • Page 225 SPEC CABLE ROUTING SDN9150 9-25...
  • Page 226 SPEC CABLE ROUTING 1 Speedometer coupler 2 Tachometer coupler 3 Headlight leads 4 Speedometer cable 5 Fasten the wire harness and speedometer cable at the white tape mark, with a plastic band. 6 Plastic band 7 Cable holder 8 Route the wire harness and speedometer cable over the shroud’s stopper wire.
  • Page 227 SPEC CABLE ROUTING SDN9160 9-27...
  • Page 228 K YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) coupler and connector L YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) check coupler. M Fasten the fuel tank breather hose, voltage regulator lead, CDI unit lead and YAMAHA POWER VALVE SYSTEM (Y.P.V.S.) lead with a plastic band. 9-28...
  • Page 229 SPEC CABLE ROUTING SDN9170 9-29...
  • Page 230 SPEC CABLE ROUTING N To the carburetor O Vacuum hose P Oil hose Q Reservoir tank hose R Oil hose S Wire harness T To the oil pump U Fasten the wire harness at the white tape mark, with a clamp. V Route the wire harness and coolant hose next to each other.
  • Page 231 SPEC CABLE ROUTING SDN9180 9-31...
  • Page 232 SPEC CABLE ROUTING 1 Starter cable 2 Fasten the starter cable, oil pump cable, and coolant hose with a plastic band without bending them. 3 Ignition coil coupler 4 T.O.R.S. connector 5 Water temperature sensor coupler 6 Fasten the wire harness, water temperature sensor lead, coolant hose, T.O.R.S.
  • Page 233 AC magneto Rectifier/regulator Condenser Main switch Thumb warmer Grip warmer Engine stop switch Throttle switch Carburetor switch Water temperature sensor CDI unit Servo motor Throttle position sensor Variable resistor Ignition coil Spark plug Engine ground Frame ground Brake light switch Tail/brake light Fuel sender Oil level switch...
  • Page 234 WIRING DIAGRAM SRX700/SRX700S Br B/R Br/W B/W Y/B1 Y/L W/B L/R Y/W Y/B2 B/Y1 B/Y2 W/G W/R2 G/Y W/R1 (BLACK) (BLACK) W/R2 W/R2 Y/B2 B/Y2 W/R1 W/R1 Y/B2 B/Y1 B/Y1 Y/L B/R W W W W/R2 B/Y1 B/Y B/W B/W B/Y2 OPEN IDLE Gy/B...
  • Page 235 99. 06 × 1.E. CR PRINTED ON RECYCLED PAPER...

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